Conair GB User Manual

Gravimetric

Blenders

GB and WSB models

with 12-component control

Installation

Maintenance

Operation

Troubleshooting

WARNING - Reliance on this Manual Could Result in Severe Bodily Injury or Death!

This manual is out-of-date and is provided only for its technical information, data and capacities. Portions of this manual

detailing procedures or precautions in the operation, inspection, maintenance and repair of the product forming the subject

matter of this manual may be inadequate, inaccurate, and/or incomplete and cannot be used, followed, or relied upon.

Contact Conair at [email protected] or 1-800-654-6661 for more current information, warnings, and materials about

more recent product manuals containing warnings, information, precautions, and procedures that may be more adequate

than those contained in this out-of-date manual.

The Conair Group, Inc.

Instant Access

Parts and Service

(800) 458-1960

One Conair Drive

Pittsburgh, PA 15202

Phone: (412) 312-6000

Fax: (412)-312-6320

(814) 437-6861

www.conairnet.com

UGB007/1103

The Conair Group Inc.

TWELVE COMPONENT SOFTWARE

GB and WSB Model Blenders

TABLE of CONTENTS

GETTING STARTED, READ THIS PAGE ................ Page 3

SAFETY HAZARDS ................................. Page 4

DISCLAIMERS .................................... Page 5

PART I

- ASSEMBLY

Assembly and Installation Instructions ......... Page 6

Wiring Considerations .......................... Page 10

Check Out Procedure / Diagnostics .............. Page 11

Selecting Correct Model ........................ Page 14

PART II - OPERATION

Load Cell Calibration .......................... Page 15

Turning on Outputs - Material Types ............ Page 16

Setting Material Types ......................... Page 18

Rate Calibration ............................... Page 19

Entering Settings .............................. Page 20

Special Instructions (Micro-Pulse) ............. Page 21

Instructions for Normal Operation .............. Page 22

Special Features ............................... Page 23

Controls and Outputs ........................... Page 25

Keypad - Summary description ................... Page 29

Automatic mode ........................ Page 30

Manual Mode ........................... Page 34

Program Mode .......................... Page 37

Parameters - Short & Long Explanations ......... Page 48

Default Settings .................. Page 71

Changing / Saving Parameters ...... Page 73

PART III - PRINTER OUTPUTS

Monitoring System Accuracy ..................... Page 74

Special Tests .................................. Page 75

Material Usage Information ..................... Page 81

PART IV - TROUBLESHOOTING / SOFTWARE

What To Do ..................................... Page 82

Typical Problems ............................... Page 83

Normal Operating Sequence ...................... Page 85

Verifying Load Cell Function ................... Page 87

Clear & Clear All Routines ..................... Page 90

PART V - HARDWARE MAINTENANCE

Hardware Adjustments ........................... Page 91

Mix Problems ................................... Page 92

Recalibration of Load Cells .................... Page 94

Preventive Maintenance ......................... Page 95

Wiring diagram & Supplements ................... Page 98

Exploded View Diagrams - Parts ................. Page 99

Warranty ....................................... Page 100

The Conair Group Inc.

One Conair Drive

Pittsburgh, PA 15202

412-312-6000

FAX # 412-312-6227

Page 2

GETTING STARTED, READ THIS PAGE.

THE NEXT 13 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: Very little assembly is required. But you

Page 6

might as well get it right the first time.

ALSO: Pay attention to the section on WIRING.

CHECK OUT PROCEDURE:

Page 11

This is to see if you did it right. It also

will tell if anything was damaged in shipping.

LOAD CELL CALIBRATION: We already did this. But shipping or rough

Page 15

handling during assembly sometimes creates

load cell problems. If weight readings are not

correct, you MUST recalibrate the load cells.

TURNING ON OUTPUTS and

SETTING MATERIAL TYPES: To "TURN ON" a component, it must be

Page 16

designated as to TYPE, either REGRIND,

NATURAL, or ADDITIVE. Each is handled

differently by the MATH routines. The

controller MUST know the material TYPE to know

what the setting means. This is IMPORTANT. Be

SURE you UNDERSTAND this section before trying

to operate your system.

RATE CALIBRATION:

Page 19

This is NOT really necessary. But if your

system uses non-standard equipment, you MAY

want to do this.

SETTINGS and NORMAL OPERATION:

Page 20

From this point forward, operating your system

is a snap. This section tells you just how

simple it is and exactly what to expect under

normal operating conditions.

SPECIAL FEATURES:

Page 23

Your system can do much more then you may

know. This page reviews briefly some of the

added features that are available to you and

where in this manual you can find them.

PROCEED TO:

SAFETY HAZARDS

Page 3

SAFETY HAZARDS

+-----------------------------------------------------------+

MIX BLADES

Mix blades are driven with substantial torque.

NEVER place your hand in the mix chamber

while blades are turning.

SERIOUS INJURY will result.

+-----------------------------------------------------------+

ADDITIONAL MIX BLADE HAZARD

Over time, mix blades may become RAZOR SHARP.

¦ Always be careful when TOUCHING or CLEANING these blades. ¦

Check for sharp edges frequently.

Replace blade if a hazard exists.

+-----------------------------------------------------------+

SLIDE VALVES

Slide valves in hoppers SLAM CLOSED without warning. ¦

They WILL injure your fingers.

ALWAYS keep fingers clear of slide gate openings.

NEVER use your fingers to clear an obstruction.

¦ NEVER use your fingers to move a sticking slide gate. ¦

+-----------------------------------------------------------+

SAFETY FEATURES

+-----------------------------------------------------------+

SAFETY INTERLOCK SWITCH

The ACCESS DOOR is equipped with a safety interlock

switch that prevents the mix motor from running and

the slide valves from opening.

DO NOT defeat this safety switch.

+-----------------------------------------------------------+

HOPPER FINGER GUARDS

¦ Finger guards are fitted into each hopper compartment. ¦

DO NOT reach through these guards.

DO NOT use your fingers to clear an

obstruction below these guards.

DO NOT remove these guards.

+-----------------------------------------------------------+

+---------------------------------------------+

PROCEED TO:

ASSEMBLY

+---------------------------------------------+

Part 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.

You must verify to your own satisfaction that this level of performance

meets your requirements. We CAN NOT be responsible for losses due to

product that is blended incorrectly, even when due to equipment

malfunction or design incorrect for your requirements; and/or for any

consequential losses due to our equipment not blending to your

requirements.

We will only be responsible to correct, repair, replace, or accept

return for full refund if our equipment fails to perform as designed,

or we have inadvertently misrepresented our equipment for your

application.

ACCURACY of THIS MANUAL

We make every effort to keep this manual as correct and current as

possible. However, technology and product changes occur more rapidly

then the reprinting of this manual. Generally, modifications made to

the design of the blender or to the operation of the software are not

reflected in the manual for 3 to 6 months. We always reserve the right

to make these changes without notice, and we do not guarantee the

manual to be entirely accurate. If you question any information in

this manual, or find errors, please let us know so that we may make the

required corrections. We will gladly provide you with updated manuals.

Part 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.

THE WARRANTY DOES NOT COVER DAMAGED LOAD CELLS.

The following items have been shipped to you:

1. FRAME and HOPPER assembly: (bolted to skid)

2. CONTROLLER BOX: with the instruction manual.

3. FEEDER BOX: contains a COLOR or ADDITIVE feeder: optional.

4. FLOW CONTROL ASSEMBLY: optional

5. FLOOR STAND or VACUUM TAKEOFF ASSEMBLY: optional

RED INSTRUCTION STICKERS will assist you during assembly.

LIFT HANGERS are available to allow lifting the blender with a strap or

chain. Call us if you require them.

1A. If your unit is to be MACHINE mounted:

For GB/WSB GBM, 100, 200, and 400 series models:

Two ways to do this are suggested ON THE NEXT PAGE: (4a)

The LEFT diagram shows the FRAME and SLIDE GATE both drilled

with the proper bolt pattern for your machine and THROUGH-

BOLTED to your press.

The RIGHT diagram shows only the 10 x 10 steel slide-gate plate

drilled for your bolt pattern and bolted to your press. The

FRAME is then bolted to it using the existing 8 x 8 inch bolt

pattern holes and bolts provided. With this method, bolt head

clearance holes are required in the poly-pro slide gate plate.

This mounting works well on smaller machines.

For GB/WSB 900 and 1800 series models:

An additional machine mount adaptor plate may be required. If

you have ANY DOUBT about the STABILITY of the unit when bolted

directly to your machine throat, please call us for advice.

NOTE: When choosing proper orientation, be sure to retain access to

the controller and weigh chamber, clearance for hinged doors,

and access to removable feeder hoppers.

1B. If your unit is STAND mounted:

A stand is provided and your unit will bolt directly to it. An

assembly DIAGRAM is provided on the following pages.

An air operated FLOW CONTROL ASSEMBLY is provided for dispensing

into a container. The purpose of this unit is to allow time for

mixing to occur after each dispense. This flow valve keeps the mix

chamber full to just below the sensor. This assembly bolts

directly to the bottom of the Blender frame.

Page 6

2. Slide the WEIGH BIN into position. It rests behind the clear

hinged access window. Install with the air cylinder toward you.

If bin is already in place, remove any shipping materials, packing

tape or string.

3. Hang the Color and Additive Feeders:

a. Lift side latches and fully extend slide assembly. Remove the

hopper. Leave slide extended.

b. Tilting the entire slide assembly, motor end up, insert one

corner of hanger cross bar behind frame corner post.

c. Rotate assembly into place so both ends of cross bar are behind

corner posts.

d. Lower into place, bottom edge resting on frame and cross bar

properly positioned behind corner posts.

e. Re-install hopper. Slide motor forward until latches engage.

4. Place the controller on the support tray and plug in all cords:

a. Air solenoid 8 or 14 pin plug into the matching receptacle.

b. Auger feeder drive motors into duplex receptacle.

c. Mixer motor into right side of controller.

d. Sensor cord plug into right side of controller.

e. Load Cell plug into port on left side of controller.

5. Plug the CONTROLLER into the receptacle located under the

controller tray.

IMPORTANT: Do NOT plug the controller into a separate power

source. The controller ground path MUST be the same as

the blender frame ground path. If your system has the

controller located in a remote location, MAKE CERTAIN

that the power to the controller comes from the

receptacle mounted on the Blender frame.

6. Plug the power cord coming from this box into a 110 volt power

source (220 volt outside U.S.). This cord MUST provide the ONLY

power source for the entire system, including the controller.

See: WIRING CONSIDERATIONS, next page. 1800 series blenders also

require a 240 volt power source for the mix motors.

7. Connect air pressure to the unit. About 80 psi (5.5 bar) is

recommended (40 psi for the Micro Blender). Lubricated air is NOT

recommended.

NOTE: GBM Micro Blenders should be set to 40 psi (2.7 bar).

The Vertical Valves used in removable hoppers on Micro

Blenders, 100, and 200 series blenders are more accurate at

the lower 40 psi pressure setting.

8. Remove all protective paper from the plastic windows.

Page 9

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. A source of voltage that

comes from a large transformer that supplies a large portion of the

plant is better then a small power supply transformer that is

intended to supply only this device. Power supplies, even though

they may be "isolation" transformers, will still pass all voltage

spikes right through. Their small size limits their ability to

dampen RF (Radio Frequency) noise that is often induced into the

system from outside sources. This proves worse then connection to

larger central transformers.

2. Avoid running the power supply line along side any heavy power

lines. An unshielded power supply in a raceway along side other

heavy power lines will pick up induced RF noise and transfer it

into the GB/WSB steel enclosure causing computer trouble.

3. Long extension cords should be avoided. They also reduce the

ability to provide a dampening effect on spikes and static. The

further the equipment is from a substantial power source, the more

susceptible it is to spikes.

4. The CONTROLLER and the GB/WSB frame MUST share the same GROUND PATH.

This is why you MUST plug the controller into the OUTLET that is

provided ON THE FRAME.

5. REMOTE SYSTEMS. If you have your controller mounted in a remote

location, you will have a number of power and signal cords running

between the frame and the controller. BE SURE that the LOW VOLTAGE

lines are NOT BUNDLED to the HIGH VOLTAGE lines and keep them away

from other nearby electrical lines.

LOW VOLTAGE lines are: Load Cell cable, Level Sensor cord, Air

Solenoid cable, and Printer and Computer cables.

HIGH VOLTAGE lines are: Mixer motor cable, Feeder motors, and MAIN

POWER line.

Keep these sets of cables SEPARATED.

6. VACUUM LOADER CONVEYING LINES. Keep them away from all electrical

lines, particularly the Load Cell lines. Conveying plastic

produces extreme static sources. A power supply line, even in

conduit, that runs next to a vacuum line, can introduce extreme

static pulses into the processor. Keep conveying lines SEPARATED

from electrical supply lines.

7. We use many internal tooth "STAR" washers in assembling the GB/WSB to

ensure good ground between painted parts. Do not remove them.

+----------------------------------------------------+

¦ PROCEED TO:

CHECK OUT PROCEDURE

NEXT PAGE ¦

+----------------------------------------------------+

Page 10

CHECK OUT PROCEDURE

As you go through this procedure, if WHAT SHOULD HAPPEN, doesn't

happen, see next section, DIAGNOSTICS, for what to check.

NOTE: 100/200 series models (3K load cells), display all weights in

1/10 grams (

x.x). 400/900/1800 series models (10K load

cells) display weights in FULL grams, NO decimal point. On this

page we show all weights with NO decimal point.

Start with NO MATERIAL in any hoppers.

Be sure an AIR SUPPLY is connected.

Place ALL switches DOWN; POWER (on front); STOP and PAUSE (on left).

PROCEDURE:

WHAT SHOULD HAPPEN:

PLUG IN CONTROLLER. Nothing should happen.

Air pressure should be holding ALL valves CLOSED.

This means all air cylinders are extended. If any

slide gate or flap is open, air lines are

reversed. If a FLOW CONTROL valve is installed,

check it.

TURN POWER ON.

Display should say ( TWELVE ),

followed by version date (V=xxxxxT),

followed by the check sum number (CKS=xxxx),

followed by (ROM OK ),

followed by (RAM = 8K),

followed by model number (MODEL220) or the model

you have (GBM, 140, 14R, 220, 240, 24R, 420, 440,

44R, 940, 184),

followed by (

0), then the actual weight of

material in the bin. This number should be zero,

plus or minus several grams ( 20) to (-20).

AT THIS POINT:

Be sure the model number that was displayed

matches your blender model number (first digit

only). If this is not the case see two sections

ahead, SELECTING CORRECT MODEL.

TOUCH WEIGH BIN VERY LIGHTLY.

Display should update the weight every second

reflecting the light pressure that you are

exerting on the bin.

PRESS "*" KEY

Display will say (PASSWORD)

PRESS "22222" (2 key five times) (entering the PROGRAM mode).

2's will be displayed as you enter them.

Display will show (P

x) when done.

PRESS "OPER" KEY

PRESS "1" KEY

Display will say (OPERATE )

Device number 1 will operate.

LED # 1 will light.

Press "1" repeatedly to observe operation.

PRESS "2" KEY

Device number 2 will operate.

Page 11

LED # 2 will light.

Press "2" repeatedly to observe operation.

REPEAT THIS SEQUENCE for each dispense valve on your WEIGH SCALE

BLENDER. Up to 12 outputs are possible numbered 1

through 9, A, B, and C. Only those connected to

devices will operate.

AT THIS POINT:

NOTE which component NUMBER is assigned to each

hopper. You will want to know each hopper's

correct component number.

FACING THE CONTROLLER SIDE OF THE BLENDER:

On 9000 and 18000 gram, FOUR hopper compartment systems:

Device 1 is the NEAR hopper, 2 the FAR hopper, 3 the LEFT CENTER,

and 4 the RIGHT CENTER hopper.

On 1000, 2000, and 4000 gram, FOUR hopper systems, devices 1, 2, 3,

and 4 are counter-clockwise starting with far left corner hopper.

On 9000 and 18000 gram SIX hopper systems, devices 1, 2, 3, 4, 7, and

8 are counter-clockwise starting with far left corner hopper.

ALL MODELS:

Device 5 is the LEFT Panel-front OUTLET.

Device 6 is the RIGHT Panel-front OUTLET.

PRESS "DUMP" KEY

The weigh bin air solenoid will operate.

LED # 13 will light.

The weigh bin dump valve will open.

Press "DUMP" repeatedly to observe operation.

PRESS "MIX" KEY

This key controls the mix motor outlet on the

side of the controller. The mixer motor will run.

LED # 14 will light.

(Mix blade turns CCW facing the motor shaft.)

(Mixer switch must be down; timed position.)

PRESS "HOLD" KEY

The Flow Control Valve will operate.

(Under the mix chamber) (This device is optional)

LED # 15 will light.

PRESS "ALARM" KEY

PRESS "EXIT" KEY

The Strobe light and Beeper will operate.

LED # 16 will light.

Press twice, to return to normal mode.

Verify normal mode by observing that there is NO

letter P in the display (

x).

+-----------------------------------------------------------+

If you have made it this far, congratulations.

You have done well.

¦ The load cells and controller are functioning properly. ¦

+-----------------------------------------------------------+

+----------------------------------------------------------+

¦ PROCEED TO:

LOAD CELL CALIBRATION

SKIP 2 PAGES ¦

+----------------------------------------------------------+

Page 12

DIAGNOSTICS - for the CHECK OUT PROCEDURE

If display fails to come on at all:

check for power at outlet.

Check the 1/2 amp panel front fuse.

If first display says ( FOUR ), then this is NOT the correct manual

for this software. Obtain and use a FOUR software manual.

Possible model numbers are:

GBM, 140, 14R, 220, 240, 24R, 420, 440, 44R, 940, 184.

If model number is not correct for you unit:

see the next page, SELECTING CORRECT MODEL.

If display shows randomly drifting numbers:

check to see load cells are plugged in.

If display shows about (- 1250.0) or ( -4500):

check that the weigh bin is in place properly.

If display is steady but not near zero:

An over stressed load cell will display a permanently high

or low reading. Recalibrate load cells; next section.

If there is no response from the display when the bin is touched:

check for damaged wires to load cells.

check that load cell plug screws are secure.

If response is not sensitive or does not return to its start point:

check for interference around weigh bin.

If pressing * does not display (PASSWORD):

you are not in the normal power-up mode or the keypad

doesn't work. Normal mode is indicated by the ABSENCE of

the letter M or P at the left of the display.

If display says INVALID after entering the password number:

you pressed the wrong keys or the password number has been

changed and it is no longer 22222. Call us for help.

If an air solenoid does not operate:

check the 1/2 amp fuse.

check solenoid cable connected properly and fully seated.

check mix chamber door closed, safety interlock engaged.

If a slide or dump valve does not open:

check the air supply and regulator adjustment:

(minimum 20 psi, 80 psi (5.5 bar) recommended).

check for proper air line connection to cylinder.

If an auger feeder motor does not run:

check the 3 amp fuse.

check that the motor is plugged into the proper outlet.

check for faulty motor by plugging it into a known source of

110 volt A.C. power (240 volt outside U.S.).

Page 13

SELECTING CORRECT MODEL

Controllers are programmed to control all sizes of Autoweigh Blenders.

The MODEL number that your unit is set for will be displayed during the

start up sequence every time power is turned on.

The possible models are:

MODEL

BATCH WT valves WEIGH BIN

LOAD CELL

RATING

(GRAMS)

DIMENSIONS

GBM

140/14R

220

240/24R

420

440/44R

940

400

5 x 5 x 5 high

10 x 6 x 6 high

10 x 10 x 7 high

10 x 10 x 10 high

16 x 16 x 12 high

16 x 16 x 17 high

1 @ 3 K

2 @ 3 K

2 @ 10 K

2 @ 20 K

1000

2000

4000

9000

18000

184

("R" models have 2 removable hoppers)

The addition of feeders will change the last digit of the model number.

This digit can be ignored for selecting the correct Model.

400, 1000 and 2000 gram systems with 3 kg. load cells; weights are

displayed in tenths of grams ( xxxx.x).

4000, 9000, and 18000 gram systems with 10 or 20 kg. load cells;

weights are displayed in full grams ( xxxxx).

If your unit is NOT set correctly to match the hardware you have, you

must change it. To do so:

Turn power on. From the NORMAL mode:

+-------------------------------------------------------+

¦ Press: *

Display will say: (PASSWORD)

¦ Press: 97531 Display will say: (MODEL220)

or whatever model it is

currently set for.

¦ Press: *

To walk through all model sizes.

When the model you want is displayed,¦

then:

¦ Press: EXIT

Wait a few seconds.

Unit will reset and restart

as the system you have selected.

+-------------------------------------------------------+

When switching models, all parameter table information is lost and the

new "default" information for this model is loaded from ROM.

Page 14

+--------------------------------------------------------------------+

PART II - OPERATION

+--------------------------------------------------------------------+

LOAD CELL CALIBRATION

NOTE: Displays shown here are in full grams. 100 and 200 series

models are in 1/10 grams, with a decimal.

If your load cells already display a weight close to zero, plus or

minus 10 grams, you may skip this section and go directly to:

TURNING ON OUTPUTS (next page).

If your unit DOES NOT display an acceptable weight, you should

recalibrate them, that is reset your ZERO weight, at this time.

To do so:

BE SURE the weigh bin is EMPTY.

BE SURE the load cell plug is plugged into the side of the controller.

BE SURE the weigh bin is resting on the load cells freely.

BE SURE the air line to the dump valve is connected as it would be

during normal operation. A disconnected air line adds weight.

BE SURE The load cells and bin are not jammed in any way. To test for

this see that a light touch on the bin causes the display to

change. When the pressure is removed the display must return

to exactly where it was, plus or minus 1 gram.

If this does not happen, something is touching something and

the bin is not entirely free to move. Check EVERYTHING around

the bin.

LOAD CELL CALIBRATION:

The sequence of keystrokes is as follows:

Press: *

Display will say: (PASSWORD)

Display will say: (P x)

Display will say: (CAL OFF)

Display will say: (CAL ON )

Press: 22222

Press: *99

Press: *

Press: EXIT

Press: ZERO

Display will say: (P

Display will say: (--WAIT--)

followed by: (P

Display will say: (

Press: EXIT

The ZERO point of the load cells is now set properly. FULL weight

calibration may also be done at this time, however, it probably is NOT

NECESSARY. When load cell readings shift due to rough handling, the

entire range of readings from ZERO to FULL shift together. The ZERO

weight calibration routine resets the full range of the cells and,

therefore, corrects FULL weight readings as well. For information on

FULL weight calibration, see RECALIBRATION OF LOAD CELLS.

+---------------------------------------------------+

¦ PROCEED TO:

TURNING ON OUTPUTS

and MATERIAL TYPES

NEXT PAGE ¦

+---------------------------------------------------+

Page 15

TURNING ON OUTPUTS - MATERIAL TYPES

This controller can control up to TWELVE (12) components; 1 through 9

and A, B, and C.

You must "TURN ON" the COMPONENT outputs that you are going to use.

Components that are TURNED OFF are not part of ANY routines.

A component becomes TURNED ON when it is set to a MATERIAL TYPE.

Material TYPES are REGRIND, NATURAL, and ADDITIVE.

The AUTOWEIGH BLENDER handles each TYPE DIFFERENTLY. Settings have

different meanings for each TYPE.

To enter SETTINGS correctly, you MUST UNDERSTAND how different

materials are handled based on their TYPE.

