GE Blender FGB M05 User Manual

MANUAL  
GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
Serial No. ...................  
ISO 08.01.02.064.GB  
986731  
Rev. May 2001  
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Rev. May 2001  
GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
Page 2  
3.7  
Settings of the user-interface  
Change the rights of an operator  
Change entrycode  
Change date and time  
Revision code of the system  
Menu hierarchy  
3.7.1  
3.7.2  
3.7.3  
3.7.4  
3.8  
4.0  
INSTALLATION  
4.1  
4.2  
Demanded connections  
Attaching  
5.0  
5.1  
6.0  
ALARMS  
Alarm reports and solutions  
MAINTENANCE AND REPAIR  
6.1  
Maintenance  
6.2  
Replacement of parts  
6.2.1  
6.3  
Replacement of printed circuit  
Cleaning the machine  
6.4  
Transportation of the GraviMaster  
7.0  
TECHNICAL INFORMATION  
7.1  
7.1.1  
7.2  
7.3  
7.4  
7.5  
General machine specications  
Safety measures  
User-interface specications  
Valves specications  
Air pressure cylinders specications  
Electrical diagrams  
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GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
Page 3  
1.0  
INTRODUCTION  
GRAVIMETRIC FEEDING  
An efcient 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, ow characteristics and particle size.  
Ferlin Plastics Automation now have a range of more than twenty blenders that deliver  
the benets of gravimetric blending at a price that makes other gravimetric ... and most  
volumetric systems ... look distinctly expensive.  
FGB SERIES GRAVIMETRIC BLENDERS  
GraviMasterblending systems are available in more than twenty different 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 ow-control-valve design or have a combination with  
auger-feeders. The proven GraviMasterblending 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  
efciency 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. 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.  
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GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
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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, 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 identication 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 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 wont 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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Gravimetric Blender  
Page 5  
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  
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.  
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  
cant 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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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 requestedthe status  
will be operateagain.  
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  
F6  
F7  
F8  
Start-command (start-key)  
Stop-command (stop-key)  
Pause-command  
Continue-command (clear pause)  
After a start-command in Manual-mode one batch will be executed. After this the machine-  
status will be standbyagain. The weighbin and mixbin-valve can be controlled manually.  
In manual mode the keys mentioned below meaning:  
F5  
F6  
F7  
F8  
Step-command (One component of a batch)  
Reset-command (Back to the rst component of a batch)  
Empty weighbin  
Empty mixbin  
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GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
Page 7  
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->Alarmhas 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-weighthigher, the controller  
will send an alarm to the operator-interface. The  
production will continue.  
The alarm can be recovered setting the production-weightto zero (0). This command is part  
of the option-menu (F2) of the status screen.  
Weight->Error  
When using the option Weight->Errora 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-weighthigher, 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 predened number of seconds, dened 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 dened 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.  
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GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
Page 8  
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 dened 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 dened, one gravimetric will be followed by a dened number of  
volumetric dispenses. This is dened by the parameter combinationRatio. This parameter can  
only be dened if combinationis chosen. This mode has the best of gravimetric and  
volumetric.  
Use: normally the dened 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 conict 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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GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
Page 9  
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 dened in two ways: Standardand Percentage. These methods can  
be dened in the recipe choosing menu (F1) recipes / edit recipes. The methods  
Standardend Percentagedene the relation of the components (Regrind, Natural and  
Additive) in a recipe.  
2.7.2.1 Method Standard  
The different components are dened as follows:  
Regrind  
Natural  
Additive  
:
:
:
Percentage of the batch weight  
Relation between other naturals  
Percentage of the totals of all naturals  
Example  
Batchweight  
Regrind  
2000.0 gr.  
20.0%  
Natural 1  
Natural 2  
Additive  
4
1
5.0%  
Regrind  
Naturals  
:
:
20.0% of 2000.0 gr.  
400.0  
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%  
natural 2 = 1/5 * 76.2 = 15.2%  
1220.0  
304.0  
Additive  
:
80.0 - 61.0 - 15.2 = 3,8%  
TOTAL  
76.0  
2000.0  
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GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
Page 10  
2.7.2.2 Method Percentage  
The different component are dened 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  
2000 gr.  
