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Table of contents for the manual
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Page 1
MANU AL Gra viMaster -FGB-M05 (S) Gra vimetric 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 INTR ODUCTION 2.0 CONTR OLS 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 Addi[...]
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Page 3
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 2 Gravimetric Blender 3.7 Settings of the user-interf ace 3.7.1 Change the rights of an operator 3.7.2 Change entrycode 3.7.3 Change date and time 3.7.4 Re vision code of the system 3.8 Menu hierarchy 4.0 INST ALLA TION 4.1 Demanded connections 4.2 Attaching 5.0 ALARMS 5.1 Alarm reports and solutions 6.0[...]
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Page 4
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 3 Gravimetric Blender 1.0 INTR ODUCTION GRA VIMETRIC FEEDING An ef fi cient materials blending system is an essential feature of the modern plastics processing industry . Dosing each component on the basis of weight shows distinct adv anta ges ov er traditional volumetric systems. The quantity of materi[...]
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Rev . May 2001 GraviMaster -FGB-M05 (S) Page 4 Gravimetric Blender RELIABLE PR OCESS CONTR OL The FGB control system incorporates the latest in computer and micro processor technology for total automation of recipe entry and stora ge, in v entory control and process monitoring. The control panel (user -interface) is pro vi ded with a micro-controll[...]
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Rev . May 2001 GraviMaster -FGB-M05 (S) Page 5 Gravimetric Blender 2.0 CONTR OLS When all components are av ailable the dispense of a batch starts. The cycle be gins 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 d[...]
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Page 7
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 6 Gravimetric Blender Paus e When the pause-command is giv en for a temporary stop the blender will stop after the cycle is complete. Stop requested The blender is operating but has recei ved a stop-command. The stop-command will be executed at the end of a batch-c ycle. This status will be replaced auto[...]
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Page 8
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 7 Gravimetric Blender 2.4 Production-modes The production-mode of the blender indicates ho w the production will stop in automatic- mode. This parameter can be changed using the menu (F1) ‘ contr oller / public parameters ’ . The production-mode has three options: Continue The blender will not stop a[...]
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Page 9
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 8 Gravimetric Blender 2.6 Dispense modes The blender has two ways of dispensing: gra vimetric and v olumetric. One mode can be selected or a combination of both. This can be de fi ned choosing menu (F1) ‘ contr oller / public parameter s ’ . Gra vimetric All component of the batch are dispensed and [...]
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Page 10
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 de fi ned in two ways: ‘ Standard ’ and ‘ Percentage ’ . These methods can be de fi ned in the recipe choo[...]
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Page 11
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 10 Gravimetric Blender 2.7.2.2 Method Per centage The dif ferent component are de fi ned as follows: Regrind : Percentage of the batch weight Natural : Percentage of the batch weight Additi ve : Percentage of the batch weight T otal sum must be 100%. Example Batchweight 2000 gr . Regrind 20.0% Natural 1[...]
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Page 12
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 11 Gravimetric Blender 2.7.4 Additive to r egrind It is possible to dispense more additi ve in relation to the amount of re grind. Choose for this de fi nition menu (F1) ‘ contr oller / public par ameters ’ . A maximum of two hoppers (additi ve) can be de fi ned (additi veT oRegrindHopper). The de [...]
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Page 13
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 12 Gravimetric Blender 2.7.5.2 Stock Silo Control A regrind silo can ha ve (optional) three sensors to detect high- lo w- and middle. If the controller has these sensors, ‘ Stock-Silo ’ regrind control can be acti v ated, choosing menu (F1) ‘ contr oller / pr otected parameters ’ . If the high-se[...]
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Page 14
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 13 Gravimetric Blender 2.7.6 Dispensing Dispensing of the dif ferent components will start after the calculation of the related weights. The components are dispensed in the order as de fi ned in the recipe (gravimetric only). In volumetric mode all components are dispensed at the same time. Every mechan[...]
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Page 15
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 14 Gravimetric Blender Dispense not correct (too much) T o 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 abov e mentioned cases a ne w dispense rate will[...]
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Page 16
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 15 Gravimetric Blender 2.8 Datalogging Some production data is stored. This is sho wn at the user interf ace and can also be printed. * Batch data - measured weight (each component) - dispenserate of each component - recalculation to recipe * T otal data - Sum of batch data * Material usage - dispensed a[...]
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Page 17
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 16 Gravimetric Blender 2.9 EQ-Net Certifi cate[...]
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Page 18
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 17 Gravimetric Blender 2.10 ISO Certi fi cat[...]
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Page 19
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 18 Gravimetric Blender 3.0 USER INTERF A CE 3.1 Operator -interface 3.1.1 K eyboard 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 W ill be used during calculation F4 Choose node number The function ke ys F5[...]
