Gravimetric Blenders GB and WSB models with 4-component control Installation Maintenance Operation Troubleshooting Instant Access Parts and Service (800) 458-1960 (814) 437-6861 www.conairnet.com The Conair Group, Inc.
Please record your equipment’s model and serial number(s) and the date you received it in the spaces provided. It’s a good idea to record the model and serial number(s) of your equipment and the date you received it in the User Guide. Our service department uses this information, along with the manual number, to provide help for the specific equipment you installed. Please keep this User Guide and all manuals, engineering prints and parts lists together for documentation of your equipment.
The Conair Group Inc. FOUR COMPONENT SOFTWARE GB and WSB Model Blenders TABLE of CONTENTS GETTING STARTED, READ THIS PAGE ................ SAFETY HAZARDS ................................. DISCLAIMERS .................................... Page Page Page 3 4 5 PART I - ASSEMBLY Assembly and Installation Instructions ......... Wiring Considerations .......................... Check Out Procedure & Diagnostics .............. Selecting Correct Model ........................
Page 2 GETTING STARTED, READ THIS PAGE. THE NEXT 9 PAGES OF THIS MANUAL WILL GUIDE YOU, STEP BY STEP, TO A SUCCESSFUL STARTUP. IT WON'T TAKE LONG; SO.... PLEASE, DON'T SKIP AHEAD. HERE ARE THE STEPS YOU WILL FOLLOW. SAFETY HAZARDS: Page 4 Two hazards exist on this unit: mix blades and slide valves. Read this short sensible page so no one gets hurt. ASSEMBLY INSTRUCTIONS: Page 6 Very little assembly is required. But you might as well get it right the first time.
Page 3 SAFETY HAZARDS +-----------------------------------------------------------+ ¦ MIX BLADES ¦ ¦ ¦ ¦ Mix blades are driven with substantial torque. ¦ ¦ ¦ ¦ NEVER place your hand in the mix chamber ¦ ¦ unless power is completely disconnected. ¦ ¦ ¦ ¦ SERIOUS INJURY may result. ¦ +-----------------------------------------------------------+ +-----------------------------------------------------------+ ¦ ADDITIONAL MIX BLADE HAZARD ¦ ¦ ¦ ¦ Over time, mix blades may become RAZOR SHARP.
Page 4 DISCLAIMERS PRODUCTION of FAULTY PRODUCT Processing conditions and materials vary widely from customer to customer and from product to product. It is IMPOSSIBLE for us to anticipate ALL processing conditions and requirements, or to be certain that our equipment will perform properly in all instances. You, the customer, must observe and verify the performance level of our equipment in your plant as part of your overall manufacturing process.
Page 5 +--------------------------------------------------------------------+ ¦ PART I - ASSEMBLY ¦ +--------------------------------------------------------------------+ ASSEMBLY and INSTALLATION INSTRUCTIONS CAUTION: LOAD CELLS ARE EASILY DAMAGED. If the FRAME is dropped from TWO FEET, the load cells WILL be DAMAGED. PLEASE, BE CAREFUL. The following items have been shipped to you: 1. 2. 3. 4. 5. FRAME, fully assembled: (bolted to pallet) CONTROLLER: the controller and the instruction manual.
2. Slide the WEIGH BIN into position. It rests high in the frame and is inserted from the side that has the hinged access window. Install with the air cylinder toward you. If bin is already in place, remove any shipping materials, tape or string. 3. Hang the Color and Additive Feeders: a. Lift side latches and fully extend slide assembly. hopper. Leave slide extended. Remove the b. Raising the rear of the slide assembly, insert one corner of hanger cross bar behind frame corner post. c.
WIRING CONSIDERATIONS The wiring of your blender is very important to its proper operation. Electronics are very susceptible to voltage spikes and static charges, both of which are very common in plastics factories. To MINIMIZE these things, consider the following. 1. The power supply should be solid; a strong supply, not limited by a "just adequate" control transformer.
CHECK OUT PROCEDURE As you go through this procedure, if WHAT SHOULD HAPPEN, doesn't happen, see the next section, DIAGNOSTICS, for what to check. NOTE: 100 and 200 series models (3K load cells), display all weight readings in 1/10 grams ( x.x). 400, 900, and 1800 series models (10K load cells) display in FULL grams, no decimal. On this page we show all weight readings WITH a decimal point. Start with NO MATERIAL in any hoppers. Be sure an AIR SUPPLY is connected.
PRESS "REG" KEY Regrind air solenoid will operate. LED # 1 will light. The Regrind dump valve will open. Press "REG" repeatedly to observe operation. PRESS "NAT" KEY Natural air solenoid will operate. LED # 2 will light. The Natural dump valve will open. Press "NAT" repeatedly to observe operation. PRESS "COL" KEY Internal relay will close powering Color outlet. Color feeder will run. LED # 3 will light. Press "COL" repeatedly to observe operation.
DIAGNOSTICS - for the CHECK OUT PROCEDURE If display fails to come on at all: check for power at outlet. Check the 1/2 amp fuse on panel front. If first display says ( TWELVE ), this is NOT the correct manual for this software. Obtain a TWELVE software manual. Possible model numbers are: 140, 220, 240, 420, 440, 940, 1840. If model number is not correct for you unit: see the next page, SELECTING CORRECT MODEL. If display stays at ( 0.0): check for damage to load cells or load cell wires.
We program every controller to match the model it is shipped with. If your controller DOES NOT display the correct model (first two digits only) on power up, follow these instructions. There are SEVEN basic models of Weigh Scale Blenders. The MODEL number your unit is set for (first two digits only) is displayed during the start up sequence every time power is turned on. Disregard the last digit of your model number when selecting from this list.