20.0%  
60.0%  
15.0%  
5.0%  
Regrind  
:
:
:
:
20.0% of 2000.0  
60.0% of 2000.0  
15.0% of 2000.0  
5.0% of 2000.0  
400.0  
1200.0  
300.0  
Natural 1  
Natural 2  
Additive  
100.0  
TOTAL  
2000.0  
2.7.3  
Adding extra materials  
The dened amount of the component dened in the recipes can be changed external  
using some special parameters. The controller has two methods: Additive to regrindand  
Regrind Control.  
IMPORTANT  
Addition of extra material using Additive to regrindand Regrind Controlis only  
possible when a standardrecipe is used.  
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GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
Page 11  
2.7.4  
Additive to regrind  
It is possible to dispense more additive in relation to the amount of regrind. Choose for  
this denition menu (F1) controller / public parameters. A maximum of two hoppers  
(additive) can be dened (additiveToRegrindHopper). The denition must be completed  
dening the requested percentage (additiveToRegrindPerc).  
ADDITIVE TO REGRIND  
Not activated  
Recipe  
Activated with 2.0%  
Recipe  
Component  
Weight (g)  
Weight (g)  
Regrind  
Natural 1  
20.0%  
4
400.0  
1219.0  
20.0%  
4
400.0  
1213.0  
Natural 2  
Additive  
1
304.8  
76.2  
1
303.2  
83.8  
5.0%  
5.0% + 2.0%  
2.7.5  
Regrind control  
The ow of regrindis very often not continuous due to the process. There are two  
methods to adjust the amount of regrind to the actual process: Empty Regrindor 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 parametersthe process can be activated. After  
the process is started a dened amount of batches (Empty regrind wait count) must be  
awaited before the percentage will be increased. The percentage will be increased in  
the dened 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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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-Siloregrind 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 dened 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 dened number of steps the process will dispense  
the original setting of the recipe.  
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GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
Page 13  
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 dened 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  
Timeto calculate the time which the dispense valve must be activated. The Hardware  
Reaction Timeis 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 rst dispense some calculations can be done, and with  
the results parameters can be changed. Result is a more accurate next dispense. After the  
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-typesare 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 WARNINGonly an error is sent  
to the user when the accuracy is not reached. Now the controller waits for a  
conrmation (enter) to initiate new dispense tries of the same material. This  
process goes on until the dispense accuracy is reached.  
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Gravimetric Blender  
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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 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 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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GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
Page 15  
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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GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
Page 16  
2.9  
EQ-Net Certificate  
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GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
Page 17  
2.10  
ISO Certicat  
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GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
Page 18  
3.0  
USER INTERFACE  
3.1  
Operator-interface  
Keyboard  
3.1.1  
Description:  
F1 Open main menu. All other sub-menus 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  
Start production  
Stop production  
Pause  
Manual  
Dispense one component  
Mixer  
Dump weightbin  
Dump mixer chamber  
F5  
F6  
F7  
F8  
Start after pause  
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GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
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Besides the function key there are some special keys:  
DIRECT MACHINE-CONTROL KEYS  
Key  
Description  
# or F4  
Select FGB  
START  
STOP  
Start command, the same as F5  
Stop command, the same as F6  
DATA ENTRY KEYS  
Key  
Description  
0-9  
Entry of numbers  
+/-  
Increase and decrease function (value of 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 rst element of row  
(End)  
INS  
(Arrow down with line) Jump to last element of row  
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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Gravimetric Blender  
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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 eld  
When a number input eld is selected it can be activated by either the <ENTER> key or  
just typing the numbers. The activated input eld shows a cursor at the position where  
the next number will be placed. To deactivate (leave) the input eld use one of the the  
following keys <ENTER>, <ESC>, or ↑  
Text input eld  
The text input eld is equal to a number input eld but it also accepts characters. Because  
the keyboard doesnt have character-keys a special method is implemented to enter  
characters.  
To enter a character in a text inputield rst activate the object with the <ENTER> key.  