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Page 20
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 19 Gravimetric Blender Besides the function ke y there are some special keys: DIRECT MA CHINE-CONTROL KEYS K ey Description # or F4 Select FGB ST AR T Start command, the same as F5 STOP Stop command, the same as F6 D A T A ENTR Y KEYS K ey Description 0-9 Entry of numbers +/- Increase and decrease functi[...]
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Page 21
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 20 Gravimetric Blender 3.1.2 User contr ol The user-interf ace consists of se veral screens which can be selected by a menu. A screen consists of objects only one object in a screen is acti ve (selected). By using the ↓ en ↑ arro w keys the actual selected object can be changed. Pressing <ENTER>[...]
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Page 22
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 21 Gravimetric Blender 3.2.1 Change components There is a components list av ailable in the controller . The list can be used by the operator to de fi ne recipes. The components list stores the name and type of a component and is maximised to 100 components. The operator is free to chose a name for a co[...]
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Rev . May 2001 GraviMaster -FGB-M05 (S) Page 22 Gravimetric Blender In the screen it is possible to select a component with the arrow k eys. After a component has been acti vated by <ENTER> the name and type can be changed. If the fi eld type has been acti vated an option list will appear . One of the options (Regrind, Natural or Additiv e) [...]
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Page 24
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 23 Gravimetric Blender If the character W has been found the ? ke y is pressed. Name T ype <W> ? [N A TURAL] Step: Repeat the same procedure for the character H, I, T and E. When the whole name is gi ven press <ENTER>. No w the name ‘ WHITE ” is stored. Name T ype ?WHITE? [N A TURAL] Step[...]
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Page 25
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 24 Gravimetric Blender 3.2.2 Add/change recipes The terminal has the capacity for 340 recipes. This space is di vided into 4 spices so e very connected FGB can contain 85 recipes. If the menu item (F1) ‘ r ecipes / edit r ecipes ’ is chosen a list with recipes will be displayed. Now recipes can be ad[...]
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Page 26
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 Character fi eld for the colour-name Batch T otal batchweight Interpretation Recipe calculation Component Link hopper to component The screen can be left by pressing the <ESC>-ke y . Now[...]
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Page 27
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 26 Gravimetric Blender Actions: Step: Menu (F1) ‘ r ecipes ’ <ENTER> Step: ‘ edit r ecipes ’ <ENTER> Name Nr . Colour Step: Press the <INS> ke y (INS = insert) Number: [1] Name: ? ? Colour: [ ] Batch: [ 2.0] kg Interpretation: [ ST AND ARD ] H# Component Quantity . Alarm Speed ([...]
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Page 28
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 27 Gravimetric Blender Step: Press the arrow-k ey <↓> once Interpretation: < ST ANDARD> Step: When the interpretation must be changed into PERCENT A GE press the <ENTER> ke y . Now select PERCENT A GE with the arrow k eys and con fi rm with <ENTER>. Interpretation: ST AND ARD P[...]
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Page 29
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 28 Gravimetric Blender Step: Use the arrow-k eys <↓> to select a component and press <ENTER>. Use the arro w-key <?> to select Quantity . Enter the quantity and press <ENTER>. Use the arro w-key <→> to select Alarmtype and press <ENTER>. Alarm Ignore Ignore W arnin[...]
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Page 30
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 29 Gravimetric Blender 3.3 Timely inf ormation It is possible to get an ov er vie w of one of the connected controllers. Therefore three screens are av ailable on the terminal: production-screen, material usage-screen and input/output- screen. 3.3.1 Production scr een The production-screen can be reached[...]
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Page 31
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 30 Gravimetric Blender OPERA TING A UT O[ ] [ ] [ ] ST A TUS:[0] FGB#00: (No name) ST A TUS OPERA TING MODE: A UT OMA TIC PR ODUCTION ST A TUS] Production mode : CONTINUE Dispense mode: GRA VIMETRIC Name: PIR-HOUSING Mix mode : PULSE Recipe CRA TES YELLO W [current] [previous] [total] H# T ype Recipe Req[...]
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Page 32
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 31 Gravimetric Blender 3.3.3 Input & Output monitor The input & Output screen menu (F1) ‘ contr oller / digital I/O monitor ’ displays all digital input and output lines. Every object in the screen can be selected by using the arro w-ke ys. When a output line is selected and <ENTER> is [...]
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Page 33
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 32 Gravimetric Blender 3.4.3 Hard ware-r eactiontime 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 o ver to the autopulse system. In the hardware-reactiontime the opening time can be [...]
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Page 34
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 33 Gravimetric Blender PUBLIC P ARAMETERS Parameter Description Init AlarmReport Indicates if alarm-reports must be printed. No *) ProductionReport Indicates if production-reports must be printed. No *) If so the parameter interv al-time must be giv en also. Interv al Pauze (time) before printing the ne [...]