So PLEASE read this page CAREFULLY.

Material TYPES are explained here.

How to set them is explained on the next page.

REGRIND

(PERCENT OF MIX)

Components designated REGRIND will be added as a PERCENT of the ENTIRE

MIX of material. For example, If component 1 is designated as REGRIND

and is set for 20.0 percent, then for every 100 pounds of blend, 20

pounds will be this component.

NATURAL

(RATIO TO EACH OTHER)

Components designated NATURAL will be added in the proportion that you

specify them to each other. Their actual percentage of the mix will

depend on how much Regrind is specified and how much Additive is

specified. For example, if components 2 and 3 are both designated

NATURAL and are set for 10 and 40 respectively, then the RATIO of

component 2 to component 3 will always be 10 to 40 or 1 to 4.

If no Regrind or Additives are specified, the mix will be:

component 2, NATURAL, SET= 10, 20.0 percent of mix,

component 3, NATURAL, SET= 40, 80.0 percent of mix.

The RATIO of 1 to 4 is maintained.

If component 1 is specified as REGRIND at 20 percent, The mix is then

component 1, REGRIND, SET=20.0, 20 percent of mix,

component 2, NATURAL, SET= 10, 16.0 percent of mix,

component 3, NATURAL, SET= 40, 64.0 percent of mix.

Components 2 and 3 are still held at a 1 to 4 ratio.

Page 16

ADDITIVE

(PERCENT OF ALL NATURALS)

Components designated ADDITIVE will be added as a percentage of all the

NATURALS added together. For example: If component 5 is an ADDITIVE

at 5 percent, Then the above example now looks like this:

component 1, REGRIND, SET=20.0, 20 percent,

component 2, NATURAL, SET= 10, 15.2 percent,

component 3, NATURAL, SET= 40, 61.0 percent,

component 4, ADDITIVE, SET=05.0, 3.8 percent.

The REGRIND is still 20 percent of the MIX.

The NATURALS are still at a RATIO of 1 to 4, although they have been

reduced to make room for the Additive.

The ADDITIVE is 5 percent of the NATURALS added together (5% of 76.2).

WHY do we do it this way? Because this is how most plastic processors

think of these components. REGRIND is generally only added when

available, and then as a limited percentage of the entire mix.

NATURALS are generally blended at a RATIO to one another. ADDITIVES

are most often only intended to be added to the entire NATURAL portion

of the mix, because regrind generally already contains these additives.

ON THE OTHER HAND:

If you prefer to think of your mix as a RATIO OF WEIGHTS, for example,

components 1, 2, 3, 4, and 5 are to be mixed at 100, 50, 5, 20 and 7

pounds respectively, then you may wish to specify ALL components as

NATURALS. In this way these weights may be entered just as listed

here. Components will be dispensed to maintain each at the proper

specified RATIO to the other components.

If you wish to think of all components as PERCENTAGES of THE MIX,

percents that always add up to 100, specify ALL components as REGRIND

and enter the exact percent for each. When ALL components are

REGRINDS, ALL settings must add up to 99 or 100 percent. If they do

not, an error message (REG >100) or (REG <100) will appear.

BUT... WE RECOMMEND that you do it this way:

REGRIND. Use this for all materials that DO NOT require the addition

of the ADDITIVES. For example, your Regrind scrap.

NATURAL. Use this for all materials that are the bulk of the mix.

These will be RATIOED to each other and will automatically constitute

the ENTIRE mix except for the space needed for Regrind and Additives.

A blend of ABS Homo-polymer and Co-polymer or a blend of Styrene Hi

Impact and Crystal are examples of NATURALS ratioed together.

ADDITIVES. Use this for all materials that are added to the NATURALS

only. For example; color, stabilizer, slip agent, etc.

+-----------------------------------------------------+

¦ PROCEED TO:

SET MATERIAL TYPES

NEXT PAGE ¦

+-----------------------------------------------------+

Page 17

SET MATERIAL TYPES

The Keystroke sequence to set TYPES is:

Press: *

Press: 22222

Display will say: (PASSWORD)

Display will say: (P x)

Press: *

Display will say: (INSTR --)

Press: 14

Display will say: (1TY= OFF)

The "1" is the component (device) number.

This is component 1. It will control Hopper 1.

Press: CE repeatedly to select one of the four options.

Display will say: (1TY= REG). (Regrind)

(1TY= NAT). (Natural)

(1TY= ADD). (Additive)

(1TY= OFF). (turned off)

When the selection you want is displayed, move on to NEXT component:

Press: *

Display will say: (2TY= OFF)

REPEAT the "* CE" sequence for ALL components you use.

The * key will walk you through all components.

The CE key will change the TYPE for a component.

Components NOT CONNECTED, or NEVER USED, set to OFF.

When done:

Press: EXIT

Display will say: (P

Display will say: (

After EXIT, if display says (NEED NAT) then you have specified an

ADDITIVE without specifying a NATURAL. This is unacceptable.

NOTE: FOUR dispense valve systems use components 1 through 4.

TWO dispense valve systems use 1 and 2.

SIX dispense valve systems use 1 through 4, then 7 and 8.

Panel front OUTLETS are always components 5 and 6.

Additional outlets are generally components 7 and 8.

+-----------------------------------------------------+

NEXT PAGE ¦

¦ PROCEED TO:

RATE CALIBRATION

+-----------------------------------------------------+

Page 18

RATE CALIBRATION

YOU DON'T HAVE TO DO THIS.

Software is set to expect STANDARD hardware. If a device meters at a

much lower feed rate then expected, the software will take 10 to 20

cycles to fully adjust. During this time cycles will take longer.

An example of this is a system using a 1/2" auger instead of 1".

If you don't mind letting the system SELF ADJUST, or

your hardware is STANDARD,

then:

+---------------------------------------------------+

NEXT PAGE ¦

¦ PROCEED TO:

ENTERING SETTINGS

+---------------------------------------------------+

To perform a RATE CALIBRATION:

Have the HOPPER LOADED with enough material to run for several cycles

without running out.

Have the "OFF AT END OF CYCLE" and "PAUSE" switches DOWN.

Press: *

Press: 22222

Display will say: (PASSWORD)

Display will say: (P x)

If you are calibrating an auger feeder, operate it briefly to ensure it

is fully primed. To do so:

Press: OPER

Press: 5 (or 6) Run until auger is dispensing.

Press: DUMP This will empty the weigh bin.

Display will say: (OPERATE )

Now you can CALIBRATE the material.

To do so:

Press: CAL

Press: 5

Display will say: (CALIBRATE)

Component #5 will calibrate itself.

(or whatever component you are calibrating)

Repeat this two key calibration routine for EACH material that you

wish to calibrate. Only components that have a TYPE selected (not

"OFF") will operate.

Each time a dispense will occur, followed by weighing, followed by

a dump to empty the weigh bin.

Press: EXIT

when all calibrations are done.

YOU ARE NOW READY FOR ACCURATE PRODUCTION BLENDING.

+---------------------------------------------------+

¦ PROCEED TO:

ENTERING SETTINGS

NEXT PAGE ¦

+---------------------------------------------------+

Page 19

ENTERING SETTINGS

Press: SET

Display will say (1 R xx.x)

or (1 N xxx)

(Regrind)

(Natural)

(Additive)

or (1 A xx.x)

1 is Component number.

R,N,A is Type.

xx.x is Setting.

Enter a 3 digit setting:

Regrind settings = PERCENTAGE of the ENTIRE MIX

Natural settings = RATIO to OTHER NATURAL SETTINGS

Additive settings = PERCENTAGE of ALL the NATURALS

Press: SET

Press: EXIT

for the NEXT setting.

Repeat this sequence for all components.

when finished.

When entering settings, remember:

Panel front OUTLETS are always components 5 and 6; (left and right).

If only one natural is present, any number will do for a setting.

Any component set to zero will not dispense.

THUMBWHEEL ASSIGNMENTS - THIS IS OPTIONAL

You may assign a component to one of the three thumbwheel switches.

You might do this for components that you wish to change settings

frequently. This is ENTIRELY OPTIONAL.

TO DO SO:

Press: SET

Display will say (1 R xx.x)

Press:

or B

or C

Display will say (1 R TW 1) (Thumbwheel 1)

Display will say (1 R TW 2) (Thumbwheel 2)

Display will say (1 R TW 3) (Thumbwheel 3)

1 = TOP switches,

2 = MIDDLE switches,

3 = BOTTOM switches.

To RETURN component to KEYPAD entry of the setting:

Press: CE

Display will return to (1 R 00.0)

when finished.

Press: EXIT

Page 20

SELECTED MODELS - SPECIAL INSTRUCTIONS

This section relates SPECIAL information about a few selected models.

MICRO PULSE

Micro Pulse valves are available on models:

GB/WSB GBM (MICRO Blender) with micro pulse valves.

GB/WSB 122 with optional MICRO PULSE valves.

GB/WSB 131 with optional MICRO PULSE valves.

GB/WSB 140 with optional MICRO PULSE valves.

GB/WSB 240R with optional MICRO PULSE valves.

GB/WSB 440R with optional MICRO PULSE valves.

These models may use our "MICRO PULSE" metering system for Color and

Additive components.

PULSED OUTPUT parameters control the on/off timing, or pulsing, of the

valves. The controlling parameters are the "_PO" component parameters.

When set to 00000, normal slide gate operation occurs.

When set to a value, such as 03030, power will pulse ON then OFF, at 30

interrupt time intervals each way. This ON/OFF cycling will repeat for

the entire dispense time.

When using a MICRO PULSE valve, you must set the related _PO parameter

to 03030.

If overall blender throughput is too low, you may increase the metering

rate of each Micro Pulse device by adjusting the cylinder air flow

control valves for higher flow rate. This causes more rapid movement

of the cylinder, ejecting more pellets per pulse. The drawback is

noisy operation.

We recommend air flow be adjusted for quiet operation, but assuring

full valve movement per on/off cycle. We have already done this. No

further adjustment should be necessary.

The approximate correct air flow adjustments are:

At nose of cylinder, 1.5 full turns out from full closed.

At rear of cylinder, 2.5 full turns out from full closed.

MICRO BLENDER slant valves, adjust by sound.

On fixed hoppers with horizontal micro pulse valves, CLEAN OUT of the

hopper can be accomplished by opening the "clean out" port provided

under the valve. Turn to one side to allow material to drain.

MICRO PULSE - ACCURACY

All MICRO PULSE valves are more accurate if the associated PT parameter

is set to 00090. Read PT parameter in the PARAMETER section.

+---------------------------------------------------+

NEXT PAGE ¦

¦ PROCEED TO:

NORMAL OPERATION

+---------------------------------------------------+

Page 21

INSTRUCTIONS FOR NORMAL OPERATION

OPERATION:

....very simple.

1. Fill HOPPERS.

2. Turn POWER ON. Verify correct settings.

3. On Controller, set STOP and PAUSE switches UP.

Turn MIXER motor switch DOWN to run for a timed period.

Unit will now operate automatically to maintain a level of material

high enough to cover the sensor.

Use the STOP or PAUSE switches to stop the blender.

Turn POWER off only on final shutdown.

----------------------------------------------------------------------

AFTER SEVERAL DAYS OF PROPER OPERATION:

Save all parameter information to the EEPROM for future retrieval just

in case software problems develop later.

To SAVE all parameter information to the EEPROM:

+---------------------------------------------------+

¦ Press: *

¦ Press: 22222

¦ Press: *

¦ Press: 23

Display will say: (PASSWORD) ¦

Display will say: (P x) ¦

Display will say: (INSTR --) ¦

Display will say: (SAVING ) ¦

¦ Wait: when done, Display will say: (P

¦ Press: EXIT Display will say: (

x) ¦

+---------------------------------------------------+

If software related problems develop later, RETRIEVE this correct copy

of the parameters from the EEPROM. This clears corrupted data from RAM

and corrects most software problems.

To Retrieve:

+----------------------------------------+

¦ Switch:

¦ Hold:

¦ Switch:

POWER OFF.

the "CE" key down.

POWER ON.

¦ Release: the "CE" key.

Display will say ( CLEAR ) ¦

If you do not see ( CLEAR )

on the display, do it again.

+----------------------------------------+

Page 22

NORMAL OPERATING SEQUENCE - EACH CYCLE

As the sensor is uncovered, the cycle begins. The target weight of a

complete batch is 18000, 9000, 4000, 2000, 1000, or 400 grams.

REGRINDS are dispensed first, in their order of size, largest dispense

first. After all the Regrind dispenses, the space remaining in the

weigh bin is determined.

NATURALS are dispensed second, in their order of size, each at the

correct ratio to the others. These dispenses are calculated to fill

the bin leaving just enough space for the Additive dispenses. After

all Natural dispense are complete the exact weight of all of the

NATURALS is determined and, based on this actual dispense weight, the

Additive dispenses are now calculated.

ADDITIVES are dispensed last. These dispenses are calculated as a

percentage of all the NATURAL components only.

If any dispense fails to reach the requested weight, the process does

NOT CONTINUE. The ALARM Strobe light flashes, the Beeper sounds, and

the system continues to retry the dispense until the problem is

remedied.

The total batch is then dropped into the mixing chamber for blending

before entering the throat of the process machine.

SPECIAL FEATURES

To use one of these SPECIAL FEATURES, read about it first. The

KEYSTROKE sequence required is given at the end of this section.

To TAG all material usage data with Work Order or Employee numbers for

better tracking of material used, read:

KEYPAD, TAG key, and set 2nd digit in the FLG parameter to 1.

To store RECIPES using the RECIPE storage feature, read:

KEYPAD, RECIPE key, and set 3rd digit in the FLG parameter to 1.

To increase throughput, using the FAST key, read:

KEYPAD, FAST key, and set 4th digit in the FLG parameter to 1.

To blend a preset BATCH amount of material and then stop, read:

KEYPAD, BATCH key, and set 5th digit in the FLG parameter to 1.

BATCH, RECIPE, FAST, and TAG keys REQUIRE that you read:

PARAMETERS, FLG parameter.

To use a lower percentage then 00.1 percent, read:

PARAMETERS, _XT parameter.

To change the MIXER RUN TIME, read:

PARAMETERS, MIX Parameter.

To place UPPER LIMITS on settings, read:

PARAMETERS, _SE Parameter.

Page 23

To LOCK OUT others from changing the settings, read:

PARAMETERS, (*78) - Changing the Password.

To VERIFY ACCURACY of the entire system, read:

PRINTER OUTPUT and TROUBLESHOOTING sections.

To TRACK MATERIAL usage, read:

KEYPAD, VIEW DATA, and PARAMETERS, PRT Parameter.

To configure TWELVE software to look and act like FOUR software, See:

KEYPAD, STAR FUNCTIONS (*04) - Configuration to FOUR software.

READ the rest of the manual at your leisure to learn more about how

your AUTOWEIGH BLENDER works and what else it can do.

KEYSTROKE SEQUENCE for these or other SPECIAL FEATURES

With STOP END OF CYCLE switch DOWN,

Turn POWER ON. Wait 5 seconds, until display says (

Press: *

Display will say: (PASSWORD)

Press: 22222

Display will say: (P

This is the PROGRAM MODE

To alter a PARAMETER; press: PARA key

Press repeatedly until the parameter you want is displayed.

If you accidentally pass it, use the * key to back up.

With the proper parameter displayed, enter the NEW number.

Enter 5 digits; use leading zeros if necessary.

For correct entries, follow specific directions given in the

PARAMETER section.

Press: EXIT

when correct parameter has been entered.

To make a (*XX) entry:

Be in the PROGRAM mode, the same as above.

Display will say (P

Press: *

Display will say (INSTR --)

Enter the 2 digit code.

For correct entries, follow specific directions given in the

KEYPAD section, STAR FUNCTIONS.

Press: EXIT when correct information has been entered.

When finished, press EXIT again to exit the PROGRAM MODE.

Page 24

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 switch that you should use to STOP the system. 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. This stops the process at the end of a full cycle.

3. IMMEDIATE PAUSE / CONTINUE switch

Causes a computer-controlled immediate pause during a cycle. Dispenses

will stop in mid-dispense if necessary. When switched back to

CONTINUE, the process continues without any error in amounts dispensed.

4. ALL AIR SOLENOID outputs

There is a single 8 pin or 14 pin (or 17 pin) Amphanol plug located on

the front of the control panel. this provides output of all 120 volt

(or 24 volt) signals to drive the air solenoids. 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.

If more then 7 outputs are to be driven, a 14 pin connector is provided

with outputs for components 8, 9, A, B, and C.

If 24 volt solenoids are used, a 17 pin connector is provided.

5. POWER OUTPUTS (receptacles on panel front)

Each outlet puts out 120 volts (240 outside USA) through internal plug-

in solid state relays rated and fused at 3 amps. These relay outputs

are designed to drive motors or other devices requiring power up to 3

amps each. The LEFT outlet is for component number 5, and the RIGHT

outlet is for component number 6.

6. EIGHT CHARACTER DISPLAY

Displays the accumulated total bin weight, in grams, after each

dispense. The display flashes when an inadequate dispense has occurred

and the dispense is going to be retried. Other information displayed

here includes material usage totals, internal parameters, component

types and settings and various information prompts to assist the

operator.

###### Numbers displayed are the total weight of material, in grams,

in the bin at any time. The weight in the bin is updated only

after an individual dispense is complete. During the dispense

the displayed weight does not change.

in the left most position indicates unit is in PROGRAM mode.

indicates unit is in MANUAL mode.

1 R 20.0 indicates: Component 1, REGRIND, SETTING of 20 percent.

Page 25

INVALID indicates:

1. you pressed an incorrect key,

2. you pressed a key for a function that is not active, or

3. you are not in the right mode for this key to operate.

PASSWORD is displayed when you press the "*" key from the normal mode.

Enter "11111" for MANUAL mode or "22222" for PROGRAM mode or

enter your own password number if you have established one.

INSTR -- is displayed when you press the "*" key from the PROGRAM mode.

Enter a 2 digit instruction number for special tasks.

SETTING, OPERATE, TIMED, and CALIBRATE are displayed when the

respective keys are pressed from the manual or program modes.

These displays are followed by pressing a device key; 1

through 9, A, B, C, DUMP, ALARM, MIX, or HOLD.

FLASHING means that retries are occurring because the first dispense

was not enough. Other error conditions also cause flashing.

ROM OK or ROM BAD indicates condition of ROM chip.

See KEYPAD, *25, for explanation.

7. LED LIGHTS

The LED lights in two rows of eight located above the 8 character

display indicate the following:

LEFT COLUMN from top:

1 through 8. Component 1 through 8 is operating.

RIGHT COLUMN from top:

1 through 4. Component 9, A, B, or C is operating.

5. Weigh bin dump valve operating.

6. Mixer motor drive relay operating.

7. Mixer flow control valve is open.

8. Alarm output operating.

NOTE: The silk screening on the panel front next to the leds is

correct for FOUR software but not for TWELVE software.

8. STROBE LIGHT AND BEEPER ALARMS

The Strobe light flashes and the Beeper sounds when a component fails

to meter properly. Alarms begin after a number of retries have

occurred, this number determined by the parameter table (see

Parameters, _AL). These alarms can also indicate an out-of-range TARE

weight. This range is set by the TL and TH parameters; above 100 or

below -50 grams.

9. ALARM SILENCE

This button stops the STROBE and BEEPER ALARMS. The continuation of

the cycle to its proper completion will also stop the alarm. When in

the BATCH mode, this button also serves to start the next batch.

10. LEVEL SENSOR input

The high level sensor in the mixing chamber plugs into this outlet and

signals the controller to start a dispense cycle when it is uncovered.

The sensor must be uncovered for at least 2 seconds before a cycle will

start (see DLY 00488 Parameter). Once a dispense cycle is started,

covering the sensor does not stop it. Operation continues until the

cycle is complete.

Page 26

11. MIXER MOTOR OUTLET

This outlet is energized by the software for a time period following

the dump of the weigh bin. You may adjust this time in the parameter

table (MIX 00010). 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. (MIX 00099) will cause the motor to run

for 360 seconds (6 minutes).

12. MIXER MOTOR ON/OFF/TIMED SWITCH

The Mixer ON/OFF/TIMED switch has been removed. To have the mixer

operate continuously, the MIX parameter may be set to 00099. 99 will

instruct the software to run the mixer for 6 minutes after the weigh

bin has emptied at the end of each cycle. This is more then enough

time. This limitation prevents accidentally running the mix motor for

hours on end when the blender is not actually operating.

13. MIXER MOTOR FUSE - 3 amp

This fuse is rated at 3 amps and protects the mixer motor circuit

separately from all other fuses. On 100, 200, and 400 series models,

this fuse protects the mix motor directly. On 900 and 1800 series

models, this circuit operates a 25 amp solid state relay in a separate

box. The mix motor is protected by a "motor starter" switch with a

"heater". This switch must be on for the motor to operate.

14. LOAD CELL input port

The system's two load cells are joined by a common connector that is

plugged into this port.

15. PRINTER output

This is a parallel printer port. A printer plugged in here allows four

types of information to be ported directly to a printer giving the

benefit of a permanent printed record. They are:

1. The totals of the material usage data.

(press VIEW and "*" keys or use the PRT parameter to

AUTOMATICALLY and periodically print these totals.)

2. A listing of the internal parameter table.

(press *77 in the PROGRAM mode.)

3. A printout of information after each cycle including actual

dispensed weights and percentages for every cycle. (press *54 in

the PROGRAM mode, use "*" to set printer flag ON.)

4. A printout of information after the TIME or CALIBRATE routines.

(*54 flag must be on)

Any common parallel printer that you would use with a small PC computer

may be used. Connect using a standard parallel printer cable, (34 pin

parallel Centronix connector to a DB25 IBM compatible connector),

available from us or at any computer store. See: PRINTED OUTPUTS for a

Page 27

detailed explanation of these printouts.

16. COMPUTER input / output

If you choose to gather material usage data automatically and

continuously by computer, then this connector allows for connection to

any 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 port on your

standard PC computer. Your computer operating system must be MS-DOS or

WINDOWS. You will need software from us for communicating with your

Autoweigh Blender. This software allows downloading settings and

retrieval of information and produces reports for those customers who

wish to take advantage of this feature. Either one or many Weigh Scale

Blenders can be connected to one computer. For multiple Weigh Scale

Blender systems, or communication over long distances, an additional

piece of hardware is required. All GB/WSB controllers are fully

programmed to communicate with your computer now or at a later date.

17. PANEL FUSE for duplex receptacle - 3 amp

Fuses the common power wire of the duplex receptacle (the color and

additive outputs). Since these outlets are only turned on one at a

time, each is protected to the full 3 amp rating of the fuse.

18. PANEL FUSE for processor - 1/2 amp

Fuses power to the circuit board power supply which includes all

solenoid outputs and solid state relay outputs.

19. INTERNAL FUSES

An in-line fuse is provided internally to protect the main 120 volt

power cord supply (10) amps. If this fuses blow, an internal short

circuit is indicated and we don't recommend that you try to fix it.

Remember, this unit carries a three year warranty; just send it back.

The MIX MOTOR timed power source and the AUGER FEEDER OUTLETS are

driven by internal solid state plug-in relays. These relays are

located on the circuit board mounted on the inside back surface of the

controller enclosure. A small 5 amp glass fuse is located to the right

of each relay. A spare fuse is also located on the board if

replacement is necessary.