When the input eld is activated a cursor is shown at the 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 eld  
Option elds are objects with a toggle function (yes/no) or (true/false). When the button  
according to the option eld is activated the value is toggled. The actual value of the option  
eld is displayed by a cross. When the cross is visible the object has the value yesor  
trueotherwise the value is noor false.  
Optionlist  
Optionlist elds are 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 recipesit 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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Gravimetric Blender  
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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 dene 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. masterbatch)  
One component of every type is already present in the list. These components have the  
name no nameand 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)  
MODE: AUTOMATIC  
[ ]  
STATUS  
[ ]  
OPERATING  
------------------------  
[Edit components]  
Name  
Type  
SCR GARDEN CHAIR REGRIND  
ADEG-2RN  
ADEG-4RN  
ANTISTATIC ALU  
NATURAL  
NATURAL  
ADDITIVE  
<ENTER> = edit component  
<INSERT> = insert component  
<DELETE> = delete component  
F1Menu F2Option F3  
F8Cont.  
F4Clear  
F5Start  
F6Stop  
F7Pauze  
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Gravimetric Blender  
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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 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 elds. The operator now can change these 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 WHITEand 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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Gravimetric Blender  
Page 23  
If the character W has been found the ? key is pressed.  
Name  
<W>  
Type  
[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 WHITEis stored.  
Name  
Type  
?WHITE?  
[NATURAL]  
Step: Press the ? key again to select the type-eld.  
Name  
Type  
[WHITE]  
NATURAL  
?
Step: Press <ENTER> to activate the eld.  
Name  
Type  
[WHITE]  
[NATURAL  
REGRIND  
NATURAL  
ADDITIVE  
]
Step: Select ADDITIVE by using the arrow keys and conrm by pressing <ENTER>.  
Name  
Type  
[WHITE]  
?ADDITIVE  
?
Step: To conrm the new component press the arrow key ? or use the <ESC> key.  
Now the ADDITIVEcomponent WHITEis added to the list. The maximum number of  
components is 100.  
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GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
Page 24  
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 recipesis  
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  
Name  
Colour  
Batch  
Interpretation  
:
:
:
:
:
[ 10]  
CRATE  
[YELLOW  
[ 2]Kg.  
]
[STANDARD ]  
H# Component  
Quant  
Alarm  
Rate (g/s)  
1 noname  
2 noname  
3 noname  
5 noname  
(r) 50.0  
IGNORE  
IGNORE  
IGNORE  
IGNORE  
957.2  
891.4  
875.5  
8.3  
(n) 2.0  
(n) 2.0  
(a) 4.0  
4
5
<ENTER> = edit line  
<INSERT> = insert line  
6
7
<DELETE> = delete line  
<HOME> = sort up  
8
<END>  
= sort down  
9
10  
11  
12  
+-------------------------------------------------------------------------  
F1Menu F2Option  
F8Cont.  
F3  
F4Clear F5Start F6Stop F7Pauze  
All 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 eld of the recipe giving some extra information about the eld.  
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FIELD OF A RECIPE  
Fields  
Description  
Number  
Name  
Unique recipe number  
Recipe name  
Colour  
Batch  
Charactereld for the colour-name  
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  
Find colour  
Searches for the recipe with the given number.  
Searches for the recipe with the given colour.  
Find name  
Print recipe  
Searches for the recipe with the given name.  
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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Page 26  
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:  
H# Component  
[ 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:  
< 2.0> 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 conrm 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  
Noname  
Noname  
WHITE  
REGRIND  
NATURAL  
ADDITIVE  
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 doesnt 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 lled with material. The controller  
calculates new dispense-rates by a fast algorithm in the 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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Gravimetric Blender  
Page 30  
OPERATING AUTO[ ]  
[ ]  
[ ]  
STATUS:[0] FGB#00: (No name)  
STATUS OPERATING  
MODE: AUTOMATIC  
PRODUCTION STATUS]  
Production mode :  
CONTINUE  
Name:  
Dispense mode: GRAVIMETRIC  
PIR-HOUSING  
CRATES  
Mix mode  
YELLOW  
[previous]  
:
PULSE  
[total]  
Dispensed Recipe Dispensed  
Recipe  
[current]  
H# Type  
1 REG  
2 NAT  
3 ADD  
Recipe Requested  
[ 20.0] 400.0  
[ 1.0] 1523.8  
[ 5.0] 76.2  
Dispensed Recipe  
20.0  
1.0  
5.0  
400.0  
1523.8  
76.2  
20.0 1600  
1.0  
5.0  
6095  
305  
4
5
6
7
8
9
10  
11  
12  
totals  
[ACCEPT]  
[UNDO CHANGES]  
Produced weight:  
0.1  
82000  
2000.0  
8000  
F1Menu  
F8Cont.  