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Page 35
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 34 Gravimetric Blender For e xample if the alarm report must be activ ated. First select the option fi eld by using the up- and down-k eys. No w press <ENTER> to activ ate the option fi eld. If the option fi eld displays a [X] the alarm report is activ ated. The parameters must be updated into t[...]
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Page 36
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 35 Gravimetric Blender PR O TECTED P ARAMETERS Parameter Description Init BatchW eight T otal weight of one batch. This v alue is copied into 0,5 [kg] e very recipe when it is created. DispenseT ry Maximum number of tries per component to reach 4 maximum accuracy DispenseAccuracy Minimum accuracy for eac[...]
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Page 37
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 36 Gravimetric Blender 3.6 Reports and overviews There is the possibility of printing sev eral reports and ov erviews. Underneath a list is made with the reports and ov erviews with behind them the section and page where instructions for printing are giv en. * batch report § 3.5.1 * production report §[...]
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Page 38
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 (F1) ‘ system / time and date ’ . 3.7.4 Revision code of the system The terminal has the possibility to display the re vision and those of the connected controllers. This information can be[...]
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Page 39
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 Calibration Hardware reaction time § 3.4.3 Load cell § 3.4.1 Load cell tarration § 3.[...]
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Page 40
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 39 Gravimetric Blender 4.0 INST ALLA TION 4.1 Services For installation 1ph or 3ph supply is required dependent on type of unit and a 1/4 ” air supply with a minimum 6bar . 4.2 Mounting There are se veral ways where to place the Gra viMaster , namely - on a frame - on a mezzanine - on the machine Befor[...]
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Page 41
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 40 Gravimetric Blender The foot plate of the Gra viMaster should be attached on a steel attachment plate on the frame or mezzanine or fl ange pertinent to the machine. The mounting holes are 9 mm and are positioned as sho wn in drawing 4.2 The unit should be mounted as stably as possible, in connection [...]
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Page 42
Rev . May 2001 GraviMaster -FGB-M05 (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.[...]
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Page 43
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 42 Gravimetric Blender ALARMS Alarm-message Description Action to cancel alarm Press enter Alarm already cancelled Press enter Operator must con fi rm No control voltage No 24V control voltage present T urn on the main-switch or check fuses Cov ers open Security cov er not present or mixerchamber Place [...]
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Page 44
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 43 Gravimetric Blender *) If this error occurs frequently contact your dealer **) Other problems which initiate this error are: - The weighbinDumpT ime too short - W eighbin v alve touches the material when mix erchamber is full When the second problem occurs the position of the mixerchamber -sensor must[...]
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Page 45
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 44 Gravimetric Blender [0]OPERA TING A UT O[ ] [ ] [ ] ST A TUS:[0] FGB#00: (No name) ST A TUS OPERA TING ----------------------------[ALARM HISTOR Y] No control voltage 1 Loadcell o verload 0 Cov ers are open 1 Loadcell not stable 0 Production weight reached 0 Loadcell needs more samples 0 No W eighbin [...]
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Page 46
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 45 Gravimetric Blender 6.0 MAINTENANCE AND REP AIR Make sure ,when maintenance or repair is carried out, the po wer is shut of f (by pulling the plugs out) and the air pressure (by disconnecting the air pressure). 6.1 Maintenance Everything is set right and tested in the f actory , adjustments should onl[...]
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Page 47
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 46 Gravimetric Blender 6.2 Replacement of parts 6.2.1 Replacement of printed circuit For the replacement of the printed circuit of the control-box, the co ver should be remo ved by unscre wing the bolts. unplug the connectors which are attached to the printed circuit. No w unscrew all M3 bolts and remo v[...]
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Page 48
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 47 Gravimetric Blender 7.0 TECHNICAL INFORMA TION 7.1 General machine speci fi cations Connecting voltage : 1-phase 240 V Communication cable : Fiber optic cable (or RS – 422) Air pressure : max. connecting pressure: 12 bar (+/- 170 psi) working pressure: 4-6 bar (+/- 57-86 psi) Sound le vel : < 70[...]
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Page 49
Rev . May 2001 GraviMaster -FGB-M05 (S) Page 48 Gravimetric Blender Drawing 7.1 Cylinder Drawing 7.2 T opview v alves 7.4 Air pressur e cylinders speci fi cations See speci fi cations on cylinder . 1 2 W H 1 H 2 B Maschine W= Wiegeschalenanschluss H1= Dosierschieber 1 H2= Dosierschieber 2 B= Mischkammerschieber ( Option ) Ein[...]
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Rev . May 2001 GraviMaster -FGB-M05 (S) Page 49 Gravimetric Blender 7.5 Electrical diagrams[...]
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Rev . May 2001 GraviMaster -FGB-M05 (S) Page 50 Gravimetric Blender[...]
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Rev . May 2001 GraviMaster -FGB-M05 (S) Page 51 Gravimetric Blender[...]