20. THUMBWHEEL SWITCHES

The three sets of THUMBWHEEL switches have no effect unless they are

assigned to a particular output device. Entry of all SETTINGS is done

by using the KEYPAD. However, if you prefer, you may assign up to

three components to the Thumbwheel switches and then use these switches

to set and alter their settings.

Since only three switch sets are available, only 3 components can be

controlled in this manner. All others must use the keypad.

See ENTERING SETTINGS for more information on how to do this.

21. KEYPAD: Explained in next section, next page.

Page 28

KEYPAD - SUMMARY DESCRIPTION

Detailed explanations are given on the pages that follow.

AUTOMATIC OPERATION MODE: (normal operation on power up)

VIEW: View Data: date, time, cycles, and each component weight.

Press VIEW,* to print data.

RCP: Enter and retrieve stored RECIPES.

BTCH: View BATCH data: Target Weight, Current Portion, Accumulated

Total, and Batch Count. CE = clear displayed field.

FAST: Run rapid FAST cycles after a normal weighed cycle.

TAG: Tag Work Order and Operator numbers to all reports.

EXIT: Press to EXIT all sequences from ALL MODES.

SET: Press to review or change settings.

CE:

Press to display "raw signal" weight readout for 3 seconds.

MANUAL MODE: Press: "*"; then (11111) or your own 5 digit password.

OPER: Operate all devices manually; open and close valves.

TIME: Operate devices for a selected time period.

CAL: Operate devices to learn rate.

Above keys use 1 through 9, A, B, C, DUMP, MIX, HOLD, ALARM.

ZERO: Zero the tare weight with the bin empty.

FULL: Using known weights, enter gram weight to calibrate load cells.

*00

*99

Clear DATA fields.

Set flag to enable weight calibration of load cells.

PROGRAM MODE: Press: "*"; then (22222) or your own password.

SET: Enter settings if access in Automatic mode has been locked out.

PARA: View or change system parameters. Press PARA for next in list,

"*" for previous, SET for next table, VIEW for previous table.

STAR FUNCTIONS: Press * and two numbers for the following functions:

*02 Extrusion and Yield Control.

*03 Four digit (xx.xx) settings.

*04 Simulate FOUR software.

*05 Inhibit table clearing.

*52 Double dump weigh bin.

*54 Print cycle information.

*66 GB/WSB I.D. number (1-255).

*69 Regrind as second natural.

*11 DATE - TIME, real-time clock. *71 Color percent of blend.

*12 Move table from ROM to RAM.

*23 Move from RAM to EEPROM.

*32 Move from EEPROM to RAM.

*72 Additive percent of blend.

*74 Stop, alarm MAX wt exceeded.

*75 Alarm on weight drop.

*14 Set types: REG, NAT, ADD, OFF. *77 Print parameters.

*25 ROM OK flag, "CE" to clear.

*33 Special Alarms.

*78 Change program mode PASSWORD.

*82 Precision Ratioing.

*44 End cycle - bin full.

*45 Change MANUAL mode password.

*47 Totalizer flag.

*87 VOLUMETRIC operation.

*88 Print display readout.

*89 Select pounds, kilos.

*98 Display raw weight number.

*48 Dispense range xx.x to xxx.

Use "*" key to select readout or toggle flags ON or OFF.

Page 29

KEYPAD - DESCRIPTION OF FUNCTIONS

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 only BETWEEN cycles or when the PAUSE switch is on.

To stop between cycles, use the "STOP END OF CYCLE" switch.

VIEW DATA: Press to display the CURRENT Date and Time, LAST CLEARED

(VIEW)

date and time, and stored material usage data. Total

CYCLES and Material totals are available: (in Pounds, Kilos,

Grams, or Ounces)

Number of CYCLES that have occurred:

TOTAL weight of each component (X):

(only active components are displayed)

Total weight of ALL materials:

(D = #####)

(X = #####)

(T = #####)

Each successive press of the VIEW key displays the next

total. The last displayed line will say (00=CLEAR) for 5

seconds. During this time, you may press 0,0 to clear the

data. Waiting 5 seconds or pressing any other key will exit

the sequence. When the sequence is exited, normal automatic

operation resumes. These totals may be displayed as pounds,

grams, kilograms, or ounces by a selection procedure

explained later (*89).

Press the VIEW key once followed by the "*" key to cause all

information to be sent to the printer (if available). To

then clear the data, press 00 within 5 seconds. Press any

other key or, wait 5 seconds, to continue the process

without clearing the totals.

RECIPE:

(RCP)

This key allows you to GET, LOAD, and SAVE RECIPES. To

SAVE a recipe you must be in the PROGRAM mode. Recipes are

thumbwheel switch settings. 50 recipes may be stored,

numbered 00 to 50.

This key is NOT FUNCTIONAL unless the third digit in the

"FLG" parameter is set to 1 (FLG xx1xx). To do this, see

the MAINTENANCE section, PARAMETER TABLE, "FLG".

Assuming a proper FLG parameter is set:

In normal Automatic mode: Press RCP key. If a RECIPE is

currently in use then display will flash through the current

stored data:

(RCP --), (1R= xx ), (2N= xx.x), etc., (CE=CLEAR)

Press CE to CLEAR CURRENT RECIPE and return settings to

those previously set. Then press RCP to look at another

Page 30

recipe. Display = (GET --).

If no RECIPE is currently in use, display says (GET --).

Enter 2 digits to retrieve one of 50 recipes.

Display will flash through this recipe data:

(RCP 01), (1R= xx ), (2N= xx.x), etc., (* = 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 --). Enter 2 digits, display will say

(SAVING ). The current settings are saved into memory under

the recipe number you have entered.

Routine will EXIT automatically.

EXIT will exit at any time.

To clear a recipe, set all component settings to zero and

save these settings into the recipe location.

BATCH:

(BTCH)

This key allows you to blend a PRE-SELECTED WEIGHT of

material, and then STOP running and sound the ALARM. The

process may also be programmed to sound the alarm but

continue running. Since each cycle will always blend a full

weigh bin amount, the total amount blended may exceed the

target batch weight by up to one cycle's blend weight.

This key is NOT FUNCTIONAL unless the last digit in the

"FLG" parameter is set to 1 or 2. (xxxx1 or xxxx2). To do

this, see the MAINTENANCE section, PARAMETER TABLE, "FLG".

The ALARM SILENCE button on the side of the controller, is

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 of the Batch Weight you have

blended so far.

Press again to view the ACCUMULATED TOTAL weight of all

batches dispensed.

Display will say (AT #####).

ACCUMULATED TOTAL is the sum weight of all batches that have

been blended. This number will continue to grow until it is

manually cleared to zero, or it exceeds its maximum possible

value.

Page 31

Press again to view the total BATCH COUNT.

Display will say (BC #####).

BATCH COUNT is the total number of batches that have run.

This number will continue to grow until it is manually

cleared to zero, or it exceeds its maximum possible value.

Press again to return to normal operation.

When any of the above totals are being displayed, you may

press the CE key to RESET that number to zero. While all

four totals can be cleared to zero manually, only the BATCH

WEIGHT number can be entered manually.

When the BATCH WEIGHT is being displayed, you may enter a

NEW batch weight using the keypad. You must enter a 5 digit

number with leading zeros, if necessary. Maximum number

that can be entered is "59999".

The unit of weight that will be used is either POUNDS or

KILOGRAMS as determined by the *89 option, explained later.

While in operation, when the total is reached, the system

will alarm and stop blending if the FLG parameter is set to

00001. The system will alarm but CONTINUE running if the

FLG parameter is set to 00002.

Use the ALARM SILENCE button (on the side of the controller)

to silence the alarm. Pressing the BTCH key to view the

information will also silence the alarm.

If the system is programmed to STOP at the end of a batch,

the ALARM SILENCE button MUST be pressed to start blending

the next batch. The First press of the ALARM SILENCE button

will silence the alarm. The Second press will start the

next batch.

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).

FAST:

This key will allow you to exceed the normal blending rate

of your unit. Once your system has learned proper flow

rates of each material, the timing of each component

dispense is very consistent cycle to cycle. The FAST key

allows one or more FAST REPEAT cycles to follow a normal

calibrated cycle. In a FAST REPEAT cycle all components are

dispensed simultaneously, without any weights being taken.

Errors in dispense amounts will not be detected. These are,

in fact, volumetric dispenses, not gravimetric. These

Page 32

dispenses take much less time. Throughput is easily doubled

in this manner.

This key is NOT FUNCTIONAL unless the 4th digit of the "FLG"

parameter is set to 1 (xxx1x). To do this, see the SOFTWARE

MAINTENANCE section, PARAMETER TABLE, "FLG".

The shorter mixing time may be a problem. So the number of

FAST REPEAT cycles is kept as low as possible. Up to 4

repeats may occur.

Press the FAST key to toggle the FAST flag ON of OFF. When

set to (FAST OFF) the FAST mode will not operate. When set

to (FAST ON) every normal calibrated dispense will be

followed by up to 4 FAST repeat dispenses.

This series of 4 dispenses is terminated as soon as the

sensor is covered, which indicates the blender has "caught

up". The next cycle will then be a weighed cycle, followed

by the required series of fast cycles to catch up again.

Press * to toggle between (FAST ON) and (FAST OFF).

Press EXIT, to exit.

When the FAST mode is in operation, the display ( FAST) will

flash intermittently.

SETTING: Press once and the current setting of component 1 is

(SET)

displayed. Display will say (1 X xx.x). X is material

type, either R, (REGRIND); N, (NATURAL); or A, (ADDITIVE).

xx.x is the current setting.

Press SET to step forward through all the settings.

Press * key to backup in the list.

NEW settings may be entered directly.

REGRIND and ADDITIVE settings are expressed as percents, up

to 99.9 percent. NATURAL is any number you wish (usually

weight). It is used to establish RATIOS with all other

NATURAL entries. When only one material is designated as a

NATURAL, the value of it's setting has no meaning, except

that it must be set to some value to operate.

If you wish to restrict the entry of settings to the PROGRAM

mode only, (password required), you may do so by altering

the _SE parameter for each component that you wish to "lock

out". See MAINTENANCE SECTION, PARAMETERS, _SE parameter.

TAG:

This key allows two pieces of information to be "tagged"

onto all data that is either printed or retrieved through

the computer port. The items are WORK ORDER number and

OPERATOR number.

This key is NOT FUNCTIONAL unless the 2nd digit of the "FLG"

parameter is set to 1 (x1xxx). To do this, see the SOFTWARE

MAINTENANCE section, PARAMETER TABLE, "FLG".

Page 33

Press once to display the current Work Order number

(WO-----). Press again to display the current Operator

number (OPRTR---). Press again for the Recipe (RECP ---).

You may enter or change the Work Order or Operator number,

when each is displayed, but not the recipe number.

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 but you can not enter or change it here. The

number will be a 2 digit number if a recipe is being run

that resides in the controller RAM; one that was entered

using the RECIPE key. If a recipe has been entered using

our MLAN software, through the computer port, then a 3 digit

number will be displayed. In either case, the number in

this field will be displayed and "tagged" to all printouts

and retrievals.

EXIT will exit the sequence at any point.

EXIT:

CE:

This key is operational in ALL MODES.

Use the EXIT key to exit any and all keypad sequences.

Press "CE" at any time to display raw data readout of the

load cells for five seconds. This is helpful in diagnosing

possible load cell problems and is explained in detail in

the MAINTENANCE section.

"CE" is used frequently in connection with other keys, to

clear or scan through selections.

KEYPAD - MANUAL MODE

In this mode, you may operate individual functions manually for test

purposes. No totals are saved and automatic operation does not take

place. The low level sensor has no control or effect over manual

operation requests.

The Row of keys marked OPER, TIME, VER, and CAL operate in this mode

coupled with all device keys; 1 through 9, A, B, C, DUMP, MIX, HOLD,

and ALRM.

You can enter this mode only when the controller is between cycles.

The sensor must be covered or the STOP switch must be in the "STOP -END

OF CYCLE" position. When in this mode, no automatic dispensing occurs.

To enter this mode, press "*", then enter the correct password number.

The password supplied with the unit is "11111." You may change this to

Page 34

any other 5 digit number, if you wish, as explained later (*45). When

in the MANUAL mode, the letter "M" shows at the left end of display.

The following manual functions are available in the MANUAL mode.

OPERATE: Press once followed by one of 16 keys: 1 through 9, A, B,

(OPER)

C, DUMP, ALRM, MIX, or HOLD. The selected output operates

until the key is pressed again or another output is

selected. Only 1 output will be active at a time.

EXIT will exit the sequence and close all outputs.

TIMED:

(TIME)

Press once followed by one of 12 component keys. A time in

interrupts is requested; (TIME ---). Three digits must be

entered specifying a dispense time up to 999 interrupts

(about 4 seconds maximum.) CE will cancel entry before last

digit is entered. Following a full 3 digit time entry, the

specified output is activated for the time requested. After

the dispense is weighed, the dump valve automatically

operates to empty the weigh bin. If a printer is on line

and the Print flag is ON, then output information will be

printed. EXIT will exit the sequence.

CALIBRATE: (RATE) Press once followed by one of the 12 component keys.

(CAL)

A dispense will occur for 2 seconds. If the amount

dispensed is less then 50 grams, a second dispense will

occur for 20 seconds. Using the resulting weight and time,

the processor calculates a proper beginning point dump rate

for the start of production blending. After each dispense

is weighed, the weigh bin dump valve automatically operates

to empty the weigh bin. If a printer is on line and the

Print flag is ON (see KEYPAD *54), then output information

will be printed. EXIT will exit the sequence.

If the display says (DO AGAIN), press any key to cause the

process to repeat itself. If the display then says

( NO GOOD), the dispense weight was below 2 grams, not

enough for a valid calibration.

During initial operation, after each power up, the blender

calibrates itself completely automatically, regardless of

how far off the initial flow rate may be. This may take

several cycles. During normal operation, calibration

correction occurs continuously.

Since this unit adjusts flow rates automatically, manual

Rate Calibration is not necessary for proper operation.

ZERO WT. THIS HAS BEEN DONE AT THE FACTORY. IT SHOULD NOT BE

(ZERO)

NECESSARY FOR YOU TO DO THIS AGAIN.

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.

Press the ZERO key once to set the displayed gram weight of

the empty bin to zero. BE SURE the load cells are plugged

into the controller. Be sure the bin is properly in place

Page 35

and EMPTY when this key is pressed.

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. All weight calculations automatically

compensate for this drift. However, when the bin is empty,

if the weight displayed is more than 50 grams above or below

zero, then you may wish to reset the electronics to display

zero when the bin is empty.

If, when the bin is empty, the weight displayed is greater

than 100, or less than -50, (Parameters TH and TL), the

dispense cycle will not begin. Instead, the dump valve will

repeatedly try to dump any material it thinks is in the bin

or will sound the alarm if weight is below -50. If the load

cell calibrations have drifted this far, it is absolutely

necessary to reset empty bin weight to zero. These minimum

and maximum tare weights are set by the TL and TH

parameters. See PARAMETERS, TL and TH for more info.

Allow system to be on for at least 5 minutes to allow for

warm up of certain components before setting ZERO or FULL

weights.

Generally, when zero weight shifts, the full weight reading

shifts the same amount. For this reason, resetting the ZERO

WT automatically shifts the FULL WT readout by the same

amount. Resetting the ZERO weight usually is all that is

necessary to also calibrate the FULL weight.

FULL WT. THIS HAS BEEN DONE AT THE FACTORY. IT SHOULD NOT BE

(FULL)

NECESSARY FOR YOU TO DO THIS AGAIN.

ZERO WT. must be entered before FULL WT. to achieve proper

calibration. The FULL WT. key will not function until you

have set ZERO WT. as described above.

If you wish to reset the controller for proper full-weight

scale display, use any known weight as close to full bin

weight as possible. Do not exceed 9999 grams. Place this

weight in the bin and press the FULL WT. key. The display

will show five dashes (FUL-----). Now enter the actual

weight in grams of the item you are weighing.

AGAIN, both FULL WT. and ZERO WT. have been set at the

factory. A drift of several grams from these settings is

normal and should not be of any concern. Recalibration

should be considered only if ZERO is more than 20 grams off

or FULL WT. is more than 50 grams off. These errors do not

prevent proper proportions from being dispensed. ZERO error

is always "tared" for proper weighing of each component.

FULL scale error will only cause accumulated totals to be

off by the degree of this error. The primary function of

the AUTOWEIGH BLENDER is to dispense materials in the

proper ratios. Because all components are weighed by the

Page 36

same load cells, the accuracy of these ratios is not

affected by zero or full scale errors.

STAR FUNCTIONS available in the MANUAL 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, you should record these

numbers periodically but clearing these totals is entirely

optional and not necessary.

After VIEWING the data or printing of data using the VIEW,*

key sequence, a display of (00=CLEAR) will appear for 5

seconds. During this 5 seconds you may reset all data

fields to zero by pressing 00. Pressing any other key or

waiting 5 seconds will exit this sequence without clearing

data.

*99

Press (*,9,9) to set flag to enable Weight Calibration of

the Load Cells. Power On will always set this flag to OFF.

This flag must be ON before the load cell weight calibration

keys, ZERO and FULL WT, will function. With ON flag

displayed, press EXIT.

KEYPAD - PROGRAM MODE

In this mode, you may perform ALL of the functions available in MANUAL

mode, plus additional functions that alter the logic with which the

controller operates.

The PARA key operates in this mode.

STAR FUNCTIONS are available by pressing the "*" key and two numbers.

Just as with the MANUAL mode, you can enter this mode only when the

controller is between cycles. The sensor must be covered or the STOP

switch must be in the "STOP - END OF CYCLE" position. In the MANUAL

mode, no automatic dispensing will occur.

To enter this mode, press "*", then enter the correct password number.

The correct password supplied with the unit is "22222". To change this

to another 5 digit number of your choice, see (*78). When in the

PROGRAM mode, the letter "P" shows at the left end of the display.

The following PROGRAM functions are available in the PROGRAM mode.

PARAMETERS: Press the PARA key to display the table of operating

(PARA)

parameters that reside in memory. There are 13 separate

groups of parameters. The first group is the GENERAL group

and contains 20 GENERAL parameters. The other 12 groups are

the COMPONENT groups and contain 13 COMPONENT parameters

each.

A FULL EXPLANATION of each PARAMETER can be found in the

next section: EXPLANATION of PARAMETERS.

Page 37

The PARAMETER LIST looks like this:

+-----------------------------------------------------+

¦General ¦ Component: 1 through 9, and A, B, and C: ¦

+--------+--------------------------------------------¦

¦FLG

¦MIX

¦FCV

¦DTI

¦KDF

¦WDF

¦BER

¦ROC

¦ROV

¦RHL

¦FUL

¦MAX

¦ TH

¦ TI

¦PRT

¦DLY

¦PRC

1TY 2TY 3TY

1CS 2CS 3CS

1AL 2AL 3AL

1XT 2XT 3XT

1SE 2SE 3SE

1WT 2WT 3WT

1TI 2TI 3TI

1MI 2MI 3MI

1NC 2NC 3NC

1RP 2RP 3RP

1RD 2RD 3RD

1LA 2LA 3LA

1PT 2PT 3PT

CTY ¦

and so on up to: CCS ¦

CAL ¦

CXT ¦

CSE ¦

CWT ¦

CTI ¦

CMI ¦

CNC ¦

CRP ¦

CRD ¦

CLA ¦

CPT ¦

¦...and so on down to:

¦TRC

+-----------------------------------------------------+

Press: PARA

Press: *

to ENTER the list at the TOP LEFT (FLG).

to move DOWN a list.

to move UP

Press: SET

Press: VIEW

Press: EXIT

to move RIGHT (1st time, goes to 1TY)

to move LEFT

when finished.

In the COMPONENT lists:

The TOP parameter (TYPE) is ALWAYS accessible.

The others are NOT accessible unless TYPE is set.

The First press of the PARA key will enter the GENERAL list

at the top.

Then the first press of the SET key will move to top of the

first component list. Press the PARA key to move down in

any list.

While in one COMPONENT list, press the SET key to jump to

the same relative position in the next list. This allows

rapid scanning of like parameters in all component groups.

To change a displayed parameter enter a new number in place

of the old one. CE will cancel a number entry before the

last digit is entered. The purpose of each parameter is

explained elsewhere in this manual.

In any component list, if TYPE is set to "OFF"; (_TY= OFF);

other parameters in that list are not accessible.

EXIT will exit the sequence at any time.

Page 38

STAR FUNCTIONS available in this mode:

*02

This flag for EXTRUSION and YIELD control, and RATE display.

Press (*,0,2) to turn on Extrusion or Yield control.

The default display is ( OFF).

Press * to toggle this flag to ( RATE ), (EXT CTRL), or

(YLD CTRL).

If you are using our EXTRUSION or YIELD control software to

control your extruder, refer to our EXTRUSION CONTROL

instruction booklet for complete information.

If you simply want to view throughput continuously on the

blender display, set this option to ( RATE ). This will

alter the display only. In all other respects, the blender

will operate normally.

*03

Press (*,0,3) to allow four digit entry of settings in the

format (xx.xx). This does not make the blender more

accurate. It does allow easier setup for customers that

have a mixture of setting requirements, that is x.xx entry

requirements as well as the standard xx.x requirements.

Normally the XT parameter would be manually adjusted to

allow the decimal shift. If this four digit entry option is

turned on, then all entries are in the format xx.xx. The

software uses only the first three digits unless the first

digit is a zero, in which case the last three digits are

selected and the related XT parameter is set to 00010. See

XT parameter for more information. Display will say (SET=

XXX) or (SET=XXXX). Use * key to toggle.

*04

Press (*,0,4) to select from 4 standard software

configurations. If you want your unit to look and act like

it is running FOUR software, then this option will do this

for you in one easy step.

Use the "*" key to toggle through all selections.

Select ( KEYPAD ) to exit without changing anything.

Select ( R,N,C,A) for system to operate like FOUR software.

Select ( N,N,C,A) to operate like FOUR software with the

"TWO NATURALS" flag on.

Select ( N,N,N,A) to operate with three Naturals and an

additive.

Select ( R,N,N,A) to operate with Regrind, two Naturals,

and an additive.

Component 2 is ALWAYS a NATURAL, and is never assigned a

thumbwheel switch. Components 1, 3, and 4 are always

assigned to thumbwheel switches.

If ( R,N,C,A) is selected, component 2 is the ONLY natural

and is set to 100.

If ( N,N,C,A), ( N,N,N,A), or (R,N,N,A) is selected, the

first, third, and forth components are assigned to switches

3, 1, and 2 respectively. Component 2 setting will be

adjusted automatically at the start of each cycle to a

Page 39

number that will make all natural settings add up to 1000.

In this way each NATURAL setting will represent a percent of

the total natural blend.

If the sum of natural settings exceeds 1000, component 2

will be set to 000, and the other naturals will be ratioed

to each other.

The TY and CS parameters are the ones that are altered.

TY sets TYPE to Regrind, Natural or Additive. CS assigns

the thumbwheel swatches. If CS = 40000 the software

knows to calculate a setting based on the other naturals

such that all settings total 1000.