F2Option  
F3  
F4Node F5Start  
F6Stop  
F7Pauze  
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 eld (arrow-keys). Next  
enter a new value and press <ENTER> to conrm. 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 usagedisplays the total  
quantity of material witch is used ordered by hopper number. The quantities which are stored  
doesnt 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 monitordisplays 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 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 ll the weighbin with a reference-weight and be  
sure that the input 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 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 isnt 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
2
3
4
3
4
4
3
0,015  
0,020  
0,020  
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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Page 33  
PUBLIC PARAMETERS  
Parameter  
Description  
Init  
AlarmReport  
ProductionReport  
Indicates if alarm-reports must be printed.  
Indicates if production-reports must be printed.  
If so the parameter interval-time must be given also.  
No *)  
No *)  
Interval  
Pauze (time) before printing the next production-report. 01:00.00  
BatchReport  
ProductionMode  
Indicates if batch-reports must be printed.  
No *)  
Actual production-mode. There are three possible  
modes; CONTINUE, WEIGHT and ALARM_  
WEIGHT. If the mode WEIGHT os ALARM_  
WEIGHT has been selected the parameter production  
Weight must also be given.  
CONTINUE  
ProductionWeight  
DispenseMode  
The FGB stops his production when the production 100 [Kg]  
Weight is reached. (productionMode must be  
WEIGHT or ALARM_WEIGHT).  
Actual dispense-mode. There are three possible  
modes; GRAVIMETRIC, VOLUMETRIC and  
COMBINATION. If the mode COMBINATION is  
chosen the parameter combinationRatio must be given.  
Relation between the volumetric and gravimetric  
dispenses. (one gravimetric dispense and x  
volumetric dispenses).  
GRAVIMETRIC  
CombinationRatio  
MixMode  
3
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  
dumped out of the weighbin.  
10 [s]  
MixerPulseOnTime  
Time the mixer is activated in pulse-mode.  
Time the mixer is not activated in pulse-mode.  
Percentage additive to regrind which must be added. 0 [%]  
5 [s]  
MixerPulseOffTime  
AdditiveToRegrind  
Percentage 1/2  
15 [s]  
AdditiveToRegrind  
Hopper 1/2  
Hoppernumber in which the additive is.  
Hopper 5  
WeighbinDumpTime  
LevelControlWaitTime  
Time the weighbinvalve is activated (dumping of  
material into the mixerchamber).  
4 [s] 0,5 kg unit  
6 [s] 1,2,5 and  
25 kg unit  
Time between the full signal of the mixerchamber  
sensor and opening the mixerchamber-valve.  
8 [s]  
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 eld by using the  
up- and down-keys. Now press <ENTER> to activate the option eld. If the option 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  
maximum accuracy  
4
DispenseAccuracy  
Minimum accuracy for each component.  
25 [%]  
30 [%]  
DispenseRate  
CorrectionBand  
Maximum deviation when a re-calculation of the  
dispense-speed is done  
SiloPresent  
Indicates the Stock-Siloregrind control process  
is activated.  
No  
MaximumTare  
Variation  
SiloHighCount  
Maximum absolute deviation from the zeropoint  
of the weighbin.  
Number of batches with the highness activated  
before the controller initiates an alarm.  
40 [g]  
100  
SiloLowCount  
EmptyRegrind  
Number of batches with the lowsensor not activated 100  
before the controller initiates an alarm.  
Indicates the Empty Regrindregrind control  
No  
process is activated.  
