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MANUAL
GraviMaster-FGB-M05 (S)
Gravimetric Blender
Serial No. ...................
ISO 08.01.02.064.GB
986731
Rev. May 2001
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Rev. May 2001 GraviMaster-FGB-M05 (S) Page 1 Gravimetric Blender 1.0 INTRODUCTION 2.0 CONTROLS 2.1 Blender startup 2.2 Blender status 2.3 Machine-mode 2.4 Production-modes 2.5 Mixer-mode 2.6 Dispense modes 2.7 Batch handling 2.7.1 Production control 2.7.2 Recipe to weight calculation 2.7.2.1 Method Standard 2.7.2.2 Method Percentage 2.7.3 Adding extra materials 2.7.4 Additive to regrind 2.7.5 Regrind control 2.7.5.1 Empty regrind Control 2.7.5.2 Stock Silo Control 2.7.6 Dispensing 2.7.7 Calcula
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Rev. May 2001 GraviMaster-FGB-M05 (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 and time 3.7.4 Revision code of the system 3.8 Menu hierarchy 4.0 INSTALLATION 4.1 Demanded connections 4.2 Attaching 5.0 ALARMS 5.1 Alarm reports and solutions 6.0 MAINTENANCE AND REPAIR 6.1 Maintenance 6.2 Replacement of parts 6.2.1 Replacement of printed circuit 6.3 Cleaning the machine 6.4 Transportation of the Gr
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Rev. May 2001 GraviMaster-FGB-M05 (S) Page 3 Gravimetric Blender 1.0 INTRODUCTION GRAVIMETRIC FEEDING An effi cient materials blending system is an essential feature of the modern plastics processing industry. Dosing each component on the basis of weight shows distinct advanta ges over traditional volumetric systems. The quantity of material delivered is precise and unaffected by variations in bulk density, fl ow characteristics and particle size. Ferlin Plastics Automation now have a ra
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Rev. May 2001 GraviMaster-FGB-M05 (S) Page 4 Gravimetric Blender RELIABLE PROCESS CONTROL The FGB control system incorporates the latest in computer and micro processor technology for total automation of recipe entry and stora ge, inventory control and process monitoring. The control panel (user-interface) is provi ded with a micro-controller and industrial PC with LCD-display, functional keyboard, fi ber optic communication cable (or RS-422) and parallel printer port. Features are:
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Rev. May 2001 GraviMaster-FGB-M05 (S) Page 5 Gravimetric Blender 2.0 CONTROLS When all components are available the dispense of a batch starts. The cycle begins with closing the weigh-pan. Then each of the requested components is dispensed and weighed in the weigh-pan. When all the components of the recipe are correctly weighed, the blend is dischar ged into the mixing-chamber. A horizontal mixer mixes the compo nents to a uniform blend which discharges to a storage bin, or direct ly i
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Rev. May 2001 GraviMaster-FGB-M05 (S) Page 6 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.
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Rev. May 2001 GraviMaster-FGB-M05 (S) Page 7 Gravimetric Blender 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->Ala
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Rev. May 2001 GraviMaster-FGB-M05 (S) Page 8 Gravimetric Blender 2.6 Dispense modes The blender has two ways of dispensing: gravimetric and volumetric. One mode can be selected or a combination of both. This can be defi ned choosing menu (F1) ‘controller / public parameters’. Gravimetric All component of the batch are dispensed and measured separately. Gravimetric is more accurate than volumetric, but takes more production time, ie., lower output. Volumetric All components of the batc
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Rev. May 2001 GraviMaster-FGB-M05 (S) Page 9 Gravimetric Blender 2.7.2 Recipe to weight calculation After a start-command the controller will calculate the requested weights of all components of the selected recipe. A recipe can be defi ned in two ways: ‘Standard’ and ‘Percentage’. These methods can be defi ned in the recipe choosing menu (F1) ‘recipes / edit recipes’. The methods ‘Standard’ end ‘Percentage’ defi ne the relation of the components (Regrind, Natural and Additive) in a re
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Rev. May 2001 GraviMaster-FGB-M05 (S) Page 10 Gravimetric Blender 2.7.2.2 Method Percentage The different component are defi ned as follows: Regrind : Percentage of the batch weight Natural : Percentage of the batch weight Additive : Percentage of the batch weight Total sum must be 100%. Example Batchweight 2000 gr. Regrind 20.0% Natural 1 60.0% Natural 2 15.0% Additive 5.0% Regrind : 20.0% of 2000.0 400.0 Natural 1 : 60.0% of 2000.0 1200.0 Natural 2 : 15.0% of
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Rev. May 2001 GraviMaster-FGB-M05 (S) Page 11 Gravimetric Blender 2.7.4 Additive to regrind It is possible to dispense more additive in relation to the amount of regrind. Choose for this defi nition menu (F1) ‘controller / public parameters’. A maximum of two hoppers (additive) can be defi ned (additiveToRegrindHopper). The defi nition must be completed defi ning the requested percentage (additiveToRegrindPerc). ADDITIVE TO REGRIND Not activated Activated with 2.0% Compone
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Rev. May 2001 GraviMaster-FGB-M05 (S) Page 12 Gravimetric Blender 2.7.5.2 Stock Silo Control A regrind silo can have (optional) three sensors to detect high- low- and middle. If the controller has these sensors, ‘Stock-Silo’ regrind control can be activated, choosing menu (F1) ‘controller / protected parameters’. If the high-sensor is true, the silo is almost full. Therefore more regrind will be dispensed. This is the same as described in ‘empty regrind control’. This will be done unt
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Rev. May 2001 GraviMaster-FGB-M05 (S) Page 13 Gravimetric Blender 2.7.6 Dispensing Dispensing of the different components will start after the calculation of the related weights. The components are dispensed in the order as defi ned in the recipe (gravimetric only). In volumetric mode all components are dispensed at the same time. Every mechanical valve has a reaction time. The controller uses the ‘Hardware Reaction Time’ to calculate the time which the dispense valve must be activated.
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Rev. May 2001 GraviMaster-FGB-M05 (S) Page 14 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 fi rst dispense try in all of the above mentioned cases a new dispense rate will be calculated. If the measured dispenserate (measured weight / dispense time) differs from the used dispenserate a correction can be made. A corre
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Rev. May 2001 GraviMaster-FGB-M05 (S) Page 15 Gravimetric Blender 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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Rev. May 2001 GraviMaster-FGB-M05 (S) Page 16 Gravimetric Blender 2.9 EQ-Net Certifi cate
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Rev. May 2001 GraviMaster-FGB-M05 (S) Page 17 Gravimetric Blender 2.10 ISO Certifi cat
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Rev. May 2001 GraviMaster-FGB-M05 (S) Page 18 Gravimetric Blender 3.0 USER INTERFACE 3.1 Operator-interface 3.1.1 Keyboard Description: F1 Open main menu. All other sub-menu’s can be selected F2 Open option menu. The contents is dependent of the actual screen. F3 Will be used during calculation F4 Choose node number The function keys F5 up to F8 is dependent of the machine mode (automatic, manual). FUNCTION KEY IN MACHINE-MODE Function key Au
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Rev. May 2001 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 +/- Increase and decrease function (value of fi eld can be changed by step) ENTER Select function. (choise is made and entered values are saved) . Decimal point ESC Escape