On 140, 240, 440 and 940 models:

If (R,N,C,A) is selected, PARAMETERS are set:

(1TY = REG) (2TY = NAT) (3TY = ADD) (4TY = ADD)

(1CS 30000) (2CS 00100) (3CS 10000) (4CS 20000)

If (N,N,C,A); same as above except:

(1TY = NAT) (2CS 40000)

If (N,N,N,A); same as the first except:

(1TY = NAT) (2CS 40000) (3TY = NAT)

If (R,N,N,A); same as the first except:

(2CS 40000) (3TY = NAT)

On 220 and 420 models:

Changes are the same as above except components 6 and 5

are altered instead of components 3 and 4.

If (R,N,C,A) is selected, PARAMETERS are set:

(1TY = REG) (2TY = NAT) (6TY = ADD) (5TY = ADD)

(1CS 30000) (2CS 00100) (6CS 10000) (5CS 20000)

If (N,N,C,A); same as above except:

(1TY = NAT) (2CS 40000)

If (N,N,N,A); same as the first except:

(1TY = NAT) (2CS 40000) (6TY = NAT)

If (R,N,N,A); same as the first except:

(2CS 40000) (6TY = NAT)

All other TYPE parameters are set to (_TY = OFF).

*05

*11

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).

Press (*,1,1) to enter the correct date and time into the

real-time clock. Correct date and time is helpful if you

are retrieving information using a printer or are collecting

data by computer. Six entries will be requested.

The first display will indicate USA or EUROPE date format.

Use the CE key to toggle from one to the other.

USA will cause all dates to be displayed MONTH/DAY/YEAR.

Page 40

EUROPE will cause all dates to display DAY/MONTH/YEAR.

The remaining five entries are two digits each;

MONTH __, DAY __, YEAR __, HOUR __, and MIN __.

Use the * key to step through all displays without change.

Enter new settings where required.

The correct date and time have been entered at the factory

and should never have to be reset. Of course you may be in

a different time zone.

*12

Press (*,1,2) to move the PARAMETER table from ROM to RAM.

This allows system to operate with the parameters that were

originally supplied as default numbers with the system.

EXPLANATION:

All PARAMETERS are stored in a table that resides in three

places: ROM, RAM, and EEPROM.

ROM (Read Only Memory) is the chip on the circuit board that

cannot be altered in any way except by physically replacing

the entire chip. It contains the program and the copy of

the parameter table that we supply as standard with all

controllers.

EEPROM (Electrically Erasable Programmable Read Only

Memory) is the portion of the processor that can be altered

by the computer by special request only; data stored here is

not lost even if the battery backed up RAM should loose

power. EEPROM contains all parameters and control numbers

that are unique to your system. It holds the information

that is automatically retrieved when the CLEAR procedure is

performed (see below). This information may be retrieved

for use only by special request from the keypad. At the

factory we have set what we believe to be the proper

parameters for your application into the EEPROM.

RAM (Random Access Memory) is the chip on the circuit board

where the processor keeps track of and stores constantly

changing data. It is the area that would go blank if power

were removed from it. We have provided a battery back-up

for the RAM so this should never be a problem. On normal

power off and power on, the data and parameters that reside

in RAM are not lost. However, RAM is the portion of memory

most easily corrupted by the poor electrical environment of

a factory. Should something cause the data in RAM to be

lost or corrupted, a "CLEAR" 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 a computer malfunction. To insure that

your changes are saved for future runs, it is necessary to

move this information from RAM to the EEPROM (*23, next).

NOTE: The battery used for backup is a lithium battery that

is part of an I.C. chip on the board. It has an expected 10

year life and is not easily accessible for replacement.

Page 41

Should it fail, we suggest that it be replaced at our

factory.

*23

*32

Press (*,2,3) to move the PARAMETER table from RAM to

EEPROM. This information is then available for retrieval

using the "CLEAR" routine or by using the *32 function

described next.

Press (*,3,2) to move EEPROM information to RAM. This is

useful for retrieving special information tables that you

may have stored earlier in the EEPROM. Also, if you have

been making changes to RAM tables and now wish to restore

all parameters to what they were at power up, this is the

function to use.

NOTE: The three functions above, *12, *23, and *32, are easily

remembered if you think of the 1, 2, 3 keys as ROM, RAM,

EEPROM. The first digit selects the source, the second

digit the destination.

*14

Press (*,1,4) to set components to one of four options.

The display will look like this:

(1TY= REG), (1TY= NAT), (1TY= ADD), or (1TY= OFF).

This is the component number and the TYPE it is set to:

REGRIND, NATURAL, ADDITIVE, or TURNED OFF.

Press the "CE" key repeatedly to scan the four options.

When proper selection is displayed, move on to NEXT

component by pressing the "*" key.

REPEAT the "* CE" sequence for ALL components you use.

The * key will walk you through all components.

The CE key will change the TYPE for a component.

Components NOT CONNECTED, or NEVER USED, set to OFF.

EXIT will exit the sequence at any time.

After EXIT, if display says (NEED NAT) then you have

specified an ADDITIVE without specifying a NATURAL. This is

an unacceptable condition.

NOTE: FOUR dispense valve systems use components 1 to 4.

TWO dispense valve systems use 1 and 2.

SIX dispense valve systems use 1 to 4, then 7 and 8.

Panel front OUTLETS are always components 5 and 6.

*25

Press (*,2,5) to check the ROM-CHECK flag. Whenever your

controller is on, the processor is continuously performing

an integrity check of the ROM program chip supplied with the

unit. Each complete scan of the program takes about one

minute. If any single check reveals an incorrectly set bit,

the ROM CHECK flag is turned on. This flag is checked every

time you power up. If the flag has been set the display

will say (ROM BAD ), followed by the date and time of the

last check that was found bad. If the flag has not been

Page 42

set, (ROM OK ) will be displayed. To turn the flag off, you

must select this option, (*25), and, with (ROM BAD)

displayed, press the "CE" key. This will clear the flag and

it will remain off until another error is detected. The

seriousness of the problem will be somewhat indicated by the

date and time of the last bad check and how frequently you

find it necessary to turn this flag off. Even with an

error, your controller may still work perfectly. However,

we suggest you request a new program chip from us as soon as

possible.

*33

*44

Press (*,3,3,) to turn on a special alarm condition. Press

* to toggle between (AL STD) and (AL-BATCH). If you are

running using the BATCH key, and (AL-BATCH) is selected,

then the ALARM will sound when a batch is completed.

This flag for SPECIAL APPLICATIONS ONLY.

Press (*,4,4) to tell the controller to end a cycle when the

weigh bin is FULL. Use the * key to toggle between (END

EMTY) or (END FULL).

Normal operation is to end the cycle EMPTY; (END EMTY). 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.

If you have a flow control valve fitted, this option will

increase output of the blender by allowing a cycle to start

even though the flow control valve is keeping the sensor

covered for an additional 6 seconds.

Leave this flag set to (END EMTY), unless you have specific

instructions to do otherwise.

*45

*47

*52

Press (*,4,5, followed by a 5 digit number) to change the

PASSWORD number for entering the MANUAL mode. The system is

supplied with the number "11111" as the password number. If

you wish to restrict use of this mode to only yourself, you

may make up your own number and enter it here.

Special function, DISPENSE systems only.

This function alters the range of requested dispense

weights. 00.1 to 99.9 is standard. 001 to 999 and 0.01 to

9.99 are optional using this function. Dispense systems are

generally used for rotational molding.

Press (*,5,2) to cause the weigh bin dump valve to operate

two times. We call this a "double dump". If you have

problems with material hanging up in the weigh pan, this may

help shake it loose.

Use the * key to toggle between (DBLD OFF) and (DBLD ON).

Press EXIT when done.

*54

Press (*,5,4) to set flag for a printout of data after each

full dispense cycle. With this flag ON and with a printer

Page 43

on line, four lines of information about the dispense cycle

that just occurred will be sent to the printer. This

information includes dispense weight and percentage of each

component, the internal rate numbers used by the computer to

determine dispense time, and the actual dispense time of

each component. This is excellent information to track the

accuracy of each dispense cycle and the accuracy of the

entire system over an extended period of time.

See: PRINTER OUTPUT for a more detailed explanation.

*66

Press (*,6,6) to enter an identification number for this

particular Autoweigh Blender. This I.D. number will

appear on all printed reports. If you have more than one

unit, this helps to identify reports. If you are using a

computer to automatically gather data, then each controller

must have a unique address. Valid numbers are 000 to 255.

When connected to a computer, do not use the number 000 for

identification.

*72

This flag for SPECIAL APPLICATIONS ONLY.

Press (*,7,2) to change the Additive settings to be

interpreted as percent of the entire MIX instead of percent

of the Natural. The display will say (APM -OFF). Press "*"

to toggle flag to (APM -ON). (APM stands for Additives

Percent of Mix). This option has been added for a customer

with a unique requirement.

Leave this flag OFF, (APM- OFF), unless you have specific

instructions to do otherwise.

CAUTION: With this flag set, additive settings combined

must NOT exceed 100 percent. From a practical standpoint,

they should not exceed 10 percent combined.

*74

Press (*,7,4) to set a flag that will cause the system to

stop and the Alarm to activate when MAX weight is exceeded.

This might occur if a valve sticks open or slightly open.

Normally the system recovers automatically from such events

with only the one batch blended incorrectly. Set the flag

only if you want the system to stop and alarm.

Press * key to toggle between (MAX OK ) and (MAX ALARM).

Press EXIT when done.

*75

*77

Press (*,7,5) to set a flag to ALARM if the weigh bin weight

drops more them 20 grams during a cycle. This serves to

detect and report a weigh bin problem, such as material

leaking from the bottom of the bin.

Press (*,7,7) to print a copy of all internal parameters.

A printer must be connected and ready. Up to 13 lists will

print, a General list and 12 component lists. Only

components that are turned "on" will print. Four columns

will print, RAM; ROM; 200 and 900 series tables; and EEPROM.

Identifying headings print above each column.

*78

Press (*,7,8, followed by a 5 digit number) to change the

Page 44

PASSWORD number for entering the PROGRAM mode. The system

is supplied with the number "22222" as the password number.

If you wish to restrict use of this mode to only yourself,

you may make up your own number and enter it here.

If you forget your password number, call us. We can help.

*82

Press (*,8,2) to produce a precision ratioing of a selected

Additive. Press CE to toggle between (P/R OFF), (P/R 1),

(P/R 2), etc. Only those components already designated as

an ADDITIVE will be displayed.

If precision rationing is selected, the specified additive

(selected by the *82 function) will dispense BEFORE the

Naturals, instead of after. Natural dispenses occur after

the selected additive dispense and are calculated to assure

the most exact percentage ratio for the selected component.

Because the Natural dispenses are larger, this method allows

for more exact ratioing of the one selected critical

component.

*83

Press (*,8,3) to select "Progressive Metering" option.

Progressive Metering allows for more accurate dispenses of

selected components. However, cycle time will be extended

by a few additional seconds.

In normal operation blenders target a dispense of the full

requested amount in one try. This almost always works, and

generally will fall within acceptable upper and lower error

limits. Making the dispense in one try allows for high

throughput rates while still achieving a level of accuracy

acceptable for most processors. When the accuracy of one

particular component is critical, or the process depends on

maintaining a tighter tolerance of this component, customers

may lengthen the blend cycle time slightly to achieve this

higher level of accuracy.

The *83 function is used to turn on the progressive metering

function for a selected component. This sets parameters

which will cause the dispense to occur in several

progressively smaller dispenses. This results in a more

accurate dispense.

The first dispense targets only 85 percent (the default

percentage) of the full required amount. After careful

weighing, each successive dispense targets 50 percent of the

remaining shortage. This continues until the amount

reaches, or is within 1 percent of, the target. In this

manner the software "sneaks up" on the target, providing the

maximum achievable accuracy possible.

When a component is selected and turned ON, the

corresponding PT and RP parameters are set to PT 00085 and

RP 00001.

The keypad sequence:

Press *,8,3. Display will say (COL OFF).

Use the "*" key to walk through all the components.

Page 45

Use the "CE" key to toggle a component ON or OFF.

When ON, Display will say (C=ON 85).

You may change the 85 by entering a different number.

Too low will just add time. Too high will cause occasional

overshooting.

Press EXIT when done to save new settings.

*86

Press (*,8,6) to select a new "Back Door" password for your

software. Display will say (BDP 00000). Enter 00001 up to

00009 to select one of nine new backdoor passwords. Contact

us for the actual number. If you just want to kill the use

of a backdoor password altogether, just enter a number from

1 to 9, and don't call us. Then no one in you plant will

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-programmed 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. If for

some reason the password has been altered and you can not

remember it, we have a special "backdoor" password that will

let you in no matter what. For obvious reasons, we do not

provide that password in this manual. You must call us.

However, there is a problem. If the wrong person in your

factory obtains this password, then he will always have

access to the Program mode of the blender no matter what.

Now, with this star function, you have the option to select

from 10 different "backdoor" passwords. If your current

"backdoor" password is known to the wrong person, you can

call us for a new one. We will not give these backup

passwords to just anyone. In fact, since only I know them,

it is not that easy to obtain these numbers.

To activate a new "backdoor" password, you will enter a

number from 00000 to 00009 using this star function. each

number activates a different password. entering 0 activates

the current backdoor password, the one we have used for over

10 years. For a new one, call us and talk with someone you

know here in the office and they will supply a number from 1

to 9, and the associated new "backdoor" password.

After this new "backdoor" password is selected, you can

safely change the regular password to one only you know, and

use that in normal production. No one will be able to use

the backdoor to get in. If you forget your regular

password, and you also forget which backdoor password you

selected, then we will help you go through the entire list

to find the one that works.

*87

Press (*,8,7) to set flag for operation in a VOLUMETRIC

mode. Use the * key to toggle flag ON or OFF. Press EXIT

when done. When power is turned off this flag is always

reset to OFF. With this flag ON (VOLUMETRIC mode), the load

cells are completely ignored. Error correction and rate

Page 46

recalibration does not take place. The unit functions like

a volumetric feeder without checking or correcting for

errors. Since load cell readings are ignored, this flag

allows operation even if the load cells become damaged.

Dispense times will be based entirely on the WT and TI

parameters.

*88

Press (*,8,8) to force a printout of the display on the

controller front. DATE, TIME, Machine number, and display

will print:

Date:

Time:

11/09/93

17:22:01

Machine number: 002

Display Readout: P 500.0

This is useful for obtaining printed verification of load

cell accuracy for 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. The different between the two weight printouts should

equal the KNOWN CERTIFIED WEIGHT.

*89

Press (*,8,9) to select the desired weight unit (GRAMS,

KILOGRAMS, OUNCES, POUNDS) for readout of data. For the

U.S.A. systems are supplied with POUND readout selected.

KILOGRAMS is preferred for nearly all countries outside the

U.S.A. GRAM or OUNCE readout are appropriate only for very

short runs or short demonstrations.

Use the * key to walk through the four possible selections.

Press EXIT when the weight unit you want is displayed.

*98

Press (*,9,8) to set flag for RAW-SIGNAL readout in place

of gram readout of scale weight. Power-On will always set

this flag to OFF. Use the * key to toggle flag ON or OFF.

Press EXIT when done. A raw signal readout is useful to

demonstrate the extreme sensitivity of the load cells. The

raw signal readout bypasses the calibration math routine.

Load cell function can be monitored without concern for any

improper weight calibration that may have been done.

These functions were explained previously in the MANUAL MODE section:

*00

*99

Press (*,0,0) to CLEAR ALL DATA fields.

Press (*,9,9) to set flag to enable Weight Calibration of

the Load Cells.

Page 47

PARAMETERS

All AUTOWEIGH BLENDER controllers operate according to certain

internal PARAMETERS. Because customer requirements vary widely, we

have made over 160 parameters accessible for change through the keypad.

There is one GENERAL group and twelve COMPONENT groups.

BRIEF explanations are given first. FULL information is given in

the section that follows.

NOTE: Values shown here are initial ROM values of a model 940. Initial

values for other models are listed at the end of this section.

Parameters are five digits, with leading zeros added.

TIMES are expressed as seconds, minutes, or interrupts.

(244 interrupts = 1 second).

WEIGHTS are always expressed as GRAMS.

100 and 200 models use tenths of grams: (xxxx.x). (00010 = 1 gram)

400, 900, and 1800 models; full grams: (xxxxx). (00050 = 50 grams)

PERCENTS are expressed in tenths for settings (0xxx.x),

and full percents for other percentage references (00xxx).

----------------------------------------------------------------------

PARAMETER LIST - BRIEF EXPLANATIONS

GENERAL PARAMETERS (20 parameters) (900 series settings shown)

FLG 00000

turns on the RECIPE, BATCH, FAST, and TAG keys.

These four keys will NOT WORK unless you set this parameter.

The RECIPE key is for storing up to 99 recipes.

The BATCH key allows for filling a barrel or gaylord.

The FAST key allows a higher output mode.

The TAG key adds certain information to all printouts.

MIX 00010

MIX TIME

This parameter times how long the MIX motor runs. The default is

set to 00010; 10 seconds of mix.

JOG 03030

JOGS, number and frequency.

This parameter specifies the number of jogs of the mix blade and

how often they occur. The default is set to 03030; a jog every

30 seconds, 30 times.

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 00004

Weigh bin dump TIME at end of cycle. (seconds)

Page 48

This parameter times how long the weigh bin dump valve opens to

empty. No change is required.

KDF 00002

WDF 00002

Maximum variation in GRAMS between two consecutive weight

readings for reading to be accepted. (x or x.x)

KDF controls sensitivity of weight readings during calibration of

load cells. No change is required.

WDF controls the sensitivity of weight readings during normal

operation. If excessive vibration interferes with weight

readings you may have to increase this number.

BER 00200

Excess GRAM weight before dispense is aborted.

This parameter controls sensitivity of the emergency "bailout"

routine that prevents overfilling of the weigh bin.

No change is required.

ROC 00000

These three parameters help control regrind usage.

ROV 00000

RHL 00000

ROC indicates the PERCENT of REGRIND that will be treated as

natural when COLOR and ADDITIVE dispenses are calculated.

This adds some color or additive to your regrind.

ROV is for closed loop fully automatic reprocessing of regrind

scrap. This parameter will detect when more regrind is being

produced than consumed, and override the current setting to

use a higher amount. This helps prevent material backing up

in your grinder.

RHL has effect only if level sensors are added to your unit to

detect material level in the regrind hopper. These level

sensors can alter regrind percent usage.

FUL 09000

MAX 13500

Full batch weight, determined by weigh bin size.

Maximum GRAM weight the software will target.

FUL is the target weight that is blended each cycle. Change only

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 01000

TL 00500

The highest and lowest acceptable TARE weights for

blend cycle to start. (full or tenth grams)

TL prevents starting with the weigh bin out of place. No change

is required.

TH prevents starting with a full weigh bin. Change TH only if

clumps of material hang up in the weigh bin.

PRT 00000

MINUTE interval between automatic print of TOTALS.

This parameter will cause your system to PRINT MATERIAL TOTALS

automatically. A printer must be connected.

DLY 00488

Delay before cycle start. (interrupts)

Page 49

This parameter is the time that the sensor must be uncovered

before a cycle will begin.

PRC 00010

Maximum allowable PERCENT rate change per cycle.

This prevents excessive swings in flow rates by the software. Do

not change.

STL 00122

Dispense settle TIME before a weight reading is taken.

The time (interrupts) allowed for material to SETTLE in the weigh

bin before a weight is taken. Lengthen only to slow the next

cycle start, thereby lowering the pile of material in the mix

chamber, and, in some cases, improving mixing.

LCL 00080

LOAD CELL limits, low slope, high slope, frequency, zero.

DO NOT CHANGE except for different weight load cells.

LCH 00120

LCF 00079

LCZ 00583

The above 4 parameters relate to the characteristics of the LOAD

CELLS on your blender. DO NOT CHANGE THEM.

DS1 00000

DS2 00000

Thumbwheel switch override setting.

The above 2 parameters allow external computer inputs to alter

the thumbwheel switch settings. They are used on computer

controlled dispense systems, using MLAN software.

XCV 00000

Extrusion control voltage output value

Rate of change of above value

Takeoff equipment voltage output value

Rate of change of above value

Trip point to force a correction

Percentage adjustment limit

XRC 00001

TCV 00000

TRC 00004

XTP 50050

XAL 00005

XUL 00200

Voltage adjustment limit

The above 7 parameters all relate to Extrusion Control Systems.

MPO 00010

MCT 00000

For air drive reciprocating mix motor.

Monitor Cycle Time

Alarms if normal cycle timing exceeds previous cycle time by a

specified amount. Used to detect mechanical failures.

COMPONENT PARAMETERS (12 Groups of 13 parameters each)

The first digit is the component number. Component 1 is shown here.

There are 11 more just like it.

1TY = OFF DESIGNATES MATERIAL TYPE for this component.

Material types are: REG, NAT, ADD, or OFF=NOT USED.

(0=OFF, 1=REG, 2=NAT, 3=ADD)

These MUST be set using the *14 function before the system will

Page 50

operate. See: "TURNING ON OUTPUTS" to complete this.

1CS 00000

Thumbwheel assignment or current setting entry.

This parameter reflects the current setting or thumbwheel

assignment for this component. No entry is required here.

1AL 00000

Last digit = number of retries before ALARM.

00001 to 00009 = sound alarm, hold process.

00011 to 00019 = sound alarm, continue process.

These parameters set ALARM functions.

When material runs out, or does not dispense fully, these flags

instruct the controller what to do. Default settings shown are

for Natural, Color, and Additive to alarm, but not Regrind.

1XT 00000

Move decimal left on setting.

These parameters allow entry of less then (00.1) percent for

a selected component.

When set to "00010" settings are read as X.XX percent.

When set to "00100" settings are read as .XXX percent.

1SE 01000

Upper SETTING limits for thumbwheels (0xxx.x).

Settings greater than limit are held to limit.

(01000) = 100%

These parameters can SET UPPER LIMITS to the thumbwheels. For

color and additive, lower settings may help ensure expensive

material is not wasted.

1WT 24000

1TI 01952

WT/TI = the rate that will be used for calculating the

next dispense time.

WT = the Weight portion of the dispense rate, calculated

such that WT/TI equals the average of the last two

actual dispense rates.

TI = the TIME portion of the dispense rate. (interrupts)

These change AUTOMATICALLY during normal operation.

They are Weight and Time portions of the flow rate calibration.

1MI 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.

1NC 00001

Allowable GRAM error within which NO correction is made.

This is the acceptable error range for each component to prevent

hunting. They adjust automatically over an extended time period

to match the flow characteristics of each material.

1PT 00000

Reduce the target of the first try dispense.

1RP 00010

1RD 00300

PERCENT shortage error that will force a retry.

GRAM weight shortage error that will force a retry.

Page 51

Retries occur until both conditions are met.

1LA 00020

Lag TIME before dispense ACTUALLY starts.

(mechanical response time, interrupts)

These parameters state the lag time between when a device is

signaled and when it actually begins to operate.

Change ONLY if you change to non-standard equipment.

1PO 00000

Pulse rate of "MICRO PULSE" valves.

PARAMETER LIST - FULL EXPLANATIONS

GENERAL PARAMETERS (20 parameters)

FLG

(change to enable the RECIPE, BATCH, FAST, and TAG keys)

FLG is a SET of flags for turning on the RECIPE, BATCH, FAST and

TAG keys. These four keys will NOT WORK and there associated functions

are not available, unless this parameter is set properly.

When all digits are set to 0 (FLG 00000), all four functions are OFF.

The second digit set to 1 (FLG 01000), will turn the TAG key on.