+--------------------------------------------------------------------+ ¦ PART II - OPERATION ¦ +--------------------------------------------------------------------+ LOAD CELL CALIBRATION NOTE: Display examples shown here are in tenths of grams as displayed On 100 and 200 series models. 400, 900 and 1800 series models display full grams, no decimal. If your load cells are displaying a weight close to ( 0.0), plus or minus 5 grams, you may skip this section and go directly to RATE CALIBRATION (next page).
RATE CALIBRATION RATE CALIBRATION is probably not necessary. The software initially expects STANDARD hardware. However, if you are using an auger feeder on a model with four dispense valves, or a 1/2 inch auger instead of a 1" auger, the software will take 10 or 20 cycles to adjust to correct operation. This slows down the process for a short time, but does not effect accuracy.
SELECTED MODELS - SPECIAL INSTRUCTIONS This section relates SPECIAL information about a few selected models. MICRO PULSE Micro Pulse valves are GB/WSB MB GB/WSB 122 GB/WSB 131 GB/WSB 140 GB/WSB 240R GB/WSB 440R available on models: (MICRO Blender) with optional MICRO PULSE valves. with optional MICRO PULSE valves. with optional MICRO PULSE valves. with optional MICRO PULSE valves. with optional MICRO PULSE valves. with optional MICRO PULSE valves.
INSTRUCTIONS FOR NORMAL OPERATION OPERATION: ....very simple. 1. Fill HOPPERS: REGRIND, NATURAL, COLOR, ADDITIVE: in hoppers as labeled. If auger feeders are used: COLOR in RIGHT side feeder, ADDITIVE in LEFT side feeder. 2. Set THUMBWHEEL switches for percentages desired. REGRIND, enter as a percent of the entire mix. (xx percent) COLOR, as a percent of the NATURAL. (xx.x percent) ADDITIVE, as a percent of the NATURAL. (xx.x percent) 3. On Controller, turn POWER ON, set STOP, and PAUSE switches UP.
NORMAL OPERATING SEQUENCE - EACH CYCLE As the sensor is uncovered, the cycle begins. The target weight of a complete depends on model; 400, 1000, 2000, 4000, 9000, or 18000 grams. REGRIND, if requested, will dispense first. After the Regrind dispense the space remaining in the weigh bin is calculated. NATURAL will dispense second. This dispense is calculated to fill the bin leaving just enough space for the Color and Additive dispenses.
To run a LOWER PERCENTAGE then 00.1 percent, read: PARAMETERS, _XT parameter. To place UPPER LIMITS on the thumbwheel settings, read: PARAMETERS, _SE Parameter. To LOCK OUT others from changing settings, read: KEYPAD, STAR FUNCTIONS, (*78) - Changing the Password. To blend TWO NATURAL materials instead of Natural and Regrind, read: KEYPAD, STAR FUNCTIONS, (*69) - the TWO NATURALS flag. To TRACK MATERIAL usage, read: KEYPAD, VIEW DATA, and PARAMETERS, PRT Parameter.
CONTROLS and OUTPUTS 1. POWER ON switch. Controls all power to the controller and all outputs. When power is switched off, battery backed-up RAM preserves all internal totals and parameters. All other functions are reset for normal start-up when power is restored. 2. STOP END OF CYCLE / CONTINUE switch This is the PREFERRED STOP switch. This switch is wired in series with the level sensor. Turning it off breaks the signal to the computer the same as covering the level sensor with material.
7. ALL AIR SOLENOID outputs This is a single 17 pin Amphanol plug located on the front of the control panel. This provides 24 volt power for the NATURAL, REGRIND, WEIGH BIN DUMP, and FLOW CONTROL (optional) air solenoids. On Models 140, 240, 440, 940, and 1840 (FOUR valve units), COLOR and ADDITIVE dispense valve solenoids are also powered. These power sources are transistor driven and are protected by the 1/2 amp panel fuse. See the wiring diagram section for the correct wiring to each pin. 8.
10. LED LIGHTS The LED lights in two vertical columns of eight located above the 8 character display indicate the following: LEFT COLUMN: 1. REG Regrind dump solenoid operating. 2. NAT Natural dump solenoid operating. 3. COL Color drive relay operating. 4. ADD Additive drive relay operating. 5. DMP Dump valve solenoid operating. 6. ALM Alarm output operating. 7. MIX Mixer motor drive relay operating. 8. HLD Mixer flow valve is open (Optional). RIGHT COLUMN: ALARMS 1. Alarm 2. Alarm 3. Alarm 4. Alarm 5.
14. MIXER MOTOR OUTLET This outlet is energized continuously when the MIXER SWITCH is ON (up). In the TIMED position, it stays energized for a time period following the dump of the weigh bin. You may adjust this time in the parameter table (MIX 03010). This time should be just long enough to provide adequate mixing. Mixing for a longer period may contribute to a static problem. Also, excessive mixing sometimes causes separation of pellets of different size and weight. 15.
19. COMPUTER input / output If you choose to gather material usage data automatically and continuously by computer, this connector allows for connection to an IBM PC type computer operating under MS-DOS or WINDOWS. The COMPUTER port is a DB9 (9 pin) male port. You will need a specially wired cable from us to connect to the serial output on your standard PC computer. You will also need software from us for communicating with your Weigh Scale Blender.
Detailed explanations are given on the pages that follow. AUTOMATIC OPERATION MODE: (normal operation on power up) These keys are operational in this mode. VIEW: RCP: BTCH: FAST: TAG: EXIT: CE: View Data: date, time, cycles, and lbs of Reg, Nat, Col, Add. Press VIEW,* to print all data. At end press 00 to clear data. Enter and retrieve stored RECIPES. Blend a preset weight, fill a container and stop. View/Enter Target Wt., Cur. Portion, Total, Batch Count. CE=clear Increase Output.
