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GE FGB-M05 User's Manual

1. ENCLOSED SWITCHING POWER SUPPLY MEAN WELL TYPE 0 60 61 amp 5V com 5V ADJ KA ag H EN KEYBOARD en INTERFACE En SS mE 2 GND Ge CONTRASTL Or d Di oY a 12 i was ELAN 104 NC 2 kal SS ei 12V z S z 32 1 lta GRAVIMIX 3 rs ra rs re Fr re Pira RS FIBER P e BOX HEADER 26 CONVERTER PARE 4 BIENEN EN DATAE EE FUSE 2A tag vz AIN WITCH mo ro 20
2. 0 CT 71TCHwHUSOO gt VA VA VALVE VALVE VALVE EM EM ODO Of ON OT ol2l2lolelelelelel2j2alolelelelelal2lolalelelejelelalololalelelel2 2 ago Ro SENSOR SENSOR SENSOR SENSOR 2lolelololelelelelelelelelelelelalelalaleleleleleleTelelalelelelele D DE LOADCELL LOADCELL LOADCELL LOADCELL LOADCELL LOADCELL LOADCELL RED WHITE BLUE BROWN GREEN BLACK GROUND wit geel LVE 1 grijs LVE 2 geel LVE 3 roze LVE 4 rood GHTBIN VALVE zwart MIXER paars MIXER VALVE roze grijs LVE blauw LVE TCH blauw rood TCH bruin groen ERGENCY SWITCH wit groen ERGENCY SWITCH roze bruin SOR bruin grijs bruin D MIXER roze wit HOPPER 1 wit HOPPER 2 groen HOPPER 3 wit geel R R R R R SOR R R R R R MACHINE wit grijs HOPPER 4 geel bruin x OPTIONS BACKLIGHT INVERTER 5 COM RED BLACK y Ci LOPPY DRIVE LCD DISPLAY SHARP LM64P83L BAMSUNG Z BFD_321B
3. Increase and decrease function value of field 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 first 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 7 J Cursor keys move cursor and menu items B Labotek Power in Plastics Rev May 2001 GraviMaster FGB MOS5 S Page 20 3 2 Gravimetric Blender 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 J en T arrow keys the actual selected object can be changed Pressing lt ENTER gt 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 field When a number input field is selected it can be activated by either the lt ENTER gt key or just typing the numbers The activated input field shows a cursor at the position where the next number will be placed To deactivate leave the input field use one of the the following keys lt ENTER gt lt ESC gt J or T Text
4. 2 Labotek Power in Plastics Rev May 2001 GraviMaster FGB MOS5 S Page 6 2 3 Gravimetric Blender 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 lt ENTER gt command The error must be solved then 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 th
5. 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 2 Edit components N 32 System Login logout Se A Change ID 3 12 Time and date 3 73 Revision 3 74 B Labotek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Page 39 4 0 4 1 4 2 Gravimetric Blender INSTALLATION Services For installation Iph or 3ph supply is required dependent on type of unit and a 1 4 air supply with a minimum 6bar 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 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 db h Fasteners Loadcell Emergency button Welgh bin FF Conner Ho box Mixer chamber e E 4 2 Mountingplate 2 Labotek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Page 40 Gravimetric Blender 6964 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 sh
6. Step Press the arrow key lt gt once Interpretation gt STANDARD gt Step When the interpretation must be changed into PERCENTAGE press the lt ENTER gt key Now select PERCENTAGE with the arrow keys and confirm with lt ENTER gt Interpretation STANDARD PERCENTAGE Step Press the arrow key lt gt 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 lt ENTER gt to activate H Component Quantity Alarm Speed g s 1 2 12 Step Press lt ENTER gt Name Type Noname REGRIND Noname NATURAL Noname ADDITIVE WHITE ADDITIVE B Labotek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Page 28 3 2 3 Gravimetric Blender Step Use the arrow keys lt gt to select a component and press lt ENTER gt Use the arrow key lt gt to select Quantity Enter the quantity and press lt ENTER gt Use the arrow key lt gt to select Alarmtype and press lt ENTER gt Alarm Ignore Ignore Warning Error Step Select an alarm type by using the arrow keys and press lt ENTER gt 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 lt o gt to select the next hopper number Depending on the model it is possible to use upto
7. This includes hoppers valves augers weigh pan mixer and mixing chamber When auger feeders are installed 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 requirements under the CE regulations Rev May 2001 2 Labotek Power in Plastics GraviMaster FGB M05 S Page 4 Gravimetric Blender 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 Features are data storage of all plant raw materials easy call up of materials for the formulation of recipes fast identification 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 fixed 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 driv
8. Time to calculate the time which the dispense valve must be activated The Hardware Reaction Time is the maximum active time ofthe 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 first dispense some calculations can be done and with the results parameters can be changed Result is a more accurate next dispense After the first 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 co