The third digit set to 1 (FLG 00100), will turn the RECIPE key on.

The forth digit set to 1 (FLG 00010), will turn the FAST key on.

The fifth digit set to 1 (FLG 00001), will turn the BATCH key on.

The TAG key is useful for entering information that you wish to be

"tagged" to all printouts and computer retrievals. Work Order and

Operator numbers may be entered and displayed. Any computer loaded

recipe number may also be displayed.

The RECIPE key is useful for storing thumbwheel switch settings under a

single numbered recipe. Up to 50 may be stored. To enable the RECIPE

key, place a 1 in the 3rd position of the parameter.

The FAST key allows the unit to operate in a faster, higher output,

mode. Output may be doubled in this way. To enable the FAST key,

place a 1 in the 4th position of the parameter.

The BATCH key allows you to signal that you have processed a certain

amount of material, or for filling a barrel or gaylord to the top

without the need for a level sensor to stop the process. To enable the

BATCH key, place a 1 or 2 in the 5th (last) position of the parameter.

Set to one (00001), the unit dispenses until the preset batch amount is

reached and then stops and alarms. Set to two (00002), the unit alarms

but continues running when the preset amount is reached.

See KEYPAD section, for full explanations of these 4 keys.

======================================================================

MIX (change to run the mixer a longer timed period)

Page 52

MIX indicates the TIME that the mixer will run after the weigh bin

dump valve opens. The number is the mix time in seconds. Adequate

mixing can be accomplished in a short time. Additional mixing may

cause separation and may create a static problem with the material.

The default value is (00015), allowing an initial mix time of 15

seconds. A maximum setting of 29999 is possible, for a mix time of

over 8 hours. Setting the mix time to 99 (MIX 00099) will cause the

mixer to run 360 seconds (6 minutes).

======================================================================

JOG

JOG indicates the number of times the blade will jog after initial

mixing is ended, plus the time interval between these jogs.

After mix TIME is complete, the mix blade is jogged about 1 turn

every 1/2 minute. These jogs serve to level the pile of material in

the mix chamber, insuring that the sensor does not remain covered for

too long. The first 3 digits (030xx) of the parameter indicate how

many jogs will occur. The last two digits (xxx30) indicate the

frequency (or interval) in seconds.

The default setting of (03030) produces a jog every 1/2 minute for

up to 30 jogs. You may lengthen or shorten these numbers as required.

A maximum setting of (29999) produces a maximum jog time of over 8

hours.

======================================================================

FCV

(Delays opening and closing of the flow control valve)

FCV controls three different items:

1) Digit 1 can reverse the output logic of the computer.

2) Digits 2 and 3 set the time delay before closing.

3) Digits 4 and 5 set the time delay before opening.

The most important and primary use of FCV is to set the TIME, in

seconds, that the flow control valve delays before opening (4th and 5th

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. This parameter controls the time that the

Mix Chamber Valve remains closed after a batch has been dropped.

The primary function of the valve is to assure mixing. As such it

seems best to keep as high a level as possible in the mix chamber.

However, if the chamber gets too full (over the blades), mixing is not

as good. To allow the chamber to empty to a lower level after the

sensor is uncovered, we can also DELAY the CLOSING of the flow control

valve. This is done by using the 2nd and 3rd digits (FCV 0xx00) to

specify a delay time. (FCV 00206) delays closing by 2 seconds.

If the first digit is set to a 1 (FCV 10006), the signal output to

the air solenoid is reversed. Normally, the computer puts out a

Page 53

voltage to open the valve. With this flag set the computer puts out a

voltage to close the valve. For this reverse logic to work correctly,

you must reverse the air lines to the flow control valve air cylinder.

Normal power-off position for the valve is closed. Some customers

prefer the valve open when all power is off. This option allows this

reversed "power off" position. With power on, no difference is

apparent.

======================================================================

DTI (probably no need to ever change this)

DTI is the maximum TIME allowed for the weighing bin to dump at

the end of the cycle. The software will close the bin earlier if it

detects no weight change occurring. This time determines the maximum

time that is allowed for the bin to empty. We set this maximum time

limit according to the model and batch size.

======================================================================

KDF, WDF (No change required)

KDF and WDF are the maximum acceptable variation in GRAMS between

two consecutive weight readings. One weight reading requires 1 second

of time. Two readings are always taken and they must be within KDF

grams of each other to be accepted as valid. Readings are taken

continuously until two consecutive readings meet the criteria. This

prevents a single accidental bump of the scale from causing a grossly

inaccurate reading. KDF is used for load cell calibration weights, WDF

for starting tare weight and component dispense weights.

======================================================================

BER

(change only if severe vibration causes problems)

BER is the BAILOUT ERROR weight. Dispenses are controlled by very

accurate timing. However, as a precaution, the weigh bin is constantly

monitored during each dispense. If bin weight is found to exceed

target weight during the dispense, then a BAILOUT occurs. This ends

the dispense immediately just as if the end of the dispense time period

had been reached. This in no way effects the accuracy of the remainder

of the cycle. The dispense is checked and retries will 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 during very small

dispenses. We set this parameter to a default of 00200 (20 grams or

200 grams). If vibration is causing false bailouts, then you may want

to set a higher value in this parameter.

If the BER parameter has a 1 in the last position, (BER 00201),

then a printout will occur of all cycle data anytime a bailout occurs

for any single component. This is helpful if you want to be aware of

occurrences where dispenses significantly exceed target. This will be

the same information that you see when the PRINT flag is on (*54). A

printer must be connected.

======================================================================

ROC

portions)

(Allows for adding some ADDITIVE to one of the REGRIND

Page 54

ROC indicates the PERCENT of one REGRIND that will be treated as

natural when ADDITIVE dispenses are calculated. If you feel it is

necessary to ADD (or subtract) color or additive to your regrind, this

parameter will automatically see that this is accomplished.

The first digit is 0 to add, 1 to subtract.

The second digit is the REGRIND component number you will be making

this adjustment for.

The last 3 digits indicate the percent of this Regrind component to add

to, or subtract from, the Naturals when computing Additive dispenses.

EXAMPLE: ROC set to (ROC 01020).

The first 0 means add. The 1 is component 1.

The 20 means take 20 % of component 1 (a Regrind) and ADJUST the total

of all NATURAL dispenses upward by this amount. Whatever amount of

component 1, Regrind, is added, 20 percent of this amount will be added

to the Natural amounts before a color calculation is made.

Regrind dispense = 600 grams, Natural portions = 1400 grams.

At 4 percent, if ROC=00000, Color would be 56 grams.

If ROC=01020; increase Natural by 20 % of 600, (120 grams).

Color is now 4 % of 1520 grams (1400+120), or 61 grams.

In some cases, the addition of pre-colored regrind tends to produce

overall better coloring because of an initial more uniform dispersion

of pigment. In this case you may want to add LESS color to the Natural

portions when Regrind is present. Placing a 1 in the first digit of

the ROC parameter (ROC 10000), will cause a portion of this Regrind

component to be SUBTRACTED from the Natural portions, instead of added.

EXAMPLE: ROC set to (ROC 11020).

The first 1 means subtract. The second 1 selects component 1.

This means take 20 % of component 1, a Regrind, and reduce the NATURAL

portions by this amount. Whatever amount of component 1 is added, 20

percent of this amount will be subtracted from the Natural amounts

before a color calculation is made.

Component 1 dispense = 600 grams, Natural portions = 1400 grams.

At 4 percent, if ROC=00000, Color would be 56 grams.

If ROC=11020; reduce Naturals by 20 % of 600, (120 grams).

Color is now 4 % of 1280 grams (1400-120), or 51 grams.

======================================================================

ROV

ROV and RHL parameters work together. Their combined purpose

is to allow the adjustment of one Regrind component up or down based on

input from one or two lever sensors.

LEVEL SENSORS are required for this parameter to work.

Both ROV and RHL must be set for these parameters to have any effect.

NOTE: The component being controlled is ALWAYS automatically assigned

to the bottom set of thumbwheel switches.

The first digit of the ROV parameter indicates which component is

controlled by the adjustment routine. Only components 1 through 9 may

be controlled.

Page 55

The last digit determines the adjustment rate. Zero in the last

position means make the full adjustment immediately. Any value from 1

to 9 indicates the percentage adjustment that will be made each cycle

when the level sensor condition changes.

See RHL below for examples.

======================================================================

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 of one

selected regrind component if optional level sensors in the regrind

hopper indicate high or low conditions. The component to be changed is

determined by the first digit of the ROV parameter above.

NOTE: The component being controlled is ALWAYS automatically assigned

to the bottom set of thumbwheel switches.

If set to all zeros (RHL 00000), then this parameter is ignored.

ROV alters the way RHL is interpreted.

If the last digit of ROV = 0, (ROV x0000), then RHL numbers indicate

NEW settings that are to be run when regrind level is high or low.

If the last digit of ROV = 1 to 9 (ROV x0001) to (ROV x0009), then RHL

indicates upper and lower regrind usage limits only, and regrind usage

will be adjusted slowly, to these limits, based on the ROV number.

IF ROV equals zero (ROV 10000):

In this (and all) examples, ROV is selecting component 1 as the

controlled component. (ROV 10000)

If RHL is set to any value, the first 3 digits of the parameter

indicate a new Regrind setting to use when the material level is ABOVE

the HIGH level sensor; (sensor is covered). The last 2 digits indicate

a new setting to use if material level is BELOW the LOW sensor; (both

High and Low sensors are uncovered).

In other words, RHL allows the selection of a percentage that is HIGHER

then normal, and a percentage that is LOWER then normal. NORMAL is

what you put on the bottom thumbwheel switch.

Sensors are assumed to be covered when NO signal is returned. If a

sensor is unplugged from the controller, it is read as "covered".

If you only have ONE SENSOR, it must be used as a HIGH level sensor.

The absence of a sensor is read as a covered sensor; so the absence of

the high sensor would signal the system to run at the high setting all

the time. This would not be acceptable. The absence of the LOW sensor

simple prevents the system from ever thinking it is very low. This is

acceptable.

With a high level sensor only, the system switches between the NORMAL

thumbwheel setting and the HIGH setting indicated by the first 3 digits

of the parameter. The last 2 digits have no effect, since a LOW

condition is never detected.

Page 56

Sensors that we supply are wired correctly for this logic. If a

"Bindicator" or similar device is used, with a micro-switch dry contact

closure signal, then wire to the normally CLOSED contact so that the

signal OPENS when regrind covers the bindicator paddle.

The circuit board "pin outs" for each sensor are positive, ground, and

signal. If you are wiring using a dry contact closure, only the

positive and signal lines are used. When the contact is open, the

signal is pulled to ground internally through a resistor.

Example: RHL is set to 90 and 10 percent (RHL 09010).

ROV last digit is set to zero, (ROV 10000).

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.

If material level is in the middle, between sensors,

the High sensor is NOT covered, (returns a signal),

the LOW sensor IS covered, (returns NO signal),

Regrind runs at the THUMBWHEEL SETTING; 25 percent.

If material level is low, below the low sensor,

BOTH sensors are NOT covered, (both return a signal),

Regrind runs at the LOW setting; 10 percent.

IF ROV equals 1 to 9 (ROV 10001 to ROV 10009):

All the same rules given above apply, except that the thumbwheel switch

regrind setting does not jump in one step to a new setting, but,

instead, moves slowly to the new setting which acts as a limit. The

usage adjustment is made each cycle by the amount specified by the ROV

parameter.

Example: RHL is set to 10 and 90 percent (RHL 09010).

ROV last digit is set to 3 (ROV 10003).

The "Regrind" thumbwheel switch is set to 25 percent (025).

The Software logic is as follows:

If material level rises, goes above the high sensor,

the HIGH sensor is COVERED,

Regrind usage will increase 3 percent each cycle up to a high

limit of 90 percent.

If material level is in the middle, between sensors,

the HIGH sensor is NOT covered,

the LOW sensor IS covered,

Regrind usage will change 3 percent each cycle, moving back

toward the THUMBWHEEL SETTING of 25 percent.

If material level drops below the low sensor,

BOTH sensors are NOT covered,

Regrind usage will decrease 3 percent each cycle down to a low

limit of 10 percent.

Page 57

======================================================================

FUL

(Change only for extremely fluffy or heavy material)

FUL is the full batch weight in GRAMS set at the factory to 1000,

2000, 4000, 9000, or 18000 grams, depending on model. The criteria for

this number is to not exceed the volume capacity of the weigh bin and

to not exceed the load cell capacity. On a 9000 gram system, load

cells are rated for 10,000 grams each. Total load capacity is 20,000

grams. The weigh bin, when empty, weighs about 2400 grams, leaving a

net capacity of 17,600 grams for weighing material. However, a

dispense over 13,000 grams probably would exceed the volume capacity of

the bin. We have set the full batch weight to 9000 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 9000 grams to be too much volume for the bin. Select a lower

total batch weight such as 7000 to ensure that the bin never overflows

or fills completely to the dump valve.

DISPENSE STATION CONFIGURATION.

When this controller is used on a dispensing system (Model WSD;

not a Autoweigh Blender) where you may wish to frequently change the

dispense weight of each batch, this parameter acts as a flag to allow

that mode of operation. When FUL is set to 00001, the controller will

read the top thumbwheel switches as the full batch weight, in pounds

from 00.1 to 99.9, and will target that weight for the batch. When set

to 00002 it will read the switch as kilograms (00.1 to 99.9).

See "MAX", next, for more information.

======================================================================

MAX

(set automatically if FUL parameter is changed)

MAX is the maximum gram weight which the software will allow as a

target for dispensing. The initial Full weight target is set by the

FUL parameter. As dispenses progress, an over dispense of one

component may cause a new target to be calculated for future dispenses

in order to maintain proper requested ratios. A recalculated target is

not allowed to exceed the value held in the MAX parameter.

If you change the FUL parameter, the MAX parameter will automatically

be set to a value 50 percent higher then the FUL setting.

DISPENSE STATION CONFIGURATION.

This controller can be configured to operate as a dispense station

(model WSD). This is generally done when exact weights of material or

blend are required to place into a process, such as rotational molding.

In this configuration, the thumbwheel switches tell the controller how

much weight to dispense in pounds (or kilos). The FUL parameter is set

to 00001 or 00002 for direct reading of the top thumbwheel switch; or

optionally, for recipe reading of the second thumbwheel switch.

When dispense weight you request exceeds the amount specified in

the MAX parameter, the unit will automatically make multiple dispenses

that will add up to the requested amount.

Page 58

======================================================================

TH AND TL (change only if material sticks in the weigh bin)

TH and TL are acceptable error limits for TARE WEIGHT.

Before a dispense cycle begins, the software checks to see that the

weigh bin is in place and that it is not already full of material. To

do this it looks at the starting TARE weight.

If Tare weight is below the value of TL, (50 grams), the software

assumes that the bin is either missing or hung up on something. In

this case the ALARM sounds.

If Tare weight is above the value of TH (100 grams), the software

assumes material is in the bin. In this case the ALARM sounds and the

weight bin dump flap operates in an attempt to empty the weigh bin.

If you are processing a material that has a tendency to hang up in the

corners of the bin, then you may wish to widen the range of acceptable

starting tare weight. Since tare weight is always subtracted from

dispense weights, these errors do not effect accuracy.

======================================================================

PRT

(change to get AUTOMATIC printing of material totals)

PRT, when set to any number other then zero, will cause the

processor to output all current material usage totals, at regular time

intervals, to the printer port. The number you enter will dictate the

time interval in MINUTES. All timing starts from MIDNIGHT. for

example, an entry of 00120 will cause totals to print at 2 AM, 4 AM, 6

AM, etc. Printing always waits until a cycle has just ended. A

setting of 10000 is a special case. This will cause a printout after

every cycle. A printer must be connected. If one is not, the routine

will abort and blending will continue.

======================================================================

DLY

(consider changing if mixing is a problem)

DLY is the TIME the mix chamber level sensor must be uncovered

before a cycle begins. The sensor must be uncovered without

interruption for the full specified DELAY time. To prevent false

starts from material movement caused by the mix blade, a minimum of 2

seconds (00488) 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

increasing the DLY parameter. The new batch is delayed and mix chamber

level has time to fall before the next batch is added.

======================================================================

PRC

(no change required)

PRC is the maximum allowable PERCENT rate change per cycle. If a

large dispense error occurs, flow rate corrections do not exceed this

percent number. This prevents large swings in timing of dispenses and

provides for stable dispense rates under difficult conditions. For

example, when dispense quantities are very small (one or two grams),

Page 59

overfeeding by several grams is a distinct possibility. This type of

error represents a very large percentage error to the controller.

However, a large correction would not be appropriate but, instead,

would cause a "hunting" of dispense time that would result in further

large errors. This parameter prevents this.

======================================================================

STL

(No change required)

STL is the TIME period allowed to pass after a dispense has

occurred, but before a weight reading is taken. This settle time

allows falling pellets to reach the bin and also prevents their impact

with the bin from adding to the weight reading.

======================================================================

LCL, LCH, LCF and LCZ

(DO NOT CHANGE THESE)

These four parameters are set to match the characteristics of the

type of load cells used in your system. DO NOT ALTER THEM. LCL and

LCH are the acceptable LOW and HIGH limits of load cell output

expressed as raw signal counts per gram of weight. LCF is the lowest

acceptable FULL scale load cell output expressed as raw signal counts

per second. LCZ is the highest acceptable ZERO scale output. LCF and

LCZ values are multiplied by 256 before being used by the software.

======================================================================

DS1 + DS2

Function in Dispenser mode only.

Override top and middle thumbwheel switch settings.

When the system is operating as a dispense system, (FUL 00001),

the dispense weight is retrieved from the top thumbwheel switch or from

the recipe file if the middle thumbwheel is set to a recipe number.

If either DS1 or DS2 is set to any value greater then zero:

substitute DS1 for the TOP switch settings, and

substitute DS2 for the MIDDLE switch settings.

These two parameters allow MLAN to download the dispense weight amount

or recipe number. They also allow entry of a "locked in" amount or

recipe.

If BOTH DS1 and DS2 are set to 00000, then nothing changes.

Note: The middle thumbwheel switch setting for a recipe will override

the top switch setting. When loading a weight into DS1, load

00000 into DS2 to be sure DS1 will control.

======================================================================

SCR Special Customer Request

If a customer has a special software requirement that has no

benefit to anyone else, then this request is hidden in the software and

activated by the appropriate code number being entered into this

parameter. Believe me when I say that these requests are useless to

anyone else.

======================================================================

BCR Use only for blenders with BAR CODE reader input.

Page 60

If you know ONE bar code input is required 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. When set to any value,

the blender will not operate until the required number of scanned

inputs are received.

======================================================================

XCV + XRC

For Extrusion Control Systems only.

XCV, "Extruder speed Control Voltage" is used in conjunction with

our extrusion control software. This number can range from 0 to 1000

(XCV 00000) to XCV 01000), and determines the voltage outputed on pin S

of the Amphonol connector. Pin R is the neutral or zero reference for

this voltage output.

The voltage ranges from 0 to 10 volts. 01000 = 10.00 volts. This

parameter can be set manually, however it is intended to be controlled

by the extrusion control logic or by MLAN communications in conjunction

with our extrusion control software.

Whenever the software control logic makes a change to this

voltage, up or down, the controller display will say (RAMPING) during

the time the voltage is being adjusted.

XRC, "Extruder speed Rate of Change", determines the ramp up or

ramp down rate of the XCV parameter, above. It can range from 0 to 10

(XRC 00000) to (XRC 00010). Default setting is 00004.

When XCV changes, it does so gradually, making small incremental

changes every 10 interrupts, or about 24 incremental changes per

second. The XRC parameter determines the maximum value of each

incremental change. For example, if XRC is set to 1 then the XCV

number will increment by 1 count (0.01 volt) every 10 interrupts, for a

rate change of 24 counts (0.24 volt) per second, which will produce a

full range change from 0 to 10 volts over about 41 seconds.

======================================================================

TCV + TRC

For Extrusion Control Systems only.

These parameters control a second 0 to 10 volt voltage output on

for controlling downsteam equipment Takeoff speed. They operate the

same as the XCV and XRC covered above except they move in the opposite

direction, higher to reduce weight per foot, lower to increase weight

per foot.

======================================================================

XTP

For Extrusion Control Systems only.

The LAST THREE digits of the XTP parameter specify the TRIP POINT

when software will make an adjustment to the throughput rate number,

which will then cause a change in extruder speed. Speed is held steady

until there is significant indication that the throughput rate is

incorrect. The software analyzes each batch watching for any

meaningful deviation from current controlling rate. These last two

digits of this parameter specify the accumulated error, indicated as a

percent of full batch weight, required to trip a change. For example,

Page 61

when set to 30 on a 200 series blender, this would indicate a 600 gram

total error must accumulate before adjustment, 30 percent of the full

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. On the other hand, if you know that you want output to be a

predetermined value, like 1000 pounds per hour, then switching sooner

is better. In this way the operator can enter the rate he desires

sooner, and the blender can immediately make any required adjustments

required to target in on this rate. Too large a number causes delayed

response, too small causes hunting. Larger is safer since you do not

want "false" adjustments to occur.

This parameter starts at XTP 50030, 30 percent of full batch

weight accumulated error and 5 cycles required without adjustment

before your operator can switch to the Throughput mode. A "T" is

displayed when the 5 cycle requirement is reached.

======================================================================

XAL

Extrusion Control Adjustment Limit

XAL limits the degree of change that the software can make in one

adjustment cycle. Default setting is 00005, 5 percent. Operator

entered rate changes are not limited.

======================================================================

XUL

Extrusion Control - Upper Adjustment Limit

XUL sets an upper limit to how far the software can adjust the

extruder speed (control voltage). If this limit is exceeded, then the

adjustment is NOT made, and the ALARM is turned on. Pressing the V/T

key switches the control to Voltage Mode. When pressed again, the unit

returns to Throughput Mode, and a new Limit is set. Further

adjustments may now occur to the new limit.

Default is 00200, 2 volts. The idea is that once control is

established, adjustments upward of more then 2 volts indicate

conditions that should be attended to, a clogged screen pack for

example. You may wish to reduce this number so that operators are

warned well in advance of such conditions.

======================================================================

CPL

Yield Control - extrusion control.

Customers using Yield Control require a pulse generator, or shaft

encoder, mounted on downstream takeoff equipment to signal the line

speed to the blender. In operation the software displays GRAMS per

unit length, which may be per foot, per yard, per meter, or whatever.

For whichever unit length you select, enter the pulses per unit length

in this parameter. In America, a typical shaft encoder delivers 600 or

1200 pulses per foot. Set the parameter to 600 or 1200. Everywhere

else you are most likely concerned with meters. The proper setting for

this parameter is the number of pulses per METER that the encoder

Page 62

generates.

======================================================================

MPO

for Micro Blender air driven reciprocating mixer.

MPO sets the timing, in tenths of seconds the clockwise and

counterclockwise timing of the mix blade. MPO 00010 is 1 second for

each direction.

======================================================================

LIQ

For LIQUID COLOR applications using dual pumps / drums.

Liquid Color users generally want the current container of color

to run completely out before switching to a new container. Switching

early requires the transfer of the unused portion to the next

container. This feature allows a standby container to be in place and

ready, and instructs the blender to switch to the backup container as

soon as the first container runs out, as detected by the lack of weight

after a dispense. The default setting is LIQ 01011, which directs that

component 10 is the normal output, and 11 is the component to switch

to. Outputs 10 and 11 must first be prewired to an outlet that is

added to the side plate of the controller. Two additional air

solenoids are also added to drive liquid pumps that require air for

operation.