Three (3) operation Modes are available; AUTOMATIC, MANUAL, PROGRAM. KEYPAD - AUTOMATIC OPERATION MODE This is the NORMAL operating mode. When power is turned on, the unit is in this mode. Automatic dispensing occurs ONLY in this mode. The AUTOMATIC mode is indicated by the ABSENCE of the letter "P" or "M" at the left end of the display. Only the VIEW, RECIPE, BATCH, FAST, TAG, *, CE, and EXIT keys are available in this mode. These keys operate BETWEEN cycles only or when the PAUSE switch is on.
Press RCP to look at another recipe. Display = (GET __). Enter 2 digits to retrieve one of 99 recipes. Display will flash through the current stored data: (RCP __), (R = xx ), (C = xx.x), (A = xx.x), (*TO LOAD) Press * to LOAD this recipe into memory. Routine will exit automatically. Press RCP or EXIT to return to the display (GET Press RCP or EXIT again to exit. __). To SAVE a RECIPE you must be in the PROGRAM mode. If you press RCP key again after display of (GET __), display says (SAVE __).
the ONLY way to CONTINUE OPERATION after a BATCH amount has been run. Assuming a proper "FLG" parameter is set: Press the BTCH key once to view the desired BATCH WEIGHT. Display will say (BW #####). BATCH WEIGHT is the amount you wish to dispense before stopping and/or sounding the alarm. Press again to view the CURRENT PORTION, of the batch, that has been dispensed. Display will say (CP #####). CURRENT PORTION shows how much has been blended so far.
NOTE: Fractional cycles are not blended. Total weight may be in over the target by as much as one cycle weight. The EXIT key will exit the BTCH sequence at any point but will NOT cause the system to start a new batch. If an additional 120 volt output is desired for an alarm, substitute a 4 or 7 for the 00001. 4 turns on the Additive outlet, 7 turns on component 7 output. If you have a printer connected, totals will print automatically. (see VIEW, * for details).
These numbers are for your TRACKING of information ONLY. They have NO EFFECT on the operation of the Weigh Scale Blender. WORK ORDER number (6 digits) allows you to tag all information with an internal accounting number such as a job or purchase order number. OPERATOR number (3 digits) allows you to track who is operating the equipment. RECIPE number (3 digits) allows you to track what recipe you are using.
The following manual functions are available in the MANUAL mode. SETTING: (SET) Press once followed by one of 3 keys: REG, COL, or ADD. The current thumbwheel setting is displayed. If, while in the program mode, the keypad was used to enter this setting then it will not match the thumbwheel setting. EXIT will exit the sequence. OPERATE: (OPER) Press once followed by one of 8 keys: REG, NAT, COL, ADD, DUP, ALM, MIX, or HOLD.
For this key to function, you must first set the weight calibration flag ON. Press *99 to observe flag status. Press * to toggle flag ON or OFF. With flag set ON, press EXIT. Power-off always resets this flag to OFF. Since the bin, even when empty, weighs about 1300 grams, it is necessary on initial setup of equipment to instruct the controller of the exact tare weight of the empty bin. Slight drift in the tare or zero weight during day to day operation is normal.
the WEIGH SCALE BLENDER is to dispense materials in the proper ratios. Because all components are weighed by the same load cells, the accuracy of these ratios is not affected by zero or full scale errors. STAR FUNCTIONS available in this mode. *00 Press (*,0,0) to CLEAR ALL DATA fields. These are the material usage totals that are viewed with the VIEW key. If you are tracking material usage WITHOUT a computer, you may wish to reset them to zero on a regular basis for simplicity of calculations.
A new setting may be entered at this time by keypad if so desired. (CE will cancel entry before last digit is entered.) Settings entered by keypad CAN NOT BE ALTERED by the thumbwheel switches. After entering a setting by keypad, verify this by rotating the appropriate thumbwheel switches. An LED will light indicating that the internal setting being used by the computer does not match the thumbwheel switches.
alter the display only. will operate normally. In all other respects, the blender *05 Press (*,0,5) to inhibit the (00=CLEAR) display at the end of the VIEW sequence. Customers using MLAN or G2 software for retrieval of material usage information, may wish to restrict an operators ability to clear the material usage data at the controller. This option allows you to remove the floor operators ability to clear this data. Press * to toggle between (CLEAROFF) and (CLEAR ON).
poor electrical environment of a factory. Should some unforeseen circumstances cause the data in RAM to be corrupted or lost, a CLEAR-RESTART procedure is provided that will retrieve the parameter table stored in the EEPROM and copy it into RAM memory for use. If you make changes to the PARAMETER table, these changes reside only in RAM and may be lost in the event of an unforeseen computer malfunction.
Normal operation is to end the cycle EMPTY. The (END FULL) option is ONLY for SPECIAL installations where the sensor has been relocated BELOW the mix chamber and the purpose of the unit is to calculate exact material usage rates in order to control an extruder. Leave this flag set to (END EMTY), unless you have specific instructions to do otherwise. *45 Press (*,4,5, followed by a 5 digit number) to change the PASSWORD number for entering the MANUAL mode.
*57 For LIQUID COLOR applications only. This function usually operates in conjunction with an additional two air solenoids mounted on the blender frame. Press (*,5,7) to allow automatic switch over to a full drum when the current drum of color runs out. When function is off, display will say (COL= 4 ). Press * to toggle to (COL= 4+7). When display says (COL= 4 ), the color setting aplies to output 4 only, the standard COLOR output.