9. Production weight reached producedWeight equals produktionweight Reset the producedWeight No weighbin or calibrate Zero weight of the weighbin is greater then maximum TareVariation Loadcell must be calibrated or a tare procedure must be done Parameters corrupted The controller can t read his parameters correctly All parameters will be filled with standard values Check the parameters Data corrupted The controller can t read the productiondata production screen The data will be cleared Confirm parameters correctly 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 Loadcell overload Loadcell not stable Weight of the weighbin is greater than the loadcellOverload parameter Weightsignal from the loadcell doesn t fit the band Remove material out of the weigbin Check in recipe the Press enter 1 Loadcell need more samples Controller needs more samples to generate a stable weight Press enter Loadcell boundary error To much weight samples doesn t fit the band Press enter Silo high Silo supply hopper is full for sever
10. 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 B Labotek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Page 26 Gravimetric Blender Actions Step Menu Fl recipes lt ENTER gt Step edit recipes ZENTER Name Nr Colour Step Press the lt INS gt key INS insert Number 1 Name 2 2 Colour Batch 2 0 kg Interpretation STANDARD H Component Quantity Alarm Speed g s 1 2 1011 2 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 lt gt to select the batch Batch lt 2 0 gt 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 B Labotek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Page 27 Gravimetric Blender
11. 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 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 lt J gt 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 filled with material The controller calculates new dispense rates by a fast algorithm in the first 5 batches B Labotek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Page 29 3 3 3 3 1 Gravimetric Blender 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 Productio
12. 234 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 B Labotek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Page 37 Gravimetric Blender 3 7 3 Change date and time Date and time of the terminal can be changed by entering menu Fl 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 gt gt gt Hardware reaction time Digital I O Loadcell monitor Loadcell tarration Select automatic mode Select manual mode B Labotek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Page 38 Gravimetric Blender 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
13. 5 S Page 46 6 2 6 2 1 6 3 6 4 Gravimetric Blender Replacement of parts 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 first 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 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 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 firm pallet B Labotek Power in Plastics Rev May 2001 GraviMaster FGB MOS5 S Page 47 7 0 7 1 7 2 7 3 Gr
14. 8 1 303 2 Additive 5 0 76 2 5 0 2 0 83 8 Regrind control The flow 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 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 defined amount of batches Empty regrind wait count must be awaited before the percentage will be increased The percentage will be increased in the defined 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 B Labotek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Page 12 Gravimetric Blender prozentsatz t q nominal m zyklen n schritte 1 m zyklen n schritte 1 dosier zyklen chargen start m Chargen kein Regenerat m Chargen kein Regenerat Produktion dosiert verfiigbar dosiert verfiigbar 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 S
15. BatchWeight Total weight of one batch This value is copied into 0 5 kg every recipe when it is created Dispense Try 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 Amplification 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 th
16. Bb Labotek Power in Plastics MANUAL GraviMaster FGB M05 S Gravimetric Blender Rev May 2001 1 0 2 0 2 1 2 2 23 24 2 5 2 6 27 2 7 1 212 2 721 212 21 3 2 7 4 2 2 1 5 1 215 2 2 7 6 2i lal 2 8 2 9 3 0 SA 3 3 1 2 3 2 3 2 1 3 2 2 3 2 3 3 3 3 3 1 3 32 3 33 3 4 3 4 1 3 4 2 3 4 3 3 9 3 5 1 3 5 2 3 6 INTRODUCTION CONTROLS Blender startup Blender status Machine mode Production modes Mixer mode Dispense modes Batch handling Production control Recipe to weight calculation Method Standard Method Percentage Adding extra materials Additive to regrind Regrind control Empty regrind Control Stock Silo Control Dispensing Calculations Datalogging Certificates USER INTERFACE Operator interface Keyboard User control Recipes Change components Add change recipes Change current recipe Timely information Production screen Material usage screen Input amp Output monitor B Labotek Power in Plastics GraviMaster FGB M05 S Page 1 Gravimetric Blender Adjustment of the gravimetric blender Calibration of the weighbin Tare of the weighbin Hardware reactiontime Overview of parameters Public parameters Protected parameters Reports and overviews B Labotek Power in Plastics Rev May 2001 GraviMaster FGB MOS5 S Page 2 Gravimetric Blender 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 an
