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Labotek FGB-M05 Manual

Gravimetric blender
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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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Summary of Contents for Labotek FGB-M05

  • Page 1 MANUAL GraviMaster-FGB-M05 (S) Gravimetric Blender Serial No..ISO 08.01.02.064.GB 986731 Rev. May 2001...
  • Page 2 3.3.3 Input & Output monitor Adjustment of the gravimetric blender 3.4.1 Calibration of the weighbin 3.4.2 Tare of the weighbin 3.4.3 Hardware-reactiontime Overview of parameters 3.5.1 Public parameters 3.5.2 Protected parameters Reports and overviews GraviMaster-FGB-M05 (S) Gravimetric Blender Page 1...
  • Page 3 6.2.1 Replacement of printed circuit Cleaning the machine Transportation of the GraviMaster TECHNICAL INFORMATION General machine specifi cations 7.1.1 Safety measures User-interface specifi cations Valves specifi cations Air pressure cylinders specifi cations Electrical diagrams GraviMaster-FGB-M05 (S) Gravimetric Blender Page 2...
  • Page 4 The mixing chamber and weigh pan can be removed easily for cleaning and access. The construction is in accordance with the essential require ments under the CE regulations. GraviMaster-FGB-M05 (S) Gravimetric Blender Page 3...
  • Page 5 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...
  • Page 6 Inactive At the start-up of the blender several internal tests will be done automatically if the controller can’t fi 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.

  • Page 7: Machine-Mode

    Rev. May 2001 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’...
  • Page 8 Rev. May 2001 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.
  • Page 9 - 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. GraviMaster-FGB-M05 (S) Gravimetric Blender...
  • Page 10 Example Batchweight Regrind Natural 1 Natural 2 Additive Regrind Naturals Additive GraviMaster-FGB-M05 (S) Gravimetric Blender Percentage of the batch weight Relation between other naturals Percentage of the totals of all naturals 2000.0 gr. 20.0% 5.0% 20.0% of 2000.0 gr. naturals + additive = 80.0% naturals + (0,05 * naturals) = 80.0%...
  • Page 11 The controller has two methods: ‘Additive to regrind’ and ‘Regrind Control’. Addition of extra material using ‘Additive to regrind’ and ‘Regrind Control’ is only GraviMaster-FGB-M05 (S) Gravimetric Blender Percentage of the batch weight Percentage of the batch weight Percentage of the batch weight 2000 gr.
  • Page 12 (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). GraviMaster-FGB-M05 (S) Gravimetric Blender Activated with 2.0% Recipe Weight (g) 20.0%...
  • Page 13 This is the inverse as described in ‘empty regrind control’. This will be done until the middle sensor will become true. In a defi ned number of steps the process will dispense the original setting of the recipe. GraviMaster-FGB-M05 (S) Gravimetric Blender Page 12...
  • Page 14 Now the controller waits for a confi rmation (enter) to initiate new dispense tries of the same material. This process goes on until the dispense accuracy is reached. GraviMaster-FGB-M05 (S) Gravimetric Blender Page 13...
  • Page 15 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). GraviMaster-FGB-M05 (S) Gravimetric Blender IMPORTANT...
  • Page 16 - 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. GraviMaster-FGB-M05 (S) Gravimetric Blender Page 15...
  • Page 17 Rev. May 2001 GraviMaster-FGB-M05 (S) Page 16 Gravimetric Blender EQ-Net Certifi cate...
  • Page 18 Rev. May 2001 GraviMaster-FGB-M05 (S) Page 17 Gravimetric Blender 2.10 ISO Certifi cat...

  • Page 19: User Interface

    Will be used during calculation 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 GraviMaster-FGB-M05 (S) Gravimetric Blender Automatic Start production Dispense one component Stop production...

  • Page 20: Data Entry Keys

    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 GraviMaster-FGB-M05 (S) Gravimetric Blender Description Select FGB Start command, the same as F5...