When conventional pumps are used, two pumps must be present, each

connected to a drum of color. Both would have to be plugged into the

two outlets on the duplex receptacle on the front of the controller.

The parameter would be set to LIQ 00506, which is to say that the

"additive" outlet (output 6) is designated as the back up output for

COLOR (which is output 5).

Other arrangements are possible, but require some wiring.

======================================================================

MCT

Monitor Cycle Time

This parameter acts as the ultimate fail safe precaution. When

used, it monitors sequential cycle times, and alarms if a cycle time

exceeds the previous cycle time by an amount that is not consistent

with proper operation. This provides a means to detect mechanical

failures such as a sticking valve or weigh bin gate.

When set to 00000, this parameter is not active.

When set to MCT 02060, an alarm will occur when either a cycle time is

double (02xxx) the previous time, or exceeds it by 60 (xx060) seconds.

At power-on this alarm is always set off and disabled. Once smooth

running is established, the alarm is enabled. Smooth operation is

established using the same logic that Extrusion Control uses.

If the alarm is activated, the display will say (TIME OUT).

Press the alarm silence button to reset the alarm. A new cycle will

also reset the alarm.

If another alarm is currently active (material not dispensing for

example) then this Monitor alarm is ignored or reset.

Page 63

======================================================================

COMPONENT PARAMETERS (12 Groups of 13 parameters each)

_TY

(Designates material type for this component)

_TY is the number that designates if this Component is used and

what material TYPE it is.

Material TYPES are REGRIND, NATURAL, ADDITIVE, or NOT USED.

This parameter is stored as a 5 digit number but displayed as a three

letter word:

OFF = Component NOT USED,

REG = REGRIND,

NAT = NATURAL,

ADD = ADDITIVE.

Use the "*" key to toggle through these four selections.

(All other parameters require input of a 5 digit number.)

The AUTOWEIGH BLENDER handles each DIFFERENTLY in the MATH routines.

REGRIND

(PERCENT OF MIX)

Those components that you designate REGRIND will be added as a PERCENT

of the ENTIRE MIX of material.

NATURAL

(RATIO TO EACH OTHER)

Those components that you designate NATURAL will be added in the

proportion that you specify them to each other. Their actual

percentage of the mix will depend on how much Regrind is specified and

how much Additive is specified.

ADDITIVE (PERCENT OF ALL NATURALS)

Each component designated ADDITIVE will be added as a percentage of all

the NATURALS added together.

If you think of your mix as a RATIO OF WEIGHTS, for example, components

1, 2, 3, 4, and 5 are to be mixed at 100, 50, 5, 20 and 7 pounds

respectively, then you may wish to specify ALL components as NATURALS.

In this way weights may be entered just as listed. They need not add

up to any particular number. Components will be dispensed to maintain

the proper specified RATIO to each other component.

If you wish to think of ALL components as PERCENTAGES of THE MIX,

percents that always add up to 100, then you can specify ALL components

as REGRIND and enter the exact percent for each. If ALL components are

specified as REGRIND, then all settings must add up to 100. If the

total exceeds 100, an error message will appear.

However, we recommend that you specify materials this way:

REGRIND; all the materials that DO NOT require the addition of the

ADDITIVES. Usually this is your Regrind scrap.

NATURAL; all the materials that are the bulk of the mix. These will be

Page 64

RATIOED to each other and will constitute the ENTIRE mix

except for space needed for Regrind and Additives.

ADDITIVE; all the materials that are added to the NATURALS only; color,

stabilizer, slip agent, etc.

======================================================================

_CS

(Set AUTOMATICALLY when you enter settings)

_CS parameter stores the current setting that has been entered

through the KEYPAD, "SET" function, for this component. You could

change it here, but the SET routine is the proper way to alter this

number.

This parameter can also be set to ASSIGN this component to one of the

three THUMBWHEEL switches. This also is normally done in the SET

routine by using the SET key followed by a letter key (A,B, or C).

When set to 10000, 20000, or 30000 the component will follow the TOP,

MIDDLE, or BOTTOM thumbwheel switches respectively. The SET routine is

the proper way to assign thumbwheels.

In the special case when there are four components, and two or more are

naturals, then one NATURAL can have its setting calculated

automatically, based on the other natural settings, so that all natural

settings total 1000. This is done by setting the CS parameter to

40000. This allows four components to be controlled by only three

thumbwheel switches, three assigned, and the forth calculated

automatically by default.

If this is a four (or less) component system, then you are using this

software because your components are not NATURAL, REGRIND, COLOR and

ADDITIVE. Our standard "FOUR" software handles that combination in a

simpler, more straightforward way. See KEYPAD, STAR FUNCTIONS, *04 for

a rapid way to set up your system for 4 or less components.

======================================================================

_AL

(Sets alarm functions)

_AL Alarm FLAGS. When material runs out, or for some other reason

material does not dispense fully, these flags will instruct the

controller what to do.

00000 = no alarm, no pause in process, no retries. This is sometimes

useful for a Regrind dispense.

00001 to 00009 = sound alarm after specified number of retries and

continue retries until successful. The process will not continue

until the fault condition is corrected. The last digit

determines the number of retries before sounding the alarm. This

is appropriate for all important and necessary components.

00011 to 00019 = sound alarm after specified number of retries but then

stop the retries and continue with the remainder of the cycle.

The alarm will continue until the fault condition is corrected or

until the next cycle begins. The last digit determines the

number of retries before sounding the alarm. This would be

appropriate if you wish to make several attempts at a dispense,

Page 65

such as regrind, but you wish the process to continue even

without the component.

00021 to 00029 = same as 1 to 9, Stop Process, Sound Alarm, but NO more

retries. Just sound alarm and wait. Press the RESET button to

clear alarm and start the retries again. Appropriate ONLY if you

absolutely want operator intervention to occur when material runs

low. In other words you do not want any automatic loading or

other correction to allow the process to continue.

The first three digits of this parameter (_AL xxx00) may be used

to STOP and ALARM the blender if an over dispense occurs by the number

of grams specified. For example, CAL 02004 will cause the system to

STOP and ALARM if the COLOR dispense is 20 grams over target.

(C - OVER) will be displayed. Use PAUSE (or POWER OFF) to reset the

Alarm condition. If a printer is connected, a standard cycle printout

will occur.

======================================================================

_XT

(Allows a setting entry of less then 00.1)

_XT, is a number that will alter the value of the setting that you

enter. The value of the XT parameter, is divided into the setting,

thereby reducing the setting's value. The only valid entries are 10

and 100. When set to "00010" the decimal point is moved to the left

one place and the setting is read as X.XX percent. When set to "00100"

the decimal point is moved to the left two places and the setting is

read as .XXX percent. This allows closer control where a requested

dispense is less than 1 percent. When set to "00000", this parameter

has no effect.

======================================================================

_SE

(Use to lock out high settings or limit access)

_SE is the upper SETTING limits for this component. 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

additives, these limits will ensure that expensive material is not

wasted. Settings that are greater than the limit are held to the

limit.

EXAMPLE:

If the highest color usage in your plant is 6%, then

you can enter this upper limit in the parameter table. Since

settings are stored as 1/10's of percent (##.#), the parameter

would be:

_SE 00060

Any setting above 060 is held to 6 percent.

When a 1 is entered as the first digit of this parameter,

(_SE 1xxxx), setting entries can only be made from the program mode.

In this way access is limited to only those who know the password.

======================================================================

_WT and _TI

(Set AUTOMATICALLY by the CALIBRATE routine)

_WT, and _TI parameters are related to the flow rate or dispense

rate of each material. These can be changed manually, set by the RATE

Page 66

CALIBRATION routine, or simply allowed to adjust automatically as

necessary after each cycle.

_WT and _TI are WEIGHT and TIME numbers that, taken together,

indicate a dispense rate for the specified material (WT/TI). This rate

is used to calculate an exact time period to dispense 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.

Since rate correction takes place continuously and the battery-

backed RAM maintains the correct rate even when power has been turned

off, these numbers will only be in error during the first several

cycles after a flow rate has been considerably altered.

Should there be a change in auger size, drive motor RPM, or some

other change that substantially alters the feed rate of one of the

components, the _WT and _TI parameters can be adjusted using the RATE

CALIBRATION routine to ensure that the feeders dispense properly right

from the beginning without waiting for adjustments to occur.

These numbers are always kept at higher values. The computer will bump

both numbers up in value by doubling them both until at least one

number exceeds 16,000. The ratio (rate) is still the same but error

correction routines work better with higher numbers.

======================================================================

_MI

(Set AUTOMATICALLY by the CALIBRATE routine and also reset

10 cycles after every power up)

_MI numbers are set to 80 percent of the amount of material, in

grams, that can feed in one second based on normal valid dispense

rates. A valid rate is considered the normal dispense rate that occurs

under normal conditions with equipment functioning properly. When a

rate lower than 80 percent of this actually occurs, it is assumed that

an equipment malfunction or loss of material has occurred. Under these

circumstances, normal rate correction routines are bypassed.

EXAMPLE:

For a 1/2" auger feeder with a 60 RPM motor drive, the

normal metering rate is about one gram per revolution or 1 gram

per second. Since the _MI number is expressed as tenths of grams,

80 % of this is expressed as:

(_MI 00008)

It is safe to use a _MI number that is too low but NOT safe to use

a number too high. Error correction routines will not work when

this number is too high.

Power-up always resets _MI to 00001. After 10 cycles have

occurred without retries, software will enter a corrected number. An

exception to this is when the _AL (Alarm) parameter is set to 0, the MI

parameter is left unchanged. RATE CALIBRATION also sets the _MI

parameter.

======================================================================

_NC

(Changes itself automatically over time)

_NC is the allowable GRAM error within which NO flow rate

Page 67

corrections are made by the software. Gram weight errors that are

equal to, or less than, this number will be accepted and no error

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 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. If, over time, the computer finds that the number is too

large or too small, it will automatically adjust it to match the actual

conditions that exist with your equipment. These adjustments occur in

increments of 1 or 1/10 gram and occur only once every 20 cycles. A

change is made only if needed. Checking this number from time to time

will indicate the normal error range that is occurring with each

dispense device on your unit.

If you manually set this number to a very high value, you will

effectively eliminate all error correction attempts for the component.

Gradually, over several months, the software will adjust this number

back down. If you wish to defeat a component's error correction

routines permanently, you may set NC to (_NC 29999). The software

recognizes this number as special and will not change it. This high

setting eliminates error correction attempts for this component. The

component is still weighed, and retries still occur if short, but the

timing of each dispense is based only on previously learned rates and

never adjusted from new experience. A very small dispense in a high

vibration environment may actually be more consistently accurate if no

adjusting occurs.

======================================================================

_PT (for augers and micro pulse devices only)

The _PT parameters will cause the first try dispense to be a

percentage of the full target weight. For example, with component 4

set to (4PT 00090), the first try will be 90 percent of the full target

amount. Retries then occur, but each will target only 50 percent of

the remaining requirement. A series of progressively shorter retries

should be expected, until the retry parameters are satisfied (RP and

RD). The _PT parameter is most effective for slow dispense devices,

like augers. When setting _PT, also set the _RP parameter to 00001.

This forces retries up to within 1 percent of target, instead of 10,

improving accuracy.

======================================================================

_RP and _RD (No change required)

(_RD is set AUTOMATICALLY by the CALIBRATE routine)

These two parameters determine the dispense shortage error that is

be acceptable for each component.

_RP is the shortage expressed as a PERCENT of the target dispense

weight and _RD is the shortage expressed in GRAMS. These parameters

are used together, either one will force a "retry".

A "retry" is an additional dispense that is calculated to add the

amount of material that is short. This comes into play only when the

amount dispensed is less than expected.

Page 68

Retries will occur until the difference between the required

amount and the metered amount is equal to or less than the _RP percent

difference AND the _RD weight difference.

These numbers dictate just how close to perfect the dispense has

to be before going on. If the dispense overshoots the target, then the

process continues. These parameters only control the degree of weight

SHORTAGE that is acceptable.

The _RP parameter is important when SMALL DISPENSE requests for

color or additive are made. Large PERCENT errors are more likely to

occur when very small dispenses are requested.

The _RD parameter is important when LARGE DISPENSE requests for

color or additive are made. Large GRAM weight errors are more likely

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. If no shortage is ever to be allowed then

these parameters can be set to prevent any shortage from occurring.

This will, however, cause an overall error on the plus side.

NOTE: Remember that EITHER ONE of the two parameters listed here will

cause retries to occur. BOTH parameter conditions must be met

before the process will continue, with one exception: If the

ALARM parameter (_AL) is set to 00000, indicated that you do not

want the process to stop, then these two RETRY parameters will

have no effect. The first dispense will always be accepted and

no retries will be made.

======================================================================

_LA

(change if you change metering device)

_LA is the lag TIME before dumping actually starts. This lagtime

is the time it takes for the dispense system to mechanically respond to

the controller's signal to start. Lag time is automatically added to

all dispense times.

Changing the means by which a device is operated such as using a

different diameter air cylinder, or a different drive system for an

auger feeder may require a change in this parameter.

These parameters represent the number of interrupts (time) that

pass before the feeder or dispense system actually begins to dispense.

There are 244 interrupts per second. To determine these times, use the

TIME dispense function in the Manual mode (KEYPAD instructions).

Following the instructions given in the KEYPAD portion of the

manual (TIME key), start with a dispense time of 1 (001). Try

successively higher time numbers until some movement is noted in the

mechanical device and a minimum amount of material IS dispensed on each

try. This is the MINIMUM lag time number; the lowest number that DOES

Page 69

cause some movement and DOES result in a minimum dispense. Add 5 to

this time period and enter as the lag time. Lag times that are too

short can cause problems. That is why the MINIMUM lag time determined

above should be increased by 5 as a safety factor.

These numbers are preset at the factory for the equipment we have

supplied. When a dispense of only a few grams is required, the _LA

number is very important. Too small a lag time will result in no

dispense at all because of inadequate time for the device to operate.

Too large a number may result in over dispenses when very small amounts

are called for. Since too small a number may stall the process, always

add 5 to the minimum as a safety.

Typical LAG TIMES are: (minimum time plus five)

12 - for an AC motor being powered through a relay.

20 - for a 1" air cylinder sliding a dispense valve.

127 - for a automatic speed controller.

======================================================================

_PO (for Micro Pulse devices only)

_PO sets the ON and OFF time of the specified device during the

time period that the device is operated. This results in a "pulsed'

output. This is used in combination with a "micro pulse" equipped

slide gate. Set to 00000 for normal operation. Set to 00101 for

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. A parameter of 00501 will produce

a 1/2 second open time (5/10 seconds), a long enough time to allow a

significant dispense, followed by a 1/10 second close time, just enough

to close the gate fully. The rapid gate movement may help in keeping

material flowing.

======================================================================

For the KEYSTROKE SEQUENCE to change PARAMETERS, see the last page of

the PARAMETER section.

Page 70

PARAMETER DEFAULT SETTINGS - TWELVE 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 200 list is the ORIGINAL BASE list.

Models 100, GBM, and 900 show only the changes from the 200 list.

Models 1800 and 400 show only further changes from the 900 list.

Component 1 is the base list for all components.

Other component lists show only the changes from list 1.

General list:

-----------------------------------------------------------------

Base 3K

¦ Base 10K

Model:220/240

140

GBM ¦ 940

1840 420/440

-----------------------------------+-----------------------------

FLG

MIX

JOG

FCV

DTI

3030

04 ¦

KDF

WDF

BER

ROC

ROV

RHL

1000

200

FUL

MAX

20000

30000

1000

500

10000

15000

4000 ¦

6000 ¦

9000

13500

1000

500

18000

27000

1000

500

4000

6000

200

100

PRT

DLY

PRC

STL

488

122

LCL

LCH

LCF

LCZ

DS1

DS2

XCV

XRC

TCV

TRC

XTP

XAL

XUL

CPL

MPO

SCR

BCR

LIQ

MCT

583

120

5050

00005

00200

00122

00183

Page 71

Component lists:

--------------------------------------------------------------

Base 3K

Model:220/240

¦ Base 10K

GBM ¦ 940

140

1840

420/440

-----------------------------+--------------------------------

(1 and 2)

(vv) ¦ (2"x3" or 3"x6" valves)

1TY

1CS

1AL

1XT

1SE

1WT

1TI

1MI

1NC

1PT

1RP

1RD

1LA

1PO

= OFF

1000

26000 18000 22400 ¦

24000

1952

20800

7808

976

500

976 15616 ¦

300

100

-----------------------------+--------------------------------

(3 and 4, and 7 and 8) (vv) ¦ (3"rd, 2"x3", or 1.5"x2" valves)

3TY

3CS

3AL

3XT

3SE

3WT

3TI

3MI

3NC

3PT

3RP

3RD

3LA

3PO

26000

128 22400 ¦

976 31232 15616 ¦

20800

7808

500

50 ¦

04 ¦

300

100

-----------------------------+--------------------------------

(5 and 6, and 9, A, B, and C) (always 1" feeders)

5TY

5CS

5AL

5XT

5SE

5WT

5TI

5MI

5NC

5PT

5RP

5RD

5LA

5PO

20480

31232

2048

300

100

--------------------------------------------------------------

Page 72

CHANGING PARAMETERS

To change a PARAMETER, the sequence of keystrokes is as follows:

+--------------------------------------------------------------+

¦ Press: *

Display will say: (PASSWORD)

Display will say: (P x.x)

Display will say: (FLGxxxxx)

Press again to walk FORWARD through list. ¦

to BACK UP in the list.

¦ Press: 22222

¦ Press: PARA

¦ Press: *

+--------------------------------------------------------------+

When the PARAMETER you want is displayed, enter a new setting using the

number keys. You must enter 5 digits. Use leading zeros.

Press: EXIT

Display will say: (P

x.x)

Additional information can be found in the KEYPAD section.

SAVING PARAMETERS in EEPROM

If the changes you have made are PERMANENT, SAVE them in EEPROM.

Sometimes during normal operation, electrical noise or RF (Radio

Frequency) noise will corrupt the processor memory. It may be

necessary to do a CLEAR to fix this problem.

A "CLEAR" will clear all data from memory and replace it with

information stored in the EEPROM.

So it is a good idea to have an exact copy of RAM stored in the EEPROM

for just such an emergency.

To copy ALL PARAMETERS into the EEPROM, the sequence of keystrokes is

as follows:

+---------------------------------------------------+

¦ Be in PROGRAM mode, first 2 steps above:

x.x) ¦

Display will say: (P

¦ Press: *

¦ Press: 23

Display will say: (INSTR --) ¦

Display will say: (SAVING ) ¦

¦ Wait: when done, Display will say: (P

x.x) ¦

¦ Press: EXIT

Display will say: (

x.x) ¦

+---------------------------------------------------+

With this done, all correct Parameters may be restored from EEPROM to

RAM at any time by doing a CLEAR.

To do a CLEAR, hold the "CE" key down when turning on power.

Page 73

+---------------------------------------------------------------------+

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 then automatically print full output information after

every cycle.

When the printer flag is ON, the controller will output a single

heading line at the top of each page and 4 information lines to the

printer at the end of each cycle. This adds several seconds to each

cycle time. To turn the printer flag on:

Press: *

Press: 22222

Press: *54

Press: *

Press: EXIT

EXIT

Display will say: (PASSWORD)

Display will say: (P x)

Display will say: (PRNT OFF)

Display will say: (PRNT ON)

Display will say: (P

Display will say: (

Any common parallel printer that you would use with a small PC computer

may be used. Connect using a standard parallel printer connecting

cable, (34 pin parallel Centronix connector to a DB25 IBM compatible

connector), available from us or at any computer store.

INTERPRETING the *54 CYCLE PRINTOUT

10 or 20 cycles of data can tell a lot about the performance of your

blender. The following will help you interpret the data.

A single cycle printout looks like this:

(dashes ---- added for clarity of spacing)

------------ ------------ ------------ ------------ ------

**1 R 20.0** **2 N 100** **3 A 04.0** **4 A 00.0** TOTAL

* 11/10/97 * * 16:17:53 * RECIPE 0000 **ID# 051** **WO 000000* OPR000

FINAL: DISP,%

RATE: GR/TIME 18224

1ST DISP,TIME 0.0

0.0

.0 1908.3

976 19993

00 1908.3 469

77.6 4.06

488 12973 31232 10240 31232

77.6 1826 0.0 00

0.0 .00 2000.1

9.9

DEFINITION OF EACH LINE

The TOP-OF-PAGE heading:

------------ ------------ ------------ ------------ ------

**1 R 20.0** **2 N 100** **3 A 04.0** **4 A 00.0** TOTAL

Prints as a heading to each page, or once every 10 cycles. This serves

as a heading over four columns of material. Additional lines will

Page 74

print for additional components as necessary, printing only those

components turned on. Thumbwheel setting and material type is shown

for each. If a thumbwheel setting is changed, a new header line will

print.

In this example, component 1 is a REGRIND; component 2, a NATURAL; 3

and 4 are set up as ADDITIVES.

The CYCLE heading:

------------ ------------ ------------ ------------ ------

* 11/10/97 * * 16:17:53 * RECIPE 0000 **ID# 051** **WO 000000* OPR000

DATE and TIME this blend cycle was completed. RECIPE, ID, Work Order,

and Operator numbers have no bearing on blender operation but aid in

identifying this particular blender, and what job was running.

DATA line 1:

------------ ------------ ------------ ------------ ------

FINAL: DISP,%

0.0 .0 1908.3

77.6

4.06 0.0

.00 2000.1

For each material, each column shows the final dispensed weight of that

material and its percentage of the blend.

In this example Natural dispensed 1908.3 grams. Color dispense is 77.6

grams, 4.06 percent of the natural dispense, slightly over the 4

percent requested.

The final number, 2000.1 is the total weight of the blend. It equals

the sum of the component dispenses.

DATA line 2:

------------ ------------ ------------ ------------ ------

RATE: GR/TIME 18224 976 19993

488 12973 31232 10240 31232

9.9

These numbers show the RATE of dispense for each material. These are

the numbers that the software used to calculate how long to open the

slide gate or run an auger, in order to dispense the required amount.

This is GRAMS per Interrupts; 1822.4 grams dispensed in 976 interrupts,

which is 4 seconds.

The final number, 9.9 grams, is the TEAR WEIGHT of the weigh bin

displayed just before the cycle began.

DATA line 3:

------------ ------------ ------------ ------------ ------

1ST DISP,TIME

0.0 00 1908.3 469

77.6 1826

0.0

This shows the first dispense in grams for each material and the timing

of that dispense (in interrupts).

Page 75

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.

Optional "BAILOUT" line:

------------ ------------ ------------ ------------ ------

232

A 4th data line (not shown in the beginning example) will print if any

single dispense goes past its target weight by a certain value, this

value set by the BER parameter, normally 200 grams. The example line

shown here would indicate component 3 overshoot the target weight after

dispensing for only 232 interrupts.

Bailouts are designed to prevent overflows of material when initial

software settings, at start up, are entirely inappropriate for the

metering device. A larger then normal error correction will occur

after a bailout.

Bailouts errors at any time other then startup, usually indicate either

very poor flowing material, or excessive vibration. When a bailout

occurs the dispense stops immediately for a weight reading. Using this

information, the cycle then continues normally.