17. N VOLTAGE eh n EC ee m HI TRANSFORMER ai al al p ee l eee ee lie S 2 SS leeeaaal veeoo 2 2 2345 6 1254 12 3456 MAIN 000 oe 4 28 28 8 8 SWITCH SA AA se 1001 Controller board F 00 E S I 230 V AC 50 HZ PE LN HAIN POWER SUPPLY FROM CUSTOMER D a a in Sa w 3 D Lei OH x w gt a w Ei x w Di WA Wa bai 2 uu ui ES LO pax pa P OPTION 5 W a m fani hu T En T o o o lt 5 5 RN 5 5 S S G 6 5 a a S gt 3 a FIB422 pcb KH be a D pa E zZ E ke je m ke Fri ka E Ha Hai Hei KI V1 UZ ER st je st jee Se er ei je Se er ei Berl jee le SE ler feel Jet 25 26 55 21 130 23 24 h i k 1 d 1 g ls 3 a is Je 3 0 i g 9 g fe fs 9 9 E z z CONNECTION CABLE J h k Yi d f 9 5 SEE 35 Hl H H H H H H H H WW H H a ue me t na o m oe mw at au mw ae int woe ne ae ne ow WI WI WI 1a WI WI 0 WI WI un aa aa ae aa Tie Tie Tia Tie aa A WIRING DIAGRAM INSERTED MODULE P amp S ON MAIN PCB INPUT 19 20 NOT AVAILABLE O 72 3 4 5 6 7 8 8100121314151617 18192 CH DPDDDDDDDDD DDDDDDDDD AI DDDD AGS 12345 6 7 8 9 10 11 12135 1415 14 17 18 19 2 PODDDDDDPDDD DOBDODO DPOP D O 1920 099659555559595 O INSERTED MODULE ON MAIN PCB P8 yz La botek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Gravime
18. Percentage of the batch weight Natural Percentage of the batch weight Additive f 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 Natural2 15 0 of 2000 0 300 0 Additive 5 0 of 2000 0 100 0 TOTAL 2000 0 Adding extra materials The defined amount of the component defined 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 Rev May 2001 2 7 4 2 1 5 2 7 5 1 B Labotek Power in Plastics 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 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
19. 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 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 Public parameters Below a list is given of all parameters which are attainable by the menu F1 controller public parameters B Labotek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Page 33 Gravimetric Blender PUBLIC PARAMETERS Parameter Description Init AlarmReport Indicates if alarm reports must be printed No Productio
20. Udatadelacadata Ledende auditor Lead euditor Ventier Date of issue Lead auctor kaa w s eet giz DANAK DANSK STANDARD Accredited by RvA Ben er 5002 DANISH STANOAROS ASSOCIATION Regia 41 Baunegdtdsve 73 21 2309 Hellerup The Danish Standards Association is a member of EONe1 The International Certification Network B Labotek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Page 18 Gravimetric Blender 3 0 USER INTERFACE 3 1 Operator interface 3 1 1 Keyboard GRAVIMIX NINI Description Fl 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 FS Start production Dispense one component F6 Stop production Mixer E7 Pause Dump weightbin F8 Start after pause Dump mixer chamber Rev May 2001 B Labotek Power in Plastics GraviMaster FGB M05 S Page 19 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
21. al batches High sensor is activated Counter will automaticaly cleared Regrind process par conflict Given hoppernumbers doesn t contain regrind or percentage Check the regrind control parameters Additive regrind par conflict Given hoppernumber doesn t contain additive Check the AdditiveToRegind parameters Rev May 2001 Er SEN B Labotek Power in Plastics GraviMaster FGB M05 S Page 43 Gravimetric Blender 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 confirmed by pressing the lt ENTER gt key The terminal stores all error messages these can be displayed by the menu F1 controller alarm history This screen shows the last 256 erro
22. avimetric Blender TECHNICAL INFORMATION General machine specifications 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 gt 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 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 User interface specifications Connecting voltage 240 V Printer connection Parallel port Valves specifications 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 Hl and H2 is as follows 81 1 onto Cl as H2 1 onto Cl 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 2 1 and B 2 one of the lines is numbered like one side of the cylinder Connect the concordant ones B Labotek Pow