  • Page 21: Option List

    By the menu (F1) ‘recipes / edit recipes’ it is possible to add recipes to the controller. One recipe consists of one or more (max 12) components which can be changed independently. GraviMaster-FGB-M05 (S) Gravimetric Blender Page 20...
  • Page 22 [0]OPERATING AUTO[ ] STATN:[0] FGB#00: (No name) MODE: AUTOMATIC ------------------------ Name SCR GARDEN CHAIR REGRIND ADEG-2RN ADEG-4RN ANTISTATIC ALU F1Menu F2Option F3 F8Cont. GraviMaster-FGB-M05 (S) Gravimetric Blender Scrap-material Basic-material Additive-material (e.g. masterbatch) STATUS [Edit components] Type NATURAL NATURAL ADDITIVE <ENTER> = edit component <INSERT>...
  • Page 23 <+> 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. GraviMaster-FGB-M05 (S) Gravimetric Blender Type Type [NATURAL] Page 22...
  • Page 24 Step: To confi rm the new component press the arrow key ? or use the <ESC> key. Now the “ADDITIVE” component “WHITE” is added to the list. The maximum number of components is 100. GraviMaster-FGB-M05 (S) Gravimetric Blender Type [NATURAL]...
  • Page 25 All fi 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 fi eld of the recipe giving some extra information about the fi eld. GraviMaster-FGB-M05 (S) Gravimetric Blender STATUS OPERATING...
  • Page 26 Example: Add a new recipe Goal: Add a 2 kg standard recipe . Remark: The required component names should have been added. GraviMaster-FGB-M05 (S) Gravimetric Blender OPTION MENU IN EDIT-RECIPE Description Copies the recipe to the same or other terminal.
  • Page 27 (§ 3.2.1). Step: Press the arrow key <↓> to select the batch. Batch: When the batchweight must be changed it can be done by the use of the numeric-keys IMPORTANT GraviMaster-FGB-M05 (S) Gravimetric Blender Colour [ 2.0] kg [ STANDARD ] Quantity.
  • Page 28 Step: Select the hopper you want to edit with the arrow-keys and press <ENTER> to activate. H# Component Step: Press <ENTER>. Name Noname Noname Noname WHITE GraviMaster-FGB-M05 (S) Gravimetric Blender < STANDARD> STANDARD PERCENTAGE QTY Alarm Speed (g/s) Quantity Alarm Speed (g/s) Type...
  • Page 29 When a new recipe is selected be sure that all hoppers are fi lled with material. The controller calculates new dispense-rates by a fast algorithm in the fi rst 5 batches. GraviMaster-FGB-M05 (S) Gravimetric Blender IMPORTANT...
  • Page 30 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. GraviMaster-FGB-M05 (S) Gravimetric Blender Page 29...
  • Page 31 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). GraviMaster-FGB-M05 (S) Gravimetric Blender STATUS OPERATING MODE: AUTOMATIC...
  • Page 32 (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’. GraviMaster-FGB-M05 (S) Gravimetric Blender IMPORTANT...
  • Page 33 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.
  • Page 34 Time between the full signal of the mixerchamber sensor and opening the mixerchamber-valve. LevelControlDumpTime Time between the free signal of the mixerchamber sensor and closing the mixerchamber-valve. No = [ ], Yes = [X] GraviMaster-FGB-M05 (S) Gravimetric Blender Page 33 Init 01:00.00...
  • Page 35 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’. GraviMaster-FGB-M05 (S) Gravimetric Blender Page 34...
  • Page 36 VariationCycles LoadcellGain LoadcellOverload LoadcellSettleTime LoadcellWeight BandWidth FGB-Name/Nr. GraviMaster-FGB-M05 (S) Gravimetric Blender Description Total weight of one batch. This value is copied into 0,5 [kg] every recipe when it is created. Maximum number of tries per component to reach maximum accuracy Minimum accuracy for each component.
  • Page 37 Standard the ID is set to 1234. After it is changed the ID 1234 can’t be used. There is no way to display the current ID so store the actual ID in a safe place. When you lost the new code, please contact your dealer. GraviMaster-FGB-M05 (S) Gravimetric Blender § 3.5.1 §...
  • Page 38 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 Production status Material usage GraviMaster-FGB-M05 (S) Gravimetric Blender CONTROLLER RECIPES Select recipe Edit recipes...
  • Page 39 Load cell tarration Digital I/O monitor Select automatic mode § Select manual mode Recipes Edit recipes Edit components System Login/logout Change ID Time and date Revision GraviMaster-FGB-M05 (S) Gravimetric Blender § 3.3.1 § 3.3.2 § § 3.5.1 § 3.5.2 §...

  • Page 40: Installation

    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. 4.2. Mountingplate GraviMaster-FGB-M05 (S) Gravimetric Blender Page 39...
  • Page 41 Rev. May 2001 GraviMaster-FGB-M05 (S) Page 40 Gravimetric Blender The foot plate of the GraviMaster 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 shown in drawing 4.2 The unit should be mounted as stably as possible, in connection with the accuracy of the loadcell.
  • Page 42 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. GraviMaster-FGB-M05 (S) Gravimetric Blender Page 41...
  • Page 43 Given hoppernumbers doesn’t contain regrind Check the regrind confl ict or percentage Additive regrind par Given hoppernumber doesn’t contain additive Check the confl ict GraviMaster-FGB-M05 (S) Gravimetric Blender Page 42 Action to cancel alarm Press enter Turn on the main-switch...
  • Page 44 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 history’ and push <ENTER>. GraviMaster-FGB-M05 (S) Gravimetric Blender Page 43...
  • Page 45 0 Date: 06-04-94 Time: 13:14:00 Covers are open F1Menu F2Option F7Pauze F8Cont. If your problems can not be solved by these directives, please contact your dealer. GraviMaster-FGB-M05 (S) Gravimetric Blender STATUS OPERATING Loadcell overload Loadcell not stable Loadcell needs more samples...

  • Page 46: Maintenance And Repair

    Weighbin dump valve: The weighbin dump valve should open and close smoothly. Two GraviMaster-FGB-M05 (S) Gravimetric Blender Set air pressure to about 6 bar for best accuracy. However, lower pressure will work. If your plant air fl uctuates, set the regulator to the low end so that the dispense valves always see a consistent pressu re.
  • Page 47 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 fi rm pallet. GraviMaster-FGB-M05 (S) Gravimetric Blender Page 46...

  • Page 48: Technical Information

    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: GraviMaster-FGB-M05 (S) Gravimetric Blender 1-phase 240 V Fiber optic cable (or RS–422) max.
  • Page 49 Rev. May 2001 Drawing 7.1 Cylinder W= Wiegeschalenanschluss H1= Dosierschieber 1 H2= Dosierschieber 2 B= Mischkammerschieber Option Drawing 7.2 Topview valves Air pressure cylinders specifi cations See specifi cations on cylinder. GraviMaster-FGB-M05 (S) Gravimetric Blender Maschine Page 48...
  • Page 50 Rev. May 2001 GraviMaster-FGB-M05 (S) Page 49 Gravimetric Blender Electrical diagrams...
  • Page 51 Rev. May 2001 GraviMaster-FGB-M05 (S) Page 50 Gravimetric Blender...
  • Page 52 Rev. May 2001 GraviMaster-FGB-M05 (S) Page 51 Gravimetric Blender...

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