NOTE: Do not use these features in combination with *82. *71 and *72 This flag for SPECIAL APPLICATIONS ONLY. Press (*,7,1) to change the Color setting to be interpreted as percent of the entire MIX instead of percent of the Natural. Press (*,7,2) to change the Additive setting in the same way. The display will say (CPM -OFF) or (APM -OFF). Press "*" to toggle flag to (CPM -ON) or (APM -ON). (CPM stands for Color Percent of Mix, APM for Additive Percent of Mix).
Natural will dispense after the Color (or Additive) dispense and will be calculated to assure the most exact percentage ratio for the selected component. Because the Natural dispense is larger, this method allows for more exact ratioing of the one selected critical component. NOTE: Do not use this feature in combination with *69. *83 Press (*,8,3) to select "Progressive Metering" option. Progressive Metering allows for more accurate dispenses of selected components.
know the number. But we still will, just in case. Then your own selected regular password will work and as long as you don't forget it, your ok. Blenders are pre-programed with two normal passwords; (22222) is the default password for the PROGRAM mode, (11111) is the default password for the MANUAL mode. You can alter these passwords to any 5 digit number, but you must know the current PROGRAM password to change it.
Date: Time: Machine number: Display Readout: 11/09/93 17:22:01 002 P 500.0 This is useful for obtaining printed verification of load cell accuracy to comply with ISO-9000 and British Standards rules. The recommended procedure is: 1. Place the unit into the Program mode. 2. Press *88 for printout of empty bin TARE weight. 3. Place a KNOWN CERTIFIED WEIGHT into the weight bin. 4. Press *88 again for printout with the weight added. 5.
PARAMETERS All WEIGH SCALE BLENDER controllers operate according to certain internal PARAMETERS. Because customer requirements vary widely, we have made over 60 parameters accessible for change through the keypad. BRIEF explanations are given first. section that follows. FULL information is given in the NOTE: Values shown here are initial ROM values of a model 220. values for other models are listed at the end of this section. Initial Parameters are five digits, with leading zeros added.
JOG 03030 Mix blade JOG count and interval This parameter sets how many jogs will occur and how often. FCV 00006 TIME the Flow Control valve delays before opening (sec.). This parameter holds each batch in the mix chamber for a time to assure mixing. This is only for units equipped with the optional flow control valve under the mix chamber. DTI 00006 Weigh bin dump TIME at end of cycle. (seconds) This parameter sets the maximum open, or dump time for the weigh bin. No change is required.
for extremely fluffy or very heavy material. MAX prevents overflowing of the weigh bin. It is reset automatically if the FUL parameter is changed. TH TL 01000 00500 TL TH PRT 00000 The highest and lowest acceptable TARE weights for blend cycle to start. (full or tenth grams) prevents starting with the weigh bin out of place. No change is required. prevents starting with a full weigh bin. Change TH only if clumps of material hang up in the weigh bin. MINUTE interval between automatic print of TOTALS.
RMI NMI CMI AMI 00001 00001 00001 00001 Minimum valid dump rate GRAMS/sec. (full or tenth grams) Error correction is bypassed when dispense rate is lower. On power up, these are always set to 1. After several consistent cycles, they are reset to 80 percent of actual flow rate. These prevent excessive swings in flow rate calculations if material is running out. RNC NNC CNC ANC 00050 00050 00010 00010 Allowable GRAM error within which NO correction is made.
SCR 00000 BCR 00000 Special Customer Request function to be activated. For BAR CODE input equipped blenders. The following parameters are all related to EXTRUSION CONTROL only. XTP 05050 Extrusion Control - TRIP POINT for a Rate adjustment. As batch timing errors accumulate, this number determines how large the accumulated error must be to force an adjustment. XCV 00000 XRC 00004 Extrusion Control - Extruder speed Control Voltage. Extrusion Control - Extruder speed Rate of Change.
FULL EXPLANATION OF PARAMETERS Most parameters begin with R, N, C, or A. These letters indicate which dispense the parameter controls: REGRIND, NATURAL, COLOR, or ADDITIVE. In the following explanations, only the 2nd and 3rd letters are referenced for each group of codes that start with R, N, C, and A. ====================================================================== FLG (change to enable the RECIPE, BATCH, FAST and TAG keys) FLG is a SET of flags for turning on the FAST, BATCH, FAST and TAG keys.
pulsed operation. The first three digits (001xx) controls ON time in tenths of seconds. The last two digits (xxx01) controls OFF time. Larger numbers produce slower dispense rates without any increase in accuracy. Smaller numbers may not allow enough time for the slide to shift fully. Pulsed Output may also assist in dispensing regrind and some powders when these materials tend to bridge.
other correction to allow the process to continue. 00031 to 00039 = DO NOT sound alarm. After specified number of retries stop the retries and continue with the remainder of the cycle. The last digit determines the number of retries before continuing with the process. This would be appropriate if you wish to make several attempts at a dispense, such as regrind, but you wish the process to continue without any alarm indication.
digits (FCV 000xx). If your unit is equipped with a Flow Control Valve, under the mix chamber, it is programmed to open whenever the sensor is covered. It will close again immediately when the sensor is uncovered. This assures that material has time to mix before dropping into a bin below. When a batch is dropped into the mix chamber the sensor is covered. To prevent unmixed material from dropping immediately out the bottom, the mix valve is delayed for a time to allow mixing to occur first.
target weight during the dispense, a BAILOUT occurs. This ends this dispense immediately just like reaching the end of the dispense time. This in no way effects accuracy. The dispense is checked and retries occur if required. A bailout does not occur unless target weight is exceeded by the weight given in the BAILOUT ERROR parameter. This is primarily to prevent vibration from causing a false bailout to occur during a very small dispense. We set this parameter to a default of 00200 (20 grams or 200 grams).