23. cedure for the character H I T and E When the whole name is given press lt ENTER gt Now the name WHITE is stored Name Type WHITE NATURAL Step Press the key again to select the type field Name Type WHITE NATURAL d Step Press lt ENTER gt to activate the field Name Type WHITE NATURAL REGRIND NATURAL ADDITIVE Step Select ADDITIVE by using the arrow keys and confirm by pressing lt ENTER gt Name Type WHITE ADDITIVE Step To confirm the new component press the arrow key or use the lt ESC gt key Now the ADDITIVE component WHITE is added to the list The maximum number of components is 100 Rev May 2001 3 2 2 Add change recipes GU GraviMaster FGB M05 S Gravimetric Blender botek Power in Plastics Page 24 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 Fl recipes edit recipes is chosen a list with recipes will be displayed Now recipes can be added changed or deleted The lt DEL gt key deletes the current recipe of course there will be a conformation for the operator By adding lt INS gt key or changing lt ENTER gt the current recipe the same screen is used STATUS OPERATING Alarm IGNORE IGNORE IGNORE IGNORE Rate g s 957 2 891 4 875 5 8 3 lt ENTER gt edit l
24. d 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 Tal General machine specifications 7 1 1 Safety measures 7 2 User interface specifications G Valves specifications 7 4 Air pressure cylinders specifications 7 5 Electrical diagrams 2 Labotek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Page 3 1 0 Gravimetric Blender 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 Ferlin Plastics Automation now have a range of more than twenty blenders that deliver the benefits 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 different models with a throughput capacity range from 10 to 750 kg hr for the
25. data Sum of batch data Material usage dispensed amount of each hopper percentages The controller saves all data in battery backup memory B Labotek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Page 16 Gravimetric Blender 2 9 EQ Net Certificate E Net THE EUROPEAN NETWORK FOR QUALITY SYSTEM ASSESSMENT AND CERTIFICATION This is to state that Labotek A S str bjergvej 29 P O Box 100 DK 3600 Frederikssund Labotek A S Dagel kkevej 4 DK 5953 Tranek r holds the Quality System Certificate DS CERTIFICATE NO 162 Issued 1993 02 16 for the standard from the ISO 9000 EN 29000 series and the scope as specified therein Signed for and on behalf of EQNet member DATE April 1993 B keb Bjarne Axelsen Certification Manager Se ON er members arc EEE AENOR Spain AFAQ France AlB Vingotte Belgium BSI QA United Kingdom CISQ Italy DS Denmark DQS Germany ELOT Greece IPQ Portugal KEMA Netherlands NCS Norway NSAI Ireland QS Austria SFS Finland SIS Sweden SQS Switzerland The issuing member holds all other EQNet members harmless for any claims arising from the existence of this document B Labotek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Page 17 Gravimetric Blender 2 10 ISO Certificat DANSK STANDARD Kvalitetsstyringssystem Certifikat Quality System Certificate Certifikat nr 162 1 Certificate No 162 1 Det attesteres hermed at kvalitetsst
26. e 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 5 No Yes X B Labotek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Page 34 3 5 2 Gravimetric Blender For example if the alarm report must be activated First select the option field by using the up and down keys Now press lt ENTER gt 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 lt ENTER gt Updating the parameters into the controller must be done for every parameter Protected parameters Below a list is given of all parameters with are attainable by the menu Fl controller protected parameters Rev May 2001 B Labotek Power in Plastics GraviMaster FGB M05 S Page 35 Gravimetric Blender PROTECTED PARAMETERS Parameter Description Init
27. e 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 first component of a batch F7 Empty weighbin F8 Empty mixbin 2 Labotek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Page 7 2 4 2 5 Gravimetric Blender 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 gt Alarm If Weight gt 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 gt Error When using the option Weight gt Error a weight has to be given After a start the requested weight will be compared with production weight I
28. e to find 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 fill the weighbin with a reference weight and be sure that the input field 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 first one 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 B Labotek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Page 32 3 4 3 3 5 3 5 1 Gravimetric Blender Hardware reactiontime
29. e weigbin signal to eliminate vibrations Loadcell Weight To read a correct weight 8 samples must fit 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 B Labotek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Page 36 3 6 3 7 3 7 1 3 7 2 Gravimetric Blender 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 Sool recipe overview 3 2 2 component overview 3 2 1 alarm overview 5 1 Settings of the user interface 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 Change entrycode To change ID chose menu F1 system change ID IMPORTANT Standard the ID is set to 1
30. en 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 2 Labotek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Page 5 2 0 2 1 2 2 Gravimetric Blender 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 A horizontal mixer mixes the components to a uniform blend which discharges to a storage bin or directly into the machine hopper 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 b