WHAT TO CHECK FOR.

TOTAL BATCH WEIGHT: (DATA line 1)

Check the TOTAL batch weight, (DATA line 3), to confirm the blender

model. 2000 grams indicates 200 series model.

400, 1000, and 2000 gram totals indicate models that use 3 K load

cells, which means output information is in 1/10's of grams.

4000, 9000, and 18000 gram totals indicate larger blenders that report

information in full grams. Since some numbers in the printout do not

include the decimal point, you will want to know if you are reading

full grams or tenths of grams.

TARE WEIGHT. (DATA line 2)

In DATA line 2, tear weights should be consistently within a few grams

of each other from cycle to cycle. Large variations in the tare weight

numbers may indicate excessive vibration, some mechanical interference

with the weigh bin, or a faulty circuit board. Tare weights above or

below zero are not a problem as long as they are consistently similar

from cycle to cycle. When problems are present, tare numbers may vary

by up to 50 grams. Variations of 2 or 3 grams are not a problem.

Page 76

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.

FLOW RATE NUMBERS: (DATA line 2)

Check the RATE numbers, (DATA line 2), to determine each dispense

device.

In the example above:

In the component 1 column, 18224 and 976 translates to 1822.4 grams in

4 seconds (244 interrupts = 1 sec). This is 455.6 grams per second,

typical for a regrind flowing through 3" round or 2"x3" dispense

valves.

In the component 2 column, 19993 and 488 indicate 1999.3 grams in 2

seconds, or 999.6 grams per second flow rate. This is a heavy natural

material, not polyethylene. Perhaps lexan or a glass filled material.

In the component 3 column, 12973 and 31232 indicate 1297.3 grams per

31232 interrupts, or 128 seconds, for a flow rate of 9.99 grams per

second. This is a 1 inch auger feeder, from which we would typically

expect about 8 grams per second. More recent auger feeders use faster

motors delivering about 16 grams per second.

In the component 4 column, 10240 and 31232 indicate a flow rate of 8

grams per second EXACTLY. Since it is exact, and since these two

numbers are, in fact, the "default" settings from when the blender was

first installed, we know that "component 4" has never been run on this

blender, or at least not since the last "CLEAR ALL" was performed.

DATA line 3 dispense weight of 0.0 for component 4, and the TOP-OF-PAGE

heading showing component 4 set to 00.0 percent also confirm that

component 4 is not being run.

The following information will help you determine what devices are in

place on a blender.

Device:

Approximate grams per second:

1/2 inch augers, micro pulse valves

1 inch augers, 60 RPM motors

1 inch augers, 120 RPM motors

1/2 to

6 to 10

12 to 20

100 series valves dispense

3" round and 2x3 inch valves

900 and 1800 series large 3x6 valves

3" round and 2x3 valves with flow restrictors

250 to 450

500 to 900

3000 to 5000

50 to 100

Regrinds are always lower then naturals. Bulk density will also cause

wide variations in flow rates.

Page 77

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 the GRAM number goes below 16,000 or above 32,000

(approximately). In this event both GRAM and TIME numbers are doubled

or halved to bring the GRAM number back to between 16,000 and 32,000.

This serves to keep all numbers as large as possible allowing for the

most accurate math, but not so large as to overflow the registers.

Only the GRAM number changes from cycle to cycle, except under the

conditions noted above.

Check the GRAM number for a series of consecutive cycles. If it

remains unchanged, then the dispenses are accurate enough to not

trigger error corrections. Another possibility is that the parameters

(MI and NC) that determine when error corrections occur are somehow out

of range preventing corrections that should be occurring.

The PRC parameter limits adjustments to 10 percent. Do not expect any

single GRAM number change larger then 10 percent.

A gradual decrease in the GRAM number indicates a slowing rate, a

hopper that is becoming empty for example. A jump in rate (increased

GRAM number) occurs when the hopper is refilled.

If Errors are occurring, but the GRAM number is NOT adjusting, check

the NC parameter and the MI parameter. These control weather or not

error corrections occur. Both are set and adjusted automatically by

the software. MI is set after each start up, after 10 cycles have run

without retries. MI will be set to indicate 50 percent of normal

dispense rate expressed as grams per second.

NC adjusts slowly over extended periods of running. NC indicates, in

grams, the upper limit of the error in 60 percent of the dispenses. A

high number usually indicates poor flowing material. Vibration or

drifting load cells are other possibilities.

DISPENSE TIMING: (DATA line 3)

The second number is the number of interrupts calculated to dispense

the material. If these times are consistent but the weight of the

first dispense varies, then the material does not flow well, or

consistently. Another possibility is excessive vibration or

interference with the weigh bin.

Excess vibration, particularly on small dispenses, may cause incorrect

weight readings even though the weight dispensed was, in fact, correct.

If the timing number is very small, 10, 20, 30 interrupts, perhaps this

is asking too much from a slide valve. Very short times mean you want

Page 78

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. This is to

compensate for the time at the beginning of a dispense when the

solenoid valve shifts and air pressure builds, before the valve starts

to move. LAG times are always set slightly longer then the necessary

minimum. If a calculated dispense time is very short, the Lag time

that is added, while small, may interfere with accuracy, and cause an

over dispense.

PERCENTAGE ERRORS: (DATA line 1)

When looking at errors of percentage of color or additive dispensed,

look further.

1. First, look for indications of "retries". Retries are evidence of

a problem that will also cause percentage errors.

When FIRST time dispense, (DATA line 3), does not equal FINAL

dispense, (DATA line 1), one or more retries have occurred. This

means 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.

Inconsistent loading resulting in large variations in hopper

material level can cause retries.

Excessive vibration can also cause bad weight readings, which can

cause unwarranted retries. If the BAILOUT line is printing

occasionally, then vibration is most likely causing this.

Increasing the BAILOUT parameter should fix this.

A LAG time set too high may cause retries to overshoot their mark

resulting in over dispensing.

2. Second, look at ACTUAL weight dispensed (DATA line 1).

Color, for example, is a percentage of the natural. In the example

above, Natural is 1908.3 grams, so color, at 4 percent of Natural,

is targeted to be 76.3 grams. In fact, 77.6 was dispensed. The

error is 1.3 grams, well within the expected accuracy of a 1 inch

auger feeder.

The actual GRAM error of a dispense is more meaningful then the

percentage error. Mechanical devices are not perfect. The most we

can expect from them is to operate within a reasonable range of

accuracy. This range is better defined by an error expressed in

grams, rather them percentage.

3. Third, look at the dispense TIME (DATA line 3).

Page 79

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. Raise the value of the BAL parameter to

200 or 300 grams to reduce or eliminate unnecessary bailouts.

Vibration may also cause throughput rates to suffer due to the added

time requiring to obtain acceptable weight readings. Increase the WDF

parameter to 2 or 3 grams, (WDF 00003) or (WDF 00030), or more if

necessary.

SPECIAL TESTS

Using the *54 flag

If you are running these special tests in the MANUAL or PROGRAM mode, a

printout will automatically occur after each test provided the PRINT

flag (*54) is turned on.

Special tests that produce printouts are TIME or CALIBRATE.

TIME (See KEYPAD, TIME; and PARAMETERS, _LA, for more information)

The TIME function is to determine lag times of different metering

devices. It also allows testing of device repeatability.

The single line printout looks like this:

TIME

key:

COMP 1

123

2749

^component number

^dispense time (in interrupts; 244 = 1 sec.)

^weight dispensed

CALIBRATE (See KEYPAD, CALIBRATE for more information)

The CALIBRATE function allows the controller to rapidly learn the flow

rate of the device. It automatically sets the WEIGHT and TIME

parameters that determine metering rate, and the MINIMUM RATE

parameter. For more information see PARAMETERS, _RA, _TI, and _MI.

The single line printout looks like this:

CALIBRATE COMP 1 732

8795

3465

key:

^component number

^dispense time

^weight dispensed

^lag time used

^min rate

Page 80

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. (See

PARAMETER, PRT)

The printout looks like this:

DATE

TIME

CURRENT

LAST PRINTED

LAST CLEARED

6/20/91 13:40:14

6/20/91 13:35:11

6/19/91 20:02:36

TOTALS: GRAND PCT

CURRENT PCT

CYCLES

COMP 1 R 05.0

COMP 2 N 100

COMP 5 N 00.5

2.4 4.8

47.4 100.0

.4 .99

1.5 5.0

28.6 100.0

.99

COMP 6 N 00.5 .4 .94

.91

TOTAL

50.8 30.7

WEIGH SCALE ID# 120

TOTALS ARE IN POUNDS

POUNDS PER HOUR 365.3

The Totals may be in POUNDS or KILOS depending on your selection of

weight unit. See: PROGRAM mode, (*89).

A line is printed for each active component. Each line shows component

number, type, setting, grand and current totals.

The GRAND totals will continue to grow until they are intentionally

cleared. This is done by the *00 routine, or pressing 00 within 5

seconds after printing these totals.

The CURRENT totals are since the last time totals were printed. The

date and times are given for LAST CLEARED and for LAST PRINTED.

The percentages given for "R" types (REGRIND) are percentages of the

total mix. Percentages given for "A" types (ADDITIVES) are percentages

of all the "N" types added together. Percentages given for "N" types

(NATURALS) are each component's percentage of all the "N" types added

together.

The POUNDS PER HOUR is calculated using the total material dispensed

from the CURRENT column, and the time difference between the CURRENT

time and the LAST PRINTED time. Cycle time variations will cause this

number to not be exact. The longer the time period, the more correct

the rate.

Page 81

+---------------------------------------------------------------------+

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, dry weather or increased

plant electrical noise can cause new problems.

2. Then follow the CHECKOUT procedure in the front of this manual.

If anything does not work right, read the diagnostics section that

follows it.

3. Read the section on NORMAL OPERATING SEQUENCE to be sure you

understand what it is supposed to be doing. If you are still

unsure as to how the software logic works, call us.

4. Read the list of TYPICAL PROBLEMS that follows on the next page.

5. Read the section on VERIFYING LOAD CELL function to be sure that

the load cells are operating correctly.

6. For difficult problems we can provide the most help if we have a

printout of the PARAMETER table (KEYPAD, *77) and a cycle by cycle

printout (KEYPAD, *54). (See PRINTED OUTPUTS section)

To print the PARAMETER table:

Press: *

Press: 22222

Display will say: (PASSWORD)

Display will say: (P x)

Press: *77

Display will say: (INSTR 77)

Parameter table will print.

To print cycle information while the unit is running:

Press: *

Display will say: (PASSWORD)

Display will say: (P x)

Display will say: (PRNT OFF)

Display will say: (PRNT ON )

Press: 22222

Press: *54

Press: *

Press: EXIT 2 times.

7. Try a CLEAR.

Turn power off. Hold the "CE" key down and turn power ON. Display

will say (CLEAR).

8. As a last resort, do a CLEARALL, (see CLEAR ALL section)

A list of TYPICAL PROBLEMS follows on the next page.

Page 82

TYPICAL PROBLEMS:

These problems are based on phone calls that we have received from

Autoweigh Blender users.

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. In this case it will most likely be off

by several hundred grams. See LOAD CELL CALIBRATION.

* The load cells are damaged. See CHECKING THE LOAD CELLS

The Controller "RESETS" itself for no reason. This indicates

electrical noise or voltage spikes disrupting the processor.

* See WIRING CONSIDERATIONS, ASSEMBLY section.

The ALARM is flashing and the display shows a weight above 100 or below

-50 grams. If above 100, the Weigh bin dump valve keeps opening and

closing every 6 or 7 seconds.

* There is material in the weigh bin that will not dump out.

* The dump flap may be stuck.

* The load cells are hung up or obstructed.

* The load cells are out of calibration.

* Incorrect grounding is causing wide load cell readouts.

The VERY FIRST DISPENSE does NOT take place. After a few seconds the

ALARM begins to flash. The display says (N

x.x) and is flashing.

* The air supply is not connected or the pressure is set too low.

* The Natural solenoid is not connected properly.

* The 1/2 amp panel front fuse is blown.

* The NATURAL slide gate is jammed. The cylinder mount may be

bent.

The NATURAL dispense valve continues to dump repeatedly even though the

weigh bin has filled to overflowing. The weight reading is still below

2000.0 grams.

* The weigh bin is not free to move.

* The load cells are jammed.

* The load cells are damaged. See CHECKING THE LOAD CELLS

The system operates but always needs MANY RETRIES to complete a

dispense and never seems to "learn" the proper dispense rate.

* Vibration is causing frequent "bailouts" causing large swings in

rate adjustment. Increase the BER parameter.

The THUMBWHEEL SWITCHES do not seem to be controlling output. One or

more LEDs (bottom row) are on all the time.

* Someone has LOCKED IN a setting using the keypad. See KEYPAD,

PROGRAM MODE, SETTING.

* The _SE parameter is LIMITING the thumbwheel switch setting. See

KEYPAD, PROGRAM MODE, and PARAMETERS, _SE.

Page 83

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.

* A valve is sticking closed. Check for free operation when air

pressure is removed.

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. See "CLEAR" RESTART or "CLEAR ALL" RESTART.

Then do a LOAD CELL CALIBRATION, and RATE CALIBRATION for ALL

materials.

The Display reads 3100.0 even with the bin empty. This is the upper

limit load cell readout.

* The Load Cells are not plugged in and the circuitry has drifted

to the top limit.

* The load cells have been overloaded way beyond their limit and

are now permanently deflected.

Dispenses from a slide gate are not as consistent as they should be. *

The slide gate is sticking slightly. With the hopper empty, move

the slide manually to see that it moves freely. Press up or down on

the air cylinder to adjust for proper alignment.

* The material does not flow very well. A bridge breaker adaptor

may be required.

Load Cell weight readings are not holding steady. They vary as much as

100 grams from second to second.

* This is static and improper grounding. See WIRING CONSIDERATIONS

* If readings drift slowly in one direction, requiring frequent

recalibration, a component on the circuit board is most likely

faulty. Call us.

* If TARE weights are not steady, something may be physically

interfering with free movement of the cells.

At the end of each cycle the MIX MOTOR runs for a fraction of a second

only.

* The MIX MOTOR pulls a heavy amp load on start up. If the power

supply is not adequate (like when using an extension cord), the

voltage will drop so low that the computer will reset and the

mix motor signal will shut off. The display will show this by

restarting as if power was just turned on. Provide a better

supply of power; remove extension cord or use larger gage wire.

Page 84

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 current program version date (V=xxxxxT) is displayed for

1 second, followed by the check sum number (CKS xxxx),

followed by a ROM check (ROM OK ), followed by a display of (

0). The weight in the weight bin is now displayed. It

should be 0 plus or minus several grams. During the first

few minutes of operation, the displayed weight readings may

drift slightly as the circuitry warms up.

BEGIN operation:

The unit will begin to operate if both switches on the left

side are UP in the CONTINUE position and the SENSOR in the

mix chamber is UNCOVERED. The sensor must be plugged into

the right side of the controller. If it is not, this has the

same effect as the sensor being covered; the unit will not

run.

If the WEIGH BIN DUMP Flap opens and closes repeatedly:

If initial empty bin TARE weight is 100 grams or more, the

weigh bin dump valve will operate in an attempt to empty the

bin and bring the starting weight closer to zero. If the bin

is empty but the weight reading is greater than 100 grams

then something is wrong. See TESTING the LOAD CELLS and LOAD

CELL CALIBRATION.

If the ALARM flashes:

If the initial TARE weight is below -50 grams the Alarm will

flash and the unit will not operate. Go to TESTING of LOAD

CELLS and LOAD CELL CALIBRATION.

The DISPENSE sequence begins:

If initial tare weight is within limits, between -50 and

+100, the sequence will begin.

DISPLAY during dispenses:

During all dispenses, the component number and Type letter

(R,N,A) will be displayed indicating which component is being

dispensed. The INITIAL display is the tare weight of the

bin. This will not change during the first dispense. After

each dispense, the new total weight of the material in the

bin is updated and displayed.

REGRINDS first:

If REGRIND is part of the blend, REGRIND dispenses will occur

first in order of size, from the largest to the smallest.

The letter "R" will appear in the display. After these

dispenses an exact weight is taken to determine the space

remaining in the weigh bin for the remaining dispenses. The

total bin weight will appear in the display 2 seconds AFTER

each dispense has ended.

Page 85

NATURALS second:

The NATURAL dispenses occur next in the sequence. They will

be dispensed in order of size, largest to smallest. The

letter "N" will appear in the display. The exact weight of

all NATURAL dispensed is now determined for calculating the

ADDITIVE dispenses.

ADDITIVES third:

The ADDITIVE dispenses occur last in the sequence. Each

dispense must meet requirements set by internal parameters or

RETRIES will occur and the sequence will not continue.

MATERIAL RUNS OUT:

If any material runs out or is not enough to meet criteria

set by parameters then the process will NOT CONTINUE past

this component. RETRIES of this dispense will occur

indefinitely until the full dispense occurs or power is

turned off. The display will FLASH. The ALARM will sound

after 4 retries. This number of retries before alarm is

based on the ALARM (_AL) parameters. REGRIND may, or may

not, be set to cause an alarm when it runs out. See

PARAMETERS, _AL, for how to set the ALARM parameters.

If ALARM flashes:

More than four retries of any single component will cause the

strobe light ALARM to begin flashing. The component that is

causing the alarm will continue to retry the dispense. The

display will blink and the first digit in the display will

signify which component is causing the problem. To continue

with the dispense sequence, you must satisfy the requirements

of the dispense or turn power off.

WEIGH BIN dump:

After all dispenses the weigh bin is emptied by the final

dump of the weigh bin into the mixing chamber. The dump valve

remains open for four seconds. (DTI parameter)

SENSOR covered:

While the sensor is covered, the dump valve remains open to

ensure the weigh bin empties completely. Dispensing stops.

The dump valve will remain open for as long as the sensor is

covered. This will be until the next cycle begins.

FLOW CONTROL Valve: (optional)

The Flow Control Valve under the mix chamber will stay closed

for 6 seconds (FCV parameter) immediately following a

dispense into the mix chamber. The rest of the time it opens

when the sensor is covered, and closes when the sensor has

been uncovered for at least two full seconds (based on DLY

parameter).

Page 86

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. Make a careful inspection of

EVERYTHING around the load cells, the hanger bolts, the weigh bin tray

and the weigh bin. NOTHING should interfere with free movement.

NOTE: It is normal for load cell readout to drift several grams over

time and with different temperatures. Since all the component

dispenses are weighed by a single set of load cells, this drift

will affect all components equally and, therefore, the ratio of

the components will remain accurate. Empty weight is always

TARED so each dispense is accurately measured.

The following observations will verify proper load cell operation:

When the bin is empty, between cycles, the display should read near

zero. An error of several grams is not important since this empty

weight reading is "tared" from all dispense readings. The "empty

weight" readings should be consistently within 1 or 2 grams of each

other.

The addition of several pellets to the weigh bin should result in a

change in the readout. 1 gram is about 40 pellets.

Most load cell problems are caused by interference to the movement of

the load cell. The load cell must be free to respond to the weight of

a single pellet as well as free to move far enough to record a full

20,000 gram weight deflection. (10,000 grams per cell - 10K cells)

If weight readout is very erratic check for damage to the load cell

wires. Check for a pinched wire in the connector.

An over stressed load cell will read high. The top limit is ( 3100.0)

for a 200 series or ( 31000) for a 400 or 900 series. A load cell

that was forced or pried upward too far will read (

0.0).

We supply and replace load cells in matched sets and we always include

the mounting enclosures. You may remove the back plate from the

enclosure for visual inspection. It is not safe to remove the load

cell itself from the enclosure. To do so may stress the cell itself.

To OPERATE with DAMAGED load cells in a VOLUMETRIC mode,

see KEYPAD, *87, Volumetric mode.

To RECALIBRATE the LOAD CELLS, see the HARDWARE MAINTENANCE section.

If you suspect load cell damage or failure, see:

LOAD CELL RAW SIGNAL READOUT, next page, and

LOAD CELL - WEIGH BIN TEST, the following page.

Page 87

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.

A properly operating set of 3 K cells will range from about 55,000 to

120,000; a span of about 65,000 from empty weight (weigh bin in place),

to a full bin weight of 2000 grams. (10 K load cells range about

90,000 from empty to a full 9000 grams). The system will work correctly

as long as the empty bin weight readout is between 1 and 149,248.

149,248 is the highest number that the software will accept for zero

weight calibration (see parameters, LCZ). If the number is over this

when you press the ZERO weight key, the display will say (ZERO LOW).

This RAW COUNT number is converted to the proper gram readout, by the

software, based on load cell calibration information.

The RAW COUNT numbers are more useful in diagnosing load cell problems

because they bypass the calibration math and, therefore, bypass any

calibration errors that might have occurred.

Press "CE" key to display this RAW number for several seconds.

To observe this number continuously, use the *98 function in the

PROGRAM mode.

Press: *

Press: 22222

Display will say: (PASSWORD)

Display will say: (P x)

Press: *

Press: 98

Press: *

Display will say: (INSTR --)

Display will say: (CNT OFF )

Display will say: (CNT ON )

Display will say: (P xxxxx)

Press: EXIT

A floating, drifting number usually indicates the load cells are not

plugged in.

A readout of 0 indicates an open circuit, a damaged wire or cell.

A full scale readout of 249,850 indicates a damaged wire or cell.

A set of 3 K load cells will put out about 33 more counts for every

gram of weight that is added. A test of sensitivity is to add a small

weight to the bin. The RAW WEIGHT count should increase by about 33

counts for each gram added. (10 counts per gram for 10K load cells.)

If you call us for help in solving a load cell problem, it is helpful

if you can tell us what the RAW COUNT number is with the bin empty, and

with a known weight in it. Pressing the CE key at any time will

display the RAW COUNT number for the current weight.

To OPERATE with DAMAGED load cells in a VOLUMETRIC mode,

see KEYPAD, *87, Volumetric mode.

Page 88

LOAD CELL - 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. Start with an empty weigh bin.

2. Dispense a very small amount, using the TIMED DISPENSE function:

Record the weight display.

Press: TIME, NAT, 040

Wait for dispense then record the new weight.

Wait for test to finish, about 10 seconds. At the end of this test

the bin will automatically empty. This is OK.

3. Now, manually add enough pellets to bring bin weight up to the

approximate full batch weight. Do this by pressing on the small

air solenoid operator pin for NATURAL. Drop in enough pellets to

be close to a normal full batch weight, like 2000 or 4000 grams.

Exact weight does not matter. We just want to place approximate

full batch weight on the load cells.

4. Repeat step 2, recording the weight readings.

5. Do this entire test 3 more times.

From the weight readings, calculate the weight of each dispense

from each test.

RESULTS TO EXPECT:

In each test, the first timed dispense, when the bin is empty, should

be very close or equal to the second dispense, when the bin is full.

Results from all 4 tests should be very similar.

If the second dispense is always less then the first, the load cells

are suspect. The enclosures may be full of pellets. Weigh bin

interference is also possible. If all dispenses vary widely with no

pattern, this is most likely caused by weigh bin interference. Weigh

Bin interference is usually visible with close inspection.

Page 89

"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. All current rate calibration

numbers that the unit has "learned" will be overwritten.

To execute a "CLEAR", hold down the "CE" key while turning POWER ON,

then release. When done correctly, the display will say ( CLEAR ).