ROC parameter (ROC 10000), will cause a portion of the Regrind to be SUBTRACTED from the Natural portion, instead of added. EXAMPLE: ROC set to (ROC 10020). The 20 means take 20 % of the REGRIND dispense and ADJUST the NATURAL dispense by this amount. The 1 means adjust by SUBTRACTION. Whatever amount of REGRIND is added, 20 percent of this amount will be subtracted from the Natural amount before a color calculation is made.
the system takes this to indicate that the regrind hopper is now empty, and the controls revert back to normal. ====================================================================== RHL (LEVEL SENSORS are required for this parameter to work) (Use only if you have regrind level sensors fitted) RHL instructs the controller to change the regrind setting if optional level sensors in the regrind hopper indicate high or low conditions. If set to all zeros (RHL 00000), then this parameter is ignored.
Example: RHL is set to 90 and 10 percent (RHL 09010). ROV is set to zero, (ROV 00000). The "Regrind" thumbwheel switch is set to 25 percent (025). The Software logic is as follows: If material level is high, above the high sensor, the HIGH sensor is COVERED, (returns NO signal); Regrind runs at the HIGH setting; 90 percent.
over 3000 grams probably would exceed the volume capacity of the bin and, therefore, not be accurate. We have set the full batch weight to 2000 grams which we considered a conservative full batch weight. Higher batch weights will increase maximum throughput rates. If your Regrind is very fluffy and you use a lot of it, you may find 2000 grams to be too much volume for the bin. Select a lower total batch weight such as 1500 to ensure that the bin never overflows of fills completely to the dump valve.
_SE (This might be useful) _SE is the upper SETTING limits for the thumbwheel switches. This allows a reasonable cap to be set for each component so that an operator cannot accidentally set the controls to an excessively high setting. For color and additive, these limits will ensure that expensive material is not wasted. Thumbwheel settings that are greater than the limit are held to the limit. EXAMPLE: If the highest color usage in your plant is 6%, you may enter this upper limit in the parameter table.
interruption for the full specified DELAY time. To prevent false starts from the mix blade, a 1 second minimum (00244) is recommended. Sometimes throughput is slow enough that each new batch buries the mix blade for a while. When this happens the material on top does not mix well. To reduce this, you can delay the start of a new batch by adding to the DLY parameter. The new batch is delayed and the level in the mix chamber has time to fall before the next batch is added.
This rate is used to calculate an exact time period to dump the required quantity of material. Both of these numbers are adjusted by the computer logic after each cycle as a means of continuously calibrating the dispense times. This rate correction takes place continuously and the batterybacked RAM maintains the correct rate even when power is turned off.
corrections will take place. Since no equipment is perfect, we must accept that a certain range of error is normal. To make corrections within this range only adds an additional error due to hunting, and broadens the error range. This parameter controls and prevents this. This parameter is adjusted automatically by the software according to the actual conditions of the metering. This number has been set based on our experience with the dispense devices.
to occur when very large dispense percentages are being requested. Depending on the accuracy of the metering device, a certain amount of hunting is to be expected from one dispense to the next. Allowing the software to stop trying when it gets sufficiently close to the target results in more perfect average dispenses. The mix chamber and the barrel of your process machine average out the small errors that occur from cycle to cycle.
is required, the _LA number is very important. A lag time number that is too small will result in no dispense at all because of inadequate time for the device to operate. A lag time number that is too big may result in over dispenses when very small amounts are called for. Since too small a number may stall the process, always add 2 to the minimum as a safety. As a further safety, the software automatically doubles the lag time number if a dispense occurs without any weight being detected.
If you know ONE bar code input is required to before a new cycle is initiated, set this parameter to 00001. The blender is then prevented from operating until one single valid input is received. If two inputs are expected, set this parameter to 00002, etc. ====================================================================== XCV + XRC For Extrusion Control Systems only. XCV, "Extruder speed Control Voltage" is used in conjunction with our extrusion control software.
batch weight of 2000 grams. The FIRST TWO digits indicate how many cycles must run without a rate adjustment before the operator is permitted to switch from voltage (manual) control to Throughput (automatic) control. This is a factor during startup only. Larger numbers assure a very accurate rate has been learned. This is preferred if you like the way your extruder is running and do not want any further adjustment unless a real problem is detected.
PTD Yield Control - extrusion control - Pulse Train Delta This allows some error in the pulse train rate. For example, if the pulses are being generated at a rate of 6030 per minute, which is 100.5 per second, and we count pulses every second, then we will count 100 for one second, 101 for the next, then 100, then 101 and so on. This "error" could cause adjustments to occur when no adjustment is warranted.
If the alarm is activated, the display will say (TIME OUT). Press the alarm silence button to reset the alarm. also reset the alarm. A new cycle will If another alarm is currently active (material not dispensing for example) then this Monitor alarm is ignored or reset.
PARAMETER DEFAULT SETTINGS - FOUR SOFTWARE Here is a complete list of the "default" entries for all parameters as they are provided in the original program, and as they will appear after a CLEAR ALL or a model change. The Model 220 list is the ORIGINAL BASE list. Models 240, 140, MB, and 940 show only changes from the 220 list. Models 1840, 420, and 440 show only further changes from the 940 list. Models 131, 122 show only changes from the 140 list.