31. er in Plastics Rev May 2001 GraviMaster FGB M05 S Page 48 Gravimetric Blender Drawing 7 1 Cylinder 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 B Labotek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Page 49 Gravimetric Blender 7 5 Electrical diagrams q EMERGENCY stop poor UE gt roe 24V 18 19 16 17 POWER SUPLY i Bes 26 TERMINAL e e b d 230 v CONNECTION CABLE DI LN e b m per ar ON OFF SWITCH H H START STOFCONTROL Bo O
32. f 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 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 predefined number of seconds defined 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 defined 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 On The mixer is always on when the machine status is active 2 Labotek Power in Plastics Rev May 2001 GraviMaster FGB MOS5 S Page 8 2 6 2 7 2 7 1 Gravimetric Blender 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 v
33. gorithm dispenseRate 4 dispenseRate measured Weight 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 first 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 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 B Labotek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Page 15 2 8 Gravimetric Blender 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
34. gt D4 SENSE 6 roan g SENSE 5 blue LOADCELL OFFSET2 4 KSE C OFFSETI 3 5 8 INPUT 2 0 white __ 5 INPUT 1 red Al lA 1 CONNECTION CABLE T 5 ei gt z g Es a gt gt s a a 4 D D a E m oa A w a w wo ind In D Ka fe w ia G w amp gt gt gt gt 5 D E 2 fra gt 5 5 gt gt im Si 4 3 a SS 34 Si a kwa a lt lt T 3 Si u 3 ei a z D Wi IM EF 3 lt 3 x Mi gt gt gt gt gt gt gt gt D oe o E gt gt gt gt a 7 ze W SE Wl SE 7 F H I i 3 Far SE SE Si E SS E ai BR E ap GB E ai BR Es 5 E ai BE Ei E si amp 8 9 10 11 12 15 14 13 H F K G N M H H H H H H R H 5 g 8 8 g 8 9 5 g g CONNECTION GABLE WH YF YJ YK YL W N YM a HM MN kb ae uw of EA m woe al ae ne EM z BILI EM DM BA EA EM ne gt 18 D wa i e D D i 18 D D CR D wa DA WIRING DIAGRAM INSERTED MODULE P7 ON MAIN PCB O 12 56 7 8 9 1112131415 17181920 O DOODODOBOOOD OOOCGODODOOD ag NOTE OUTPUT 13 AVE SUPPORTED FROM CONTROLLER SOFTWARE V5 15 ONWARDS O INSERTED MODULE ON MAIN PCB P7 Rev May 2001 yz La GraviMaster FGB M05 S Gravimetric Blender botek Power in Plastics Page 51 VA VA VA VA WE erg BS an
35. in additive according to recipe The blender will not start unless all conditions are met A message will be sent to the user interface Rev May 2001 2 7 2 2 7 2 1 B Labotek Power in Plastics GraviMaster FGB M05 S Page 9 Gravimetric Blender 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 Method Standard The different components are defined 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 2 Labotek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Page 10 Gravimetric Blender 2 7 2 2 Method Percentage 2 7 3 The different component are defined as follows Regrind j
36. ine lt END gt lt INSERT gt insert line lt DELETE gt delete line lt HOME gt sort up sort down OJOPERATING AUTO STATN 0 FGB 00 No name EDIT RECIPE Number 10 Name CRATE Colour YELLOW Batch 2 Kg Interpretation STANDARD H Component Quant 1 noname r 50 0 2 noname n 2 0 3 noname n 2 0 5 noname a 4 0 4 5 6 7 8 9 10 11 12 E DEE FlMenu F2Option F8Cont F3 F4Clear F5Start F6Stop F7Pauze MODE AUTOMATIC All fields of the recipe are visible in the screen By selecting the objects with the arrow keys and activate them with the lt ENTER gt key it is possible the change the them Below a list is given with every field of the recipe giving some extra information about the field B Labotek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Page 25 Gravimetric Blender 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 lt ESC gt 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
37. input field The text input field is equal to a number input field 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 first activate the object with the lt ENTER gt key When the input field is activated a cursor is shown at the first position At this moment it possible to select a character with the lt gt and lt gt keys After a character is chosen the next position can be selected with the arrow key Option field Option fields are objects with a toggle function yes no or true false When the button according to the option field is activated the value is toggled The actual value of the option field 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 fields are fields 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 T and J key and select it with lt ENTER gt 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 B Labotek Po