EmptyRegrindHopper Indicates the hopper which is used in the empty  
regrind process  
Hopper 1  
EmptyRegrindCycles Number of batches empty regrind waits before  
increasing regrind (startprocess)  
1
Dispense inc/dec  
Maximum percentage for the regrind control  
processes  
Number of steps in whitch the maximum must  
10 [%]  
10  
Dispense  
VariationCycles  
LoadcellGain  
LoadcellOverload  
be reached.  
Amplication-factor for the loadcell signal  
Maximum weight in the weighbin. The controller  
initiates an error on this point.  
16  
800 [g]  
LoadcellSettleTime  
Time between the dispense of the last component  
and reading the weigbin-signal.  
(to eliminate vibrations).  
1 [s]  
LoadcellWeight  
BandWidth  
To read a correct weight 8 samples must t to this 10 [g]  
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  
§ 3.5.1  
§ 3.3.2  
§ 3.5.1  
§ 3.2.2  
§ 3.2.1  
§ 5.1  
* production report  
* material usage report  
* error report  
* recipe overview  
* component overview  
* alarm overview  
3.7  
Settings of the user-interface  
3.7.1  
Change the rights of an operator  
The terminal has some areas which are protected by a password; protected-parameters, debug-  
monitor etc. Before an operator can use, modify or see these areas he has to perform a login  
procedure. This procedure starts by choosing menu (F1) system / loginthe 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 / logoutthe menu item changes to login again.  
Change entrycode  
3.7.2  
To change ID chose menu (F1) system / change ID.  
IMPORTANT  
Standard the ID is set to 1234. After it is changed the ID 1234 cant 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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Gravimetric Blender  
Page 37  
3.7.3  
3.7.4  
Change date and time  
Date and time of the terminal can be changed by entering menu (F1) system / time and date.  
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  
Select recipe  
RECIPES  
SYSTEM  
Production status  
Material usage  
Edit recipes  
Login/logout  
Change ID  
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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Rev. May 2001  
GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
Page 38  
Reference to section:  
Production  
Production status  
Material usage  
§
3.3.1  
§
3.3.2  
5.1  
Controller  
Select recipe  
Public parameters  
Protected parameters  
Alarm history  
Calibration  
§
§
§
2.1  
3.5.1  
3.5.2  
§
Hardware reaction time§ 3.4.3  
Load cell  
Load cell tarration  
Digital I/O monitor  
§
§
§
3.4.1  
3.4.2  
3.3.3  
Select automatic mode § 2.3  
Select manual mode  
§
2.3  
Recipes  
Edit recipes  
Edit components  
§
§
3.2.2  
3.2.1  
System  
Login/logout  
Change ID  
Time and date  
Revision  
§
§
3.7.1  
3.7.2  
§
3.7.3  
§
3.7.4  
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Rev. May 2001  
GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
Page 39  
4.0  
4.1  
INSTALLATION  
Services  
For installation 1ph or 3ph supply is required dependent on type of unit and a 1/4air 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 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.  
s
4.2. Mountingplate  
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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 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 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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Rev. May 2001  
GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
Page 41  
5.0  
5.1  
Alarms  
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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Rev. May 2001  
GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
Page 42  
ALARMS  
Alarm-message  
Press enter  
Description  
Action to cancel alarm  
Alarm already cancelled  
Press enter  
Operator must conrm  
No control voltage  
Covers open  
No 24V control voltage present  
Turn on the main-switch  
or check fuses  
Place security-cover /  
mixer-chamber  
Security cover not present or mixerchamber  
removed  
Production weight  
reached  
producedWeight equals produktionweight  
Reset the  
producedWeight  
No weighbin or  
calibrate  
Zero weight of the weighbin is greater then  
maximumTareVariation’  
Loadcell must be  
calibrated or a tare  
procedure must be done.  
Check the parameters *)  
Parameters corrupted  
The controller cant read his parameters  
correctly. All parameters will be lled with  
standard values.  
The controller cant read the productiondata  
(production-screen). The data will be cleared.  
The hoppersensor (optional) indicates that a  
hopper runs out of material.  