NPT CPT APT 00 00 00 RWT RTI NWT NTI CWT CTI AWT ATI 26000 976 26000 976 20480 31232 20480 31232 RMI NMI CMI AMI 01 01 01 01 RNC NNC CNC ANC 10 10 10 10 RRP NRP CRP ARP RRD NRD CRD ARD 10 10 10 10 500 500 50 50 RLA NLA CLA ALA 20 20 15 15 PRC STL LCL LCH LCF LCZ 10 122 27 39 79 583 SCR BCR XCV XRC TCV TCR XTP XAL XUL CPL PTD LIQ MCT END 00 00 00 00 00 00 20020 05 200 00000 00020 00007 00000 00000 26000 976 26000 976 26000 976 26000 976 20 20 18000 976 18000 976 1280 31232 1280 31232 20 20
CHANGING PARAMETERS To change a PARAMETER, the sequence of keystrokes is as follows: +--------------------------------------------------------------+ ¦ Press: * Display will say: (PASSWORD) ¦ ¦ Press: 22222 Display will say: (P x.x) ¦ ¦ Press: PARA Display will say: (RRAxxxxx) ¦ ¦ Press: PARA Press again to walk FORWARD through list. ¦ ¦ Press: * to BACK UP in the list. ¦ ¦ ¦ ¦ When the PARAMETER you want is displayed, ¦ ¦ enter a new setting using the number keys. ¦ ¦ You must enter 5 digits.
+--------------------------------------------------------------------+ ¦ PART III - PRINTED OUTPUTS ¦ +--------------------------------------------------------------------+ MONITORING SYSTEM ACCURACY *54 - CYCLE PRINTOUT INFORMATION The best way to monitor system accuracy is to connect a printer to the printer port and turn the printer flag ON (KEYPAD section, *54). The printer will now print full output information after every cycle.
Notice that REG shows a full percentage only, no tenths. The software only accepts full percentage entries for regrind. Tenths are ignored. TWELVE software will print up to 3 line groups, 4 components per line, printing only those that are currently turned on. The CYCLE heading: * 11/10/97 * -----------* 16:17:53 * -----------RECIPE 0000 -----------**ID# 051** -----------**WO 000000* -----OPR000 DATE and TIME this blend cycle was completed.
If the first dispense weight, (data line 3), matches the final dispense, (data line 1), then no "retries" occurred. In other words, the first try was accepted by the software. If they do not match, then the first try was short and one or more retries occurred. The second number is the dispense time that the software calculated to be a correct first try for the dispense. The last number (22) is the CYCLE count, a convenient way to keep pages of data in order, like page numbers.
RETRIES: (DATA line 3 and 1, FIRST and FINAL dispense) When FIRST time dispense, (DATA line 3), does not equal FINAL dispense, (DATA line 1), one or more retries have occurred. Retries are evidence of a problem that will also cause percentage errors. Retries may indicate possible problems; perhaps the hopper ran out of material, or the flow rate is so erratic that the first dispense was short for no good reason. Parameters _RT and _RP determine what shortage error is necessary to force a retry.
ERROR CORRECTIONS: RATE NUMBERS. (DATA line 2) The RATE numbers are used by the software, each cycle, to calculate material dispense times. They are adjusted every cycle until flow rates stabilize. When a significant error is detected, the software adjusts the RATE numbers. The GRAM number is adjusted first. The TIME number (interrupts) is changed only if either number falls above 32,768, or both fall below 16,384.
small amounts, but are using a high rate dispense valve to do the job. An auger, a vertical valve, a horizontal valve with a flow restrictor, or a smaller valve would help to improve accuracy and control. If the timing number is below 5, you are operating in a range were it is difficult for the blender to perform well. The LAG time parameter adds time to every dispense.
3. Third, look at the dispense TIME (DATA line 3). Very short times (10, 20, 30 interrupts) indicate dispense devices not well matched to the task. Accuracy on a percentage basis, cycle to cycle, will suffer. This may very well be acceptable as long as overall usage percentages are still accurate. BAILOUT: (line 4) If bailouts occur, vibration is usually the cause and these bailouts may be causing other problems.
MATERIAL USAGE INFORMATION Pressing the VIEW key followed by the * key will cause all material usage totals to be printed. The (*54) flag need not be on. These totals are since the last time printed, and since the last time cleared. This same information may be periodically, and automatically, printed by setting the PRT parameter to a time interval number.
+--------------------------------------------------------------------+ ¦ PART IV - TROUBLESHOOTING ¦ +--------------------------------------------------------------------+ WHAT TO DO If you are reading this section, you are having problems. To locate and correct the problem we suggest that you take the following steps: 1. Start by reading the WIRING CONSIDERATIONS section. Even if the system worked well for a time, new wiring or increased plant electrical noise can cause new problems. 2.
INCREASING THROUGHPUT A correctly sized blender should have throughput that always exceeds your process requirements. If, for some reason, your blender is not keeping up, here are a few ways to increase throughput. 1. If your blender is equipped with a flow control slide gate, under the blender, this will reduce throughput up to 25 percent. To counter this, set the "END FULL" flag on using the *44 function explained earlier.
TYPICAL PROBLEMS These problems are based on phone calls that we have received from GB/WSB Autoweigh Blender. The display does not read close to zero when power is turned on, bin empty (plus or minus 10 grams). * The load cells are not plugged in. * The weigh bin is not resting properly and freely in its platform or the platform is not resting properly on the bolts that protrude from the load cell enclosures. * The controller was never calibrated for these load cells or you just did a CLEAR ALL.
Occasionally, the system gets STUCK doing retries of a component but the retry time is so short that nothing gets dispensed. * The LAG TIME parameter is set for too short a time. See KEYPAD, TIME, and PARAMETER, _LA. * The dispense valve is sticking, slightly delaying it's opening. The time period is too short for the valve to begin moving. The system USED TO WORK but now it does unexplainable things. * Static or a voltage surge has altered RAM memory. Do a CLEAR or CLEAR ALL.