38. ities 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 lt ENTER gt 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 B Labotek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Page 31 3 3 3 3 4 3 4 1 3 4 2 Gravimetric Blender Input amp Output monitor The input amp 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 lt ENTER gt is given the digital output will toggle The operator has control of the digital outputs when the controller is in manual mode 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 Calibration of the weigh bin The controller uses two known entered calibration points to calculate a weighline The controller uses this lin
39. n screen The production screen can be reached by selecting menu Fl production production status The production screen displays information about the current controller The information on the screen is updated every 0 3 sec B Labotek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Page 30 Gravimetric Blender 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 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 4 5 6 7 8 9 10 11 12 totals ACCEPT UNDO CHANGES 0 1 2000 0 8000 Produced weight 82000 F1Menu F2Option F3 F4Node F5Start F6Stop F7Pauze F8Cont 3 3 2 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 field arrow keys Next enter a new value and press lt ENTER gt to confirm Now the recipe is changed but the controller uses the new values at the start of a new batch Material usage screen The material usage screen menu Fl production material usage displays the total quantity of material witch is used ordered by hopper number The quant
40. nReport 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 Percentag
41. olumetric 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 defined one gravimetric will be followed by a defined number of volumetric dispenses This is defined by the parameter combinationRatio This parameter can only be defined if combination is chosen This mode has the best of gravimetric and volumetric Use normally the defined 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 Batch handling Production control Ifa 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 conflict 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 conta
42. onnecting the air pressure Maintenance Everything is set right and tested in the factory adjustments should only be carried out ifa part of the machine is not working correctly Air pressure Level sensor Set air pressure to about 6 bar for best accuracy However lower pressure will work If your plant air fluctuates set the regulator to the low end so that the dispense valves always see a consistent pressure 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 stepl step2 step3 step4 stepS fill the mixer chamber until the sensor is covered turn screw counter clockwise until the led goes on ifthe led already is on then turn clockwise until led goes off and proceed with step 4 turn screw clockwise until led goes off turn screw another 3 4 turn clockwise 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 airflow regulators are attached on the cylinder This can be adjusted by the screw that is on top of it B Labotek Power in Plastics Rev May 2001 GraviMaster FGB MOS
43. own 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 fluctuations 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 2 Labotek Power in Plastics Rev May 2001 GraviMaster FGB MOS5 S Page 41 Gravimetric Blender 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 Rev May 2001 ALARMS Alarm message 2 Labotek GraviMaster FGB M05 S Gravimetric Blender Description Power in Plastics Page 42 Action to cancel alarm Press enter Alarm already cancelled Operator must confirm Press enter No control voltage No 24V control voltage present Turn on the main switch or check fuses Covers open Security cover not present or mixerchamber removed Place security cover mixer chamber
44. rrected 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 confirmation enter to initiate new dispense tries of the same material This process goes on until the dispense accuracy is reached B Labotek Power in Plastics Rev May 2001 GraviMaster FGB MOS5 S Page 14 2 7 7 Gravimetric Blender 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 ofthe 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 al
45. rs 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 lt ENTER gt B Labotek Power in Plastics Rev May 2001 GraviMaster FGB MOS5 S Page 44 Gravimetric Blender OJOPERATING AUTOT II STATUS 0 FGB 00 No name STATUS OPERATING 200 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 Conflict with regrind parameter 0 Loadcell is not calibrated 0 Conflict 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 lt Home gt top of list lt T gt scroll up lt J gt scroll down F1Menu F2Option F3 F4Clear F5Start F6Stop F7Pauze F8Cont If your problems can not be solved by these directives please contact your dealer Rev May 2001 6 0 6 1 B Labotek Power in Plastics GraviMaster FGB MO05 S Page 45 Gravimetric Blender 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 disc