Data corrupted  
Hopper low  
Conrm *)  
Fill hopper with material  
Hopper empty  
No material is dispensed so the controller  
indicates that a hopper must be empty.  
Fill hopper with material and  
press the start-button.***)  
Loadcell not calibrated The controller cant read the loadcell  
Calibrate the weighbin  
parameters correctly.  
Loadcell overload  
Loadcell not stable  
Weight of the weighbin is greater than the  
loadcellOverload parameter.  
Remove material out of  
the weigbin.  
Check in recipe the  
Weightsignal from the loadcell doesnt t  
Press enter *) **)  
the band.  
Loadcell need  
more samples  
Controller needs more samples to generate a Press enter *)  
stable weight.  
Loadcell boundary error To much weight-samples doesnt 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 doesnt contain regrind Check the regrind  
conict  
or percentage  
control parameters  
Additive regrind par  
conict  
Given hoppernumber doesnt contain additive Check the  
AdditiveToRegind  
parameters  
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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.  
***) 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 conrmed 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 historyand push <ENTER>.  
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Rev. May 2001  
GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
Page 44  
[0]OPERATING AUTO[ ]  
[ ]  
[ ]  
STATUS:[0] FGB#00: (No name)  
STATUS OPERATING  
----------------------------[ALARM HISTORY]  
No control voltage  
Covers are open  
1
1
0
0
0
0
0
0
Loadcell overload  
0
0
0
0
0
0
Loadcell not stable  
Loadcell needs more samples  
Loadcell boundary error  
Silo full error  
Silo empty error  
Conict with regrind parameter 0  
Production weight reached  
No Weighbin / Need calibration  
Parameters are corrupted  
Production data corrupted  
Hopper number (n) is empty  
Loadcell is not calibrated  
Conict 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  
F7Pauze  
F2Option  
F8Cont.  
F3  
F4Clear  
F5Start  
F6Stop  
If your problems can not be solved by these directives, please contact your dealer.  
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Rev. May 2001  
GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
Page 45  
6.0  
6.1  
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).  
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 uctuates, set the regulator to the  
low end so that the dispense valves always see a consistent pressure.  
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:  
step2:  
ll the mixer chamber until the sensor is covered.  
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).  
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.  
step3:  
step4:  
step5:  
Weighbin dump valve:The weighbin dump valve should open and close smoothly. Two  
airow regulators are attached on the cylinder. This can be adjusted  
by the screw that is on top of it.  
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Rev. May 2001  
GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
Page 46  
6.2  
Replacement of parts  
Replacement of printed circuit  
6.2.1  
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 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 rm pallet.  
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Rev. May 2001  
GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
Page 47  
7.0  
7.1  
TECHNICAL INFORMATION  
General machine specications  
Connecting voltage  
Communication cable  
Air pressure  
:
:
:
1-phase 240 V  
Fiber optic cable (or RS422)  
max. connecting pressure: 12 bar (+/- 170 psi)  
working pressure: 4-6 bar (+/- 57-86 psi)  
Sound level  
Surroundings temperature  
Batch weight  
Machine weight  
Machine dimensions  
:
:
:
:
:
< 70 dB (A)  
-18°C to +50°C  
0,5 kg  
25 kg  
450 x 450 x 640 mm  
7.1.1  
7.2  
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 specications  
Connecting voltage :  
Printer connection  
240 V  
Parallel port  
:
7.3  
Valves specications  
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.  
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Rev. May 2001  
GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
Page 48  
Drawing 7.1 Cylinder  
Maschine  
1
Ein  
2
W
H 1  
H 2  
B
W= Wiegeschalenanschluss  
H1= Dosierschieber 1  
H2= Dosierschieber 2  
B= Mischkammerschieber  
Option  
(
)
Drawing 7.2 Topview valves  
7.4  
Air pressure cylinders specications  
See specications on cylinder.  
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Rev. May 2001  
GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
Page 49  
7.5  
Electrical diagrams  
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Rev. May 2001  
GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
Page 50  
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Rev. May 2001  
GraviMaster-FGB-M05 (S)  
Gravimetric Blender  
Page 51  
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