NORMAL OPERATING SEQUENCE This section tells you how the system is supposed to work. If your system is not operating correctly, this description may help you spot exactly where the system is failing, providing a clue to the problem. Turn POWER ON: The following displays occur for 1 second each: Program version date (V=21031A), the check sum number (CKS XXXX), ROM check (ROM OK ), RAM size, (RAM = 8K), Model number (MODEL220), display of ( 0.0), actual weight in the bin is displayed last.
NATURAL second: The NATURAL dispense occurs next in the sequence. The letter "N" will appear in the display. The exact weight of the NATURAL dispensed is now determined for calculating the COLOR and ADDITIVE dispenses. The TOTAL weight of NATURAL and REGRIND combined will appear in the display 3 seconds AFTER the Natural dispense has ended. COLOR third and ADDITIVE fourth: COLOR is dispensed followed by ADDITIVE as requested by the thumbwheel switch settings.
VERIFYING LOAD CELL FUNCTION Most Problems are related to LOAD CELL function. There are several ways to VERIFY that the load cells are functioning properly. The slightest touch on the weigh bin should result in a change in the readout. If this is not the case, something is wrong. When the light touch is removed, the display should return to its starting point. If this does not happen, something is interfering with free movement of the cell or the bin.
LOAD CELL RAW SIGNAL READOUT Press "CE" key to check this RAW number for several seconds. Load cells put out a very small voltage that varies slightly as the load cell is deflected. This voltage is converted, on the circuit board, to a pulse train and these pulses are counted for 1 full second to determine a weight load. The software can handle a range of counts from 0 to approximately 249,850.
LOAD CELL plus WEIGH BIN TEST to verify correct operation This test is to help you determine if the load cells are working correctly, and if the weigh bin and weigh bin hanger are moving freely and registering weight correctly. Have a pad and pencil ready to write down the weight readings that appear on the display, both before and after each dispense. If you prefer, you can use a printer to record all test data. Have the printer flag (*54) set to ON. Be in the PROGRAM mode. (*22222). 1.
"CLEAR" ROUTINE A "CLEAR" routine is available that will clear all data, flags, and all other current information from memory. Since MEMORY is battery backed up, turning power off does not clear all fields. A great deal of information is intentionally held for later use. A "CLEAR" routine will clear all RAM data and start with the information stored in the EEPROM. This is the same data that existed when new or data that you may have intentionally saved earlier.
+--------------------------------------------------------------------+ ¦ PART VI - HARDWARE MAINTENANCE ¦ +--------------------------------------------------------------------+ HARDWARE ADJUSTMENTS AIR PRESSURE Set AIR PRESSURE to about 80 PSI for best accuracy. However, lower pressures will work. If you plant air fluctuates, set the regulator to the low end so that the dispense valves always see a consistent pressure. Lubricated air is NOT recommended. Micro Blenders should be set to 40 PSI (2.7 bar).
CLEAN OUT ISSUES We always try to design with clean out in mind. For this reason all models have removable weigh bins, mix blades, and mix chambers. Selected models have additional clean out issues. GBM Micro Blenders and all blenders with removable hoppers use our verticalor pivot style valves. Most pivot valves are fitted with a sleeve over the air cylinder that shields the dispense valve when it is retracted. Dust can accumulate under this sleeve, between the sleeve and the air cylinder.
MIX PROBLEMS Customers with mix problems have several options available. 1. Decrease the batch size by lowering the FUL parameter value. This does two things. First, it causes the components to be dispensed in smaller, more frequent batches which places more and smaller layers of material into the mix chamber. Second, it lowers the level of material in the mix chamber immediately after a dispense.
9. Models GB/WSB-GBM, 100 series, and some 200 series units use an air drive for the mix blade, instead of an electric motor. Air drives have these advantages: a) Improved mixing due to back and forth motion of the blades. b) No EMF (Electro Magnetic Force) feedback to the processor from electrical demands of the motor resulting, the results in less processor problems.
RECALIBRATION OF LOAD CELLS This unit was calibrated at the factory to match the load cells that were supplied with it. If you recalibrate, note the following: Recalibration can not be done until the Recalibration flag is turned ON. The proper sequence of keystrokes is given below. BE SURE the load cell plug is plugged into the side of the controller. BE SURE the weigh bin is hanging from the load cells freely. BE SURE the air line to the dump valve is connected as it would be during normal operation.
BLENDER PREVENTIVE MAINTENANCE There are no components of your blender that require periodic maintenance. However, over the years, blenders may be subjected to abuse or difficult conditions, and accuracy can suffer. To maintain control over the cost of expensive color and additives, you must maintain accuracy. We recommend that blenders be examined once a year, and all necessary repairs be made to insure continued accuracy.
The blade assembly should slip on and off the motor shaft easily. The need to use excessive force to remove the mixer assembly may bend the blades and they may eventually break off. Correct this if it is a problem. *77 and *54 PRINTOUTS After you have fixed any problems, use the *77 and *54 functions to obtain printouts and fax them to us for evaluation.
SPECIAL TOTALIZER FUNCTION A special function is available that allows throughput TOTALS to be displayed at all times. This flag is for TOTALIZER models only. When set, the display will continuously display the total amount of material that has passed through the unit since the total fields were last cleared. When the unit is functioning as a totalizer, this is the information that is most meaningful.
COMPUTER OUTPUTS - WIRING SUPPLEMENT 17 pin connector This computer output; | drives this device on the board; | that goes to the outside world through this connector; | to drive this external device.
Conair has made the largest investment in customer support in the plastics industry. Our service experts are available to help with any problem you might have installing and operating your equipment. Your Conair sales representative also can help analyze the nature of your problem, assuring that it did not result from misapplication or improper use.