46. 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 flow 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 extrusion 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 efficiency 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 preceding 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
47. ted an option list will appear One of the options Regrind Natural or Additive must be chosen By pressing the lt INS gt insert button a new component will be added to the list The controller places a standard name and type into the fields The operator now can change these fields to the correct name and type Deleting a component from the list can be done by pressing the lt DEL gt 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 lt ENTER gt Example Add a new component Goal Component with he name WHITE and type ADDITIVE Actions Step Menu Fl recipes lt ENTER gt Step edit components lt ENTER gt By using the arrow keys Name Type Step Press lt INS gt key INS insert Name Type lt gt NATURAL Step Search for the character W by using the or key lt gt Starts with special characters and numbers then the alphabet lt gt Starts at the end of the alphabet When the or key is hold down the character will change fast B Labotek Power in Plastics Rev May 2001 GraviMaster FGB M05 S Page 23 Gravimetric Blender If the character W has been found the key is pressed Name Type lt W gt NATURAL Step Repeat the same pro
48. tock 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 defined 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 defined number of steps the process will dispense the original setting of the recipe Prozentsatz niedrig Zensor mitten Zensor BEE ER frei bedeckt p Dosier zyklen nominal a 4 n schritte hoch Zensor mitten Zensor badeckt frai 26 nominal satz p B Labotek Power in Plastics Rev May 2001 GraviMaster FGB MOS5 S Page 13 2 7 6 Gravimetric Blender 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
49. tric Blender Page 50 No link placed no link placed link 1 or 2 placed normal condition clipping on topver scaled with heavy weight bin for offset movement max 105 100 4 100 max 95 Used scale sed scale gt 50 Og 40 0 weight of bin weight of bin H min min 0 Use link 1 or 2 for moving scale downwards when top of scale becomes over the 100 This makes the use of heavy weight bin possible Link 1 is for a low scale offset move Link 2 is for a high scale offset move The top of the scale must not be higher as 95 The examples above is only to illustrate the movement of the scale 100 100 a tT ourTPUT lid black __ 5 green OUTPUT 2 Link 2Link 1 OUTPUT 8 5 5 0OUTPUT 3 ID
50. utton 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 lt T gt or lt gt and press lt ENTER gt 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 lt START gt The blender will now operate automatically on the select recipe 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 find 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
51. wer in Plastics Rev May 2001 GraviMaster FGB M05 S Page 21 Gravimetric Blender 3 2 1 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 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 OJOPERATING AUTOJ 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 lt ENTER gt edit component lt INSERT gt insert component lt DELETE gt delete component FlMenu F2Option F3 F4Clear F5Start F6Stop F7Pauze F8Cont 2 Labotek Power in Plastics Rev May 2001 GraviMaster FGB MOS5 S Page 22 Gravimetric Blender In the screen it is possible to select a component with the arrow keys After a component has been activated by lt ENTER gt the name and type can be changed If the field type has been activa
52. yringssystemet hos This is to certify that the Quality System of Labotek A S Strebjergvej 29 P O Box 100 DK 3600 Frederikssund Labotek A S Dagelakkevej 4 DK 5953 Tranek r er i averensstammelse med kravene i fulfils the requirements in DS EN ISO 9001 1994 Certifikatets gyldighedsomrade er The scope of this certificate is Periferiudstyr til plastindustrien Ancillary Equipment for The Plastics Industry Detta certifikat or udstedt i ovsrerissternmelae med DS bestemmelser vadrerende certificering af kvalitetastyringssysterner Certifikatets danske tekst betragies som den juridiak geeldande 1llfaside af tvivl om overscottelsens korrekthed Certifikatat ar gyldigt 1 Ar efter udatedelam eler 1 Ar efter sidste optelgningsaudit gennemlart med tilfredsstillende reavitat og s framt dokumentation herlor framg r al bilag A til dette certifikst This cesniticate ss granted in comformity with the DS rules for the Certification of Quality Systems The Danish certificate text of the is considered legally Binding or case of doubl with regard te the correctness of the transiation The certiicdte is vabd for che year kum the date of sue or for ane year hom Hie latest sutvedfance auch carved out with a satisfactory result and only if attestation to tvs effect appears from Anrex A of tvs certificate 1996 01 19 Revisionsdato Date of revision 7 Deng Mark Krelner 1993 02 16 Steen Djursgard Ledenda auditor sagsvarifikator

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