EQUIPMENT GUARANTEE Conair guarantees the machinery and equipment on this order, for a period as defined in the quotation from date of shipment, against defects in material and workmanship under the normal use and service for which it was recommended (except for parts that are typically replaced after normal usage, such as filters, liner plates, etc.). Conair’s guarantee is limited to replacing, at our option, the part or parts determined by us to be defective after examination.
TPBS015/0700 SPECIFICATIONS GRAVIMETRIC BATCH BLENDERS Autoweigh GBM Series Models CONTROL (REMOTE MOUNTED) MODELS Performance characteristics Batch size lbs {g} Maximum throughput lbs/hr {kg/hr}* Bin capacity - large bins ft3 {liter} Maximum number of materials Number of standard dispensing valves† Number of micro dispensing valves Control software (# of components) Dimensions inches {mm} A - Height above mounting plate B - Width C - Depth D - Controller height E - Controller width F - Controller depth
TPBS010/1199 SPECIFICATIONS GRAVIMETRIC BATCH BLENDERS AutoWeigh GB100 Series Models CONTROL B C C A B TOP VIEW FRONT VIEW MODELS Performance characteristics Batch size lbs {g} Maximum throughput lbs/hr {kg/hr}* Bin capacity - main ingredient ft3 {liter} Bin capacity - minor ingredient ft3 {liter} Maximum number of materials Number of discharge valves Number of micro pulsing valves Control software (# of components) Dimensions inches {mm} A - Height above mounting plate† B - Width C - Depth D - Cont
TPBS011/1199 SPECIFICATIONS GRAVIMETRIC BATCH BLENDERS GB 220 and 420 Models TOP VIEW B A C 2 C 1 MOUNTING INTERFACE B A A 14 in. {355.6 mm} IBO4 B 10 in. {254 mm} CONTROL 8 in. {203.
TPBS012/1199 SPECIFICATIONS GRAVIMETRIC BATCH BLENDERS AutoWeigh GB240 and GB440 Models TOP VIEW B 4 C C B 3 A B 1 2 A MOUNTING INTERFACE IB04 8 in. {203.2 mm} square bolt pattern 14 in. {355.6 mm} 10 in. {254 mm SIDE VIEW FRONT VIEW (4) 9/16 in. {14.3 mm} diameter bolt holes CONTROL 3 in. {76.
TPBS013/1199 SPECIFICATIONS GB920 D C C FEEDER LOCATIONS NOTE: Any one of the feeders (A,B,C or D)can be designated position 5 or 6.
TPS014/1199 SPECIFICATIONS GRAVIMETRIC BATCH BLENDERS AutoWeigh GB1840 and 1860 Models FEEDER LOCATIONS D FEEDER LOCATIONS B C C 4 C 2 1 8 7 4 1 2 3 C 3 A C C D A B B A B B TOP VIEW GB1840 TOP VIEW GB1860 NOTE: Any one of the feeders (A,B,C or D) can be designated position 5 or 6.
TPBS016/0700 SPECIFICATIONS GRAVIMETRIC BATCH BLENDERS WSBM Series models B CONTROL (REMOTE MOUNTED) A MODELS Performance characteristics Batch size lbs {g} Maximum throughput lbs/hr {kg/hr}* Bin capacity - standard bins ft3 {liter} Maximum number of materials Number of standard dispensing valves Number of micro dispensing valves Control software (# of components) Dimensions inches {mm} A - Height above mounting plate B - Width C - Depth D - Controller height E - Controller width F - Controller depth W
TPBS001/0700 SPECIFICATIONS GRAVIMETRIC BATCH BLENDERS WSB 100 and 100R Models Top View D Top View, R Model D 1 2 1 2 B 4 C CONTROL 3 4 D B 3 D A Side View MODELS Performance characteristics Batch size lbs {g} Maximum throughput lbs/hr {kg/hr}* Bin capacity - main ingredient ft3 {liter} Bin capacity - minor ingredient ft3 {liter} Maximum number of materials Number of discharge valves Number of micro pulsing valves Control software (# of components) Dimensions inches {mm} A - Height abov
TPBS002/1199 SPECIFICATIONS GRAVIMETRIC BATCH BLENDERS WSB 220 and 420 Models A MOUNTING INTERFACE 14 in. {355.6 mm} B IBO4 0 0 8 in. {203.2 mm} square bolt pattern 0 0 0 0 0 0 0 10 in. {254 mm} (4) 9/16 in. {14.3 mm} diameter bolt holes 3 in. {76.
TPBS003/1199 SPECIFICATIONS GRAVIMETRIC BATCH BLENDERS WSB 240/440 and 240/440R Models Top View Top View, R Models 1 2 MOUNTING INTERFACE D C 14 in. {355.6 mm} IB04 3 B 10 in. {254 mm} 8 in. {203.2 mm} square bolt pattern D (4) 9/16 in. {14.3 mm} diameter bolt holes D 3 in. {76.
TPBS004/1199 SPECIFICATIONS GRAVIMETRIC BATCH BLENDERS WSB 920, 940, 950 and 960 Models NOTE: Loader configuration is the same for all models.
TPBS005/0700 SPECIFICATIONS GRAVIMETRIC BATCH BLENDERS WSB 1840, 1850 and 1860 Models B C C A 0 0 0 0 0 0 0 0 0 Note: loader configuration same for all models CONTROL MODELS Performance characteristics Batch size lbs {g} Maximum throughput lbs/hr {kg/hr}* Bin Capacity - Main Ingredient ft3 {liter} Bin Capacity - Minor Capacity ft3 {liter} Maximum number of materials Number of discharge valves Number of additive feeders Control Software (# of components) Dimensions inches {mm} A - Height above
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