CLEAR does not clear EEPROM information but instead loads EEPROM into

RAM. Load Cell weight calibration numbers are NOT lost.

(To load EEPROM with correct RAM information, see KEYPAD, *23)

CLEAR ALL - RESTART

The same as the CLEAR, above, but EEPROM information is also cleared.

There are only TWO times when you want to do a CLEAR ALL.

1. When a NEW PROGRAM CHIP has been installed.

New chips often have different PARAMETER table layouts.

Information may reside in memory locations that do not match the

new program. CLEAR ALL - RESTART fixes this.

2. When all else fails.

CLEAR ALL - RESTART will sometimes fix problems that the simple

CLEAR routine misses.

The keys to press on power up are VIEW, BTCH, and EXIT (Top row: left,

center, and right). Hold all three down as power is turned on, then

release. When done correctly the display will say (CLEARALL).

LOAD CELL calibration WILL be lost. You will have to follow the Load

Cell calibration procedure given in this manual.

Since parameter table information is lost, you will want to reenter

parameters that were previously modified. See BRIEF EXPLANATION of

PARAMETERS for a quick review of which ones might have been changed.

Be certain that your unit displays the proper MODEL number when you

turn on power. If not, see SELECTING CORRECT MODEL, next page.

CORE DUMP

During production or between cycles, the controller can be forced to

print a CORE DUMP of Memory. This is helpful to us when elusive

problems are occurring related to non predictable environmental

problems. If you are having reoccurring problems, we may ask you to

use this routine during production to help us diagnose the problem.

To obtain a MEMORY CORE DUMP, have a printer connected. Press three

keys at the same time; the PARA, FULL, and ALRM keys; bottom row: left

center and right.

Page 90

+--------------------------------------------------------------------+

PART V - 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. GBM Micro Blenders should

be set to 40 PSI (2.7 bar). Vertical Valves used in removable hoppers on

GBM Micro Blenders, and 100 and 200 series blenders, are more accurate at

60 PSI pressure setting.

LEVEL SENSOR

Sensor position; 200 and 400 series models only:

The sensor should protrude into the mix chamber about 1/4 inch past

the inside surface of the stainless mounting plate. If it does not

protrude far enough, it will sense the mounting plate itself. If

it protrudes too far, it will sense the mix blade.

Adjusting sensor sensitivity:

1. The adjustment screw is located at the rear of the sensor.

It may be protected by a small plastic screw like cover. You

will need a very small screwdriver to adjust it.

2. Fill the mix chamber until the sensor is about 3/4 covered.

3. Turn screw counter-clockwise until the LED goes OFF.

4. Then turn clockwise until the LED just goes ON.

5. Empty the chamber and check to be sure the sensor LED does not go

on when the mix blade passes near it.

NOTE: 18 mm sensors, LED logic is reversed, ON when UNCOVERED.

WEIGH BIN DUMP VALVE

The WEIGH BIN DUMP VALVE should be adjusted to close softly. A

needle valve is installed next to the quick disconnect so that air flow

to the flap air cylinder may be restricted. Adjust as required for a

soft close.

SLIDE VALVES

Slide valves must move very freely. If they seem to jam slightly

as they reach the full extended position (closed), this may be due to

the air cylinder mount being slightly bent. If someone has pulled down

or pushed up on the air cylinder, they may have bent the cylinder

mount. You can correct this by pressing up or down on the cylinder as

required to correct the problem.

If you process very hard pellets (polycarbinate and glass filled

resins), your slide gate dispense valves may stick closed occasionally.

We provide spacers that limit the full stoke of the air cylinder. This

stops the slide from going any further then the just closed position

and prevents jamming. Call us for information.

INTERNAL MIX MOTOR and AUGER FEEDER FUSES

The MIX MOTOR timed power source and the AUGER FEEDER OUTLETS are

driven by internal solid state plug-in relays. A small 5 amp glass

fuse is located to the right of each relay. A spare fuse is also

located on the board if replacement is necessary.

Page 91

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.

It is critical to proper mixing that the mix blades reach up

through the top of the material in the mix chamber during mix time.

Dispensing a large batch may bury these blades, particularly when

the process is not running at full blender capacity. A smaller

batch size, while reducing throughput rate, will help prevent the

mix blades being covered during mix time.

2. Be sure level sensor is mounted in its lowest position, and

increase sensitivity as much as possible. Both serve to keep a

batch from being dispensed so early as to cover the mix blades.

3. On units without flow control valves (FCA), increase the DLY

parameter to as number as high as 50 percent of the time between

cycles. DLY is the time delay (in interrupts) from the sensor being

uncovered until we begin the batch. Increasing DLY allows the mix

chamber to empty somewhat before the next batch drops. The maximum

possible value for DLY is 29999 or 122 seconds.

4. You may increase the mix time at the end of each batch by changing

the last two digits of the MIX parameter. If throughput is very

high it may be better to run the mixer continuously. However,

added mix time sometimes causes separation after an initial mixing.

Different bulk densities and static electricity both aggravate this

potential for separation from excessive mixing.

5. If a blender is mounted on a stand over a surge hopper, there

should be a FCA, automatic flow control valve, fitted to the bottom

of the blender. This valve must be plumbed so that it is closed

when the level sensor is uncovered. When the sensor is covered the

valve opens to release material. The purpose of this valve is to

ensure mixing. The FCV parameter delays the opening of this valve

for 6 seconds. You can increase this delay time if you feel

additional mixing is required before release.

6. On model GB/WSB-940, be sure the weigh bin has two baffles installed.

These ensure horizontal layering (as opposed to side by side

layering) of materials prior to dropping into the mix chamber.

7. Bulk density and pellet shape differences, specifically smooth

virgin pellets mixed with square higher density color pellets, can

separate when dropped onto a sloping pile, as exists in a hopper,

Gaylord, or surge bin. The light round pellets flow like water to

the edges, while the heavier square color pellets stay put. This

is difficult to correct. It is best not to drop these kinds of

blends into large containers.

8. Vacuum conveying can also separate materials of different bulk

densities. Maintain high air velocity to minimize this.

Page 92

9. Modesl 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.

c) Less electronic parts on the board, parts that are vulnerable to

failure from in-plant voltage spikes, from storms and power

failures, parts that can represent a percentage of failures over

the lifetime of the blender.

d) Inherent safety for plant personnel due to the more controlled,

more limited torque of an air drive compared to an electric

motor drive. A correctly sized electric motor can deliver 10

times the normal design and operating torque when stalled. In

spite of interlocks, this presents a potential safety hazard.

If you are having mix problems with air drives, be sure the blades

moves a full 270 degrees (3/4 turn) with each sweep. If they do not,

try the following:

a) Increase the air pressure. If the gauge pressure drops more

then 5 pounds during operation of the blades, the air supply

line is too small.

b) Lower the pile in the mix chamber to reduce torque requirements

on the mix blade. This is explained above.

c) Increase the MPO parameter from 122 (1/2 second) to 183 (3/4

second) or 244 (1 full second). This allows more time for a

full mix blade sweep to occur. You may also want to increase

mix time from 10 seconds to 15 or 20 seconds so that, in spite

of slower mix blade speed, the same amount of mixing occurs.

Page 93

RECALIBRATION OF LOAD CELLS

This unit was properly calibrated at the factory to match the load

cells that were supplied with it. If you are going to 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. (A disconnected air line adds weight.)

Air pressure to the line is not necessary.

BE SURE there is nothing touching the weigh bin or air line.

BE SURE the bin is EMPTY when ZEROING the load cells,

ZERO WT. must be done before FULL WT. Since changes in ZERO WT will

also shift the FULL WT scale by the same amount, it may not be

necessary to go any farther than this.

When SETTING FULL WEIGHT, BE SURE you know the exact weight (in GRAMS)

that you are adding to the bin. Place this weight in the bin and then

press the FULL WT. key. Five dashes (FUL-----) will be displayed.

Enter the EXACT weight in GRAMS that you have placed in the bin. The

weight should be close to the designed full bin weight; (400, 1000,

2000, 4000, 9000, or 18000). The example below uses 2000.

When done, their is no need to turn the Calibration Flag off. The next

time power is turned off this flag will be reset to OFF.

The sequence of keystrokes is as follows:

Press: *

Display will say: (PASSWORD)

Display will say: (P x)

Display will say: (CAL OFF)

Display will say: (CAL ON )

Press: 22222

Press: *99

Press: *

Press: EXIT

Press: ZERO

Display will say: (P

Display will say: (--WAIT--)

followed by: (P 0)

Place a 2000 (or 1000, 4000 or 9000) Gram weight in the bin.

Press: FULL

Press: 2000

Display will say: (FUL-----)

Display will say: (--WAIT--)

followed by: (P 2000.0)

If YOUR weight is not exactly 2000 grams,

then enter the ACTUAL weight that YOU use.

Press: EXIT

Display will say: ( 2000.0)

Remove weights:

Display will say: (

x.x)

Actual displayed weights may be plus or minus a few grams.

After FULL weight calibration, if the display says (BAD CELL), the

weight you are using does not match the weight you entered, the weigh

bin is not free to move, OR the load cells are bad.

Page 94

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.

DISPENSE GATES

To be accurate, gates must open and close freely, quickly, and

completely. Check for wear on the slide gate guide rods. Check

cylinder clevis adjustment for correct closing of the gate. A gate

should close just enough to block the hole, but no further. It is best

if they do not pass over the far edge of the opening as this might

catch and jam on a pellet. Check that the clevis pin connecting the

air cylinder is intact, not broken or worn through. Check for correct

air pressure, tight fittings, and no damaged or crimped air lines.

LOAD CELLS

It is a good idea to remove the load cells, remove the back cover off

each enclosure, and inspect for contamination that might have entered

and built up over time. Do not remove the load cell from its mounting.

Just blow out any contaminants. Load cell enclosure design has evolved

over the years. If you find significant contamination, request new

enclosures from us. GBM and 100 series have recently improved

enclosures, since 2000. Other models had improvements made before

1997. We will provide these parts for free if you need them.

WEIGH BINS

Check for smooth correct operation of the dump flap. Hinge points

should not be worn. Gate should overlap the forward edge enough to

prevent dribble when closed, even when closed against pellets. Space

at the rear of the flap should allow for static build up of pellets on

the rear edge of the dump flap without interfering with the closing of

the flap. Again, if you see evidence of these problems, newer design

parts are available to solve these problems. Check that the flap

closes fully, and closes softly. The soft close is adjustable.

CLEARANCES - FREE MOVEMENT OF WEIGH BIN.

Carefully examine all the parts of the weigh bin and the bin hanging

bracket to be sure that nothing touches any fixed parts. A quarter

(1/4) inch of space should exist on all sides of the weigh bin. Over

the years, windows and guards have been added, and this has required

that the weigh bin size be reduced to maintain 1/4 inch clearance per

side. Be sure you do not have an older larger bin installed where

windows have been added.

A light touch of the bin should show a change in the weight readout.

Remove the touch and the display should return to exactly the same

number, plus or minus 1 or 1/10 gram depending on model. Only the last

digit should drift, or vary, and by no more then one count. If ANY

interference is detected, it MUST be fixed.

MIX CHAMBER

No bent blades. No SHARP blades. Bent blades might brake off and

severally damage your process screw. Sharp blades are a safety hazard.

Replace if mix blades are not perfect.

Page 95

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.

Page 96

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.

wire color

formerly optical coupler outputs

17 pin amphonal connector

pin A

pin B

pin C

pin D

pin E

pin M

pin F

weigh bin dump air solenoid

brown

orange

blue

component 1 air solenoid

component 2 air solenoid

component 3 air solenoid

component 4 air solenoid

flow control air solenoid

component 7 air solenoid

gray

purple

yellow

red

solid state plug-in relays (4) on separate board

comp. 5 - color auger motor outlet, panel front

comp. 6 - additive auger motor outlet, panel front

strobe and beeper + opt. alarm relay output

mix motor outlet, panel side

pin G

pin H

pin J

pin K

comp. 8 - external SS relay

comp. 9 - external SS relay

comp. 10 - external SS relay

comp. 11 - external SS relay

wt./red

wt./yellow

wt./green

wt./blue

pin L

pin N

pin P

alarm

common line, all outputs.

comp. 12 - ext. relay (also air drive mixer)

white

pin R

pin S

pin T

neutral to 10 volt signals (S,T)

0-10 volt extruder control signal

0-10 volt line speed control signal

External SS relays are optional.

External SS relays and air solenoids may be exchanged.

Page 98

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.

WE’RE HERE

TO HELP

To contact Customer Service personnel, call:

HOW TO CONTACT

CUSTOMER

SERVICE

From outside the United States, call: 814-437-6861

You can commission Conair service personnel to provide on-

site service by contacting the Customer Service Department.

Standard rates include an on-site hourly rate, with a one-day

minimum plus expenses.

If you do have a problem, please complete the

following checklist before calling Conair:

BEFORE YOU

CALL ...

❒ Make sure you have all model, serial and parts list

numbers for your particular equipment. Service

personnel will need this information to assist you.

❒ Make sure power is supplied to the equipment.

❒ Make sure that all connectors and wires within

and between control systems and related

components have been installed correctly.

❒ Check the troubleshooting guide of this manual

for a solution.

❒ Thoroughly examine the instruction manual(s)

for associated equipment, especially controls.

Each manual may have its own troubleshooting

guide to help you.

Additional manuals and

prints for your Conair

equipment may be

ordered through the

Customer Service or

Parts Departments for

a nominal fee.

❒ Check that the equipment has been operated as

described in this manual.

❒ Check accompanying schematic drawings for

information on special considerations.

IMS0002/0296

SERVICE INFORMATION

APPENDIX A-1

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. The customer assumes the cost

of transportation of the part or parts to and from the factory.

EQUIPMENT

GUARANTEE

Conair warrants that this equipment will perform at or above

the ratings stated in specific quotations covering the equip-

ment or as detailed in engineering specifications, provided the

equipment is applied, installed, operated and maintained in the

recommended manner as outlined in our quotation or specifi-

cations.

PERFORMANCE

WARRANTY

Should performance not meet warranted levels, Conair at its

discretion will exercise one of the following options:

● Inspect the equipment and perform alterations or

adjustments to satisfy performance claims. (Charges

for such inspections and corrections will be waived

unless failure to meet warranty is due to misapplica-

tion, improper installation, poor maintenance practices

or improper operation.)

● Replace the original equipment with other Conair

equipment that will meet original performance claims

at no extra cost to the customer.

● Refund the invoiced cost to the customer. Credit is

subject to prior notice by the customer at which time a

Return Goods Authorization Number (RGA) will be

issued by Conair’s Service Department. Returned

equipment must be well crated and in proper operating

condition, including all parts. Returns must be prepaid.

Purchaser must notify Conair in writing of any claim and pro-

vide a customer receipt and other evidence that a claim is

being made.

Except for the Equipment Guarantee and Performance

Warranty stated above, Conair disclaims all other warranties

with respect to the equipment, express or implied, arising

by operation of law, course of dealing, usage of trade or oth-

erwise, including but not limited to the implied warranties of

merchantability and fitness for a particular purpose.

WARRANTY

LIMITATIONS

IMS0003/0795

APPENDIX A-2

WARRANTY INFORMATION

TPBS015/0700

SPECIFICATIONS

GRAVIMETRIC BATCH BLENDERS

Autoweigh GBM Series Models

CONTROL (REMOTE MOUNTED)

MODELS

GBM22

GBM31

GBM40

MOUNTING INTERFACE

Performance characteristics

Batch size lbs {g}

.882 {400}

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

97 {44}

0.4 {11.3}

111 {50}

0.4 {11.3}

132 {60}

0.4 {11.3}

†

4 or 12

27.25 {693}

21.75 {552.4}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

27.25 {693}

21.75 {552.4}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

27.25 {693}

21.75 {552.4}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

SPECIFICATION NOTES:

* Maximum throughput rates are based on

using all dispense valves and dispensing no

more than 1.0% colorant and/or additive per

each micropulsing valve. Refer to the selec-

tion guide for more specific throughput infor-

mation.

Weight lbs {kg}

Installed

Shipping

Voltage Running load amps

120V/1 phase 50/60 hz

220V/1 phase 50/60 hz

Compressed air requirements

70 {32}

90 {41}

70 {32}

90 {41}

70 {32}

90 {41}

†

The Regrind position features a 1.5-inch

diameter valve to ensure flow or irregularly

shaped material.

1.0

0.5

1.0

0.5

1.0

0.5

If you will be using this blender for central

blending applications, it will be necessary to

use a flow control valve with an air solenoid.

40 psi @ 1 ft³/min { 2.8 bars @ 0.47 liters/sec}

1/4 in. NPT fitting

Material filling options

Self-contained vacuum loader

Central vacuum receiver

Hand-fill

ML8 or Z2HL

DL8

flat lid

One Conair Drive G Pittsburgh, PA 15202 G 412-312-6000 G FAX 412-312-6227 G www.conairnet.com

APPENDIX B

TPBS010/1199

SPECIFICATIONS

GRAVIMETRIC BATCH BLENDERS

AutoWeigh GB100 Series Models

CONTROL

TOP VIEW

FRONT VIEW

SIDE VIEW

MODELS

GB122

GB131

GB140

MOUNTING INTERFACE

Performance characteristics

Batch size lbs {g}

10 in.

{254 mm}

IB04

2.2 {1000}

square

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}

200 {90}

1.0 {28.32}

0.5 {14.16}

280 {128}

1.0 {28.32}

0.5 {14.16}

450 {204}

1.0 {28.32}

0.5 {14.16}

8 in. {203.2 mm}

square

bolt pattern

(4) 9/16 in.

{14.3 mm}

diameter

3 in. {76.2 mm}

diameter

through hole

4 or 12

bolt holes

†

A - Height above mounting plate

B - Width

38.9 {989.6}

33.2 {843.3}

38.9 {989.6}

33.2 {843.3}

38.9 {989.6}

33.2 {843.3}

SPECIFICATION NOTES:

C - Depth

31.4 {797.6}

Each stationary bin compart-

ment can support a 12-inch

loader or vacuum receiver.

Removable bins can support a

maximum of an 8-inch loader.

D - Controller height

E - Controller width

F - Controller depth

Weight lbs {kg}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

Installed

Shipping

200 {90.7}

300 {136.1}

200 {90.7}

300 {136.1}

200 {90.7}

300 {136.1}

* Throughput rates are based on

bins with each micro-pulsing

valve dispensing no more than

1% colorant and/or additive

material and using a material

with a bulk density of 35 lb/ft³.

Voltage Total amps

120V/1 phase/50-60 hz

240V/1 phase/50-60 hz

Compressed air requirements

Discharge valves

Micro pulsing valves

2.0

1.0

2.0

1.0

2.0

1.0

†

The optional flow control valve

adds 6.5 in. {165 mm} to total

height.

80 psi @ 0.2 ft³/min {5.5 bars @ 0.09 liters/sec}; 1/4 in. NPT fitting

40 psi @ 0.2 ft³/min {2.8 bars @ 0.09 liters/sec}; 1/4 in. NPT fitting

One Conair Drive G Pittsburgh, PA 15202 G 412-312-6000 G FAX 412-312-6227 G www.conairnet.com

APPENDIX B

TPBS011/1199

SPECIFICATIONS

GRAVIMETRIC BATCH BLENDERS

GB 220 and 420 Models

TOP VIEW

MOUNTING INTERFACE

14 in.

{355.6 mm}

IBO4

10 in.

{254 mm}

CONTROL

8 in.

{203.2 mm}

square bolt

pattern

(4) 9/16 in.

{14.3 mm}

diameter

3 in. {76.2 mm}

diameter

through hole

FRONT VIEW

SIDE VIEW

GB420

bolt holes

MODELS

GB220

GB221

GB222

GB421

GB422

Performance characteristics

Batch size lbs {g}

4.4 {2000}

8.8 {4000}

Maximum throughput lbs/hr {kg/hr}*

Bin capacity - each ft³{liter}

Maximum number of materials

Number of discharge valves

Number of additive feeders

Control software (# of components)

Dimensions inches {mm}

1239 {562}

2.2 {62.3}

575 {261}

2.2 {62.3}

540 {245}

2.2 {62.3}

1966 {892}

2.2 {62.3}

700 {318}

2.2 {62.3}

680 {308}

2.2 {62.3}

4 or 12

†

A - Height above mounting plate

48 {1217.9}

34 {863.6}

17.5 {444.5}

11.25 {285.75} 11.25 {285.75}

12.25 {311.15} 12.25 {311.15}

8.19 {208.03}

48 {1217.9}

34 {863.6}

17.5 {444.5}

48 {1217.9}

34 {863.6}

17.5 {444.5}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

54 {1370.3}

34 {863.6}

17.5 {444.5}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

54 {1370.3}

34 {863.6}

17.5 {444.5}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

54 {1370.3}

34 {863.6}

17.5 {444.5}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

‡

B - Width

C - Depth

‡

D - Controller height

E - Controller width

F - Controller depth

Weight lbs {kg}

8.19 {208.03}

Installed

Shipping

220 {100}

325 {147}

260 {118}

265 {120}

300 {136}

405 {183}

245 {111}

350 {159}

285 {129}

390 {177}

325 {147}

430 {195}

Voltage Total amps

120V/1 phase/50-60 Hz

240V/1 phase/50-60 Hz

Compressed air requirements

Discharge valves

4.8

2.5

5.8

3.0

6.8

3.5

4.8

2.5

5.8

3.0

6.8

3.5

80 psi @ 0.2 ft³/min. {5.5 bars @0.09 liters/sec}, 1/4 in. NPT fitting

40 psi @ 2 ft³/min. {2.8 bars @0.94 liters/sec}, 1/4 in. NPT fitting

Compressed air feeder

SPECIFICATION NOTES:

Each bin compartment will support a 12-inch to 15-inch loader or vacuum receiver.

* Throughput rates are based on using no more than 5% additive or colorant material total in either the CAF3 compressed

air or F03 auger feeder. Always refer to the selection guide for specific throughput information.

† The optional flow control valve adds 6.5 in. {165 mm} to the total height. We recommend using the flow control valve when

mounting the blender to a stand, surge bin or hopper.

‡ Feeders will increase width and depth dimensions. Please refer to feeder specifications.

One Conair Drive G Pittsburgh, PA 15202 G 412-312-6000 G FAX 412-312-6227 G www.conairnet.com

APPENDIX B

TPBS012/1199

SPECIFICATIONS

GRAVIMETRIC BATCH BLENDERS

AutoWeigh GB240 and GB440 Models

TOP VIEW

MOUNTING

INTERFACE

14 in.

{355.6 mm}

IB04

10 in.

{254 mm

8 in. {203.2 mm}

square bolt pattern

SIDE VIEW

CONTROL

FRONT VIEW

(4) 9/16 in.

3 in. {76.2 mm}

diameter

through hole

{14.3 mm}

diameter

bolt holes

MODELS

GB240

GB241

GB242

GB440

GB441

GB442

Performance characteristics

Batch size lbs {g}

4.4 {2000}

8.8 {4000}

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 additive feeders

993 {451}

3.5 {99.12}

678 {308}

3.5 {99.12}

0.5 {14.16}

518 {235}

3.5 {99.12}

0.5 {14.16}

1645 {748}

3.5 {99.12}

983 {446}

3.5 {99.12}

0.5 {14.16}

704 {319}

3.5 {99.12}

0.5 {14.16}

Control software (# of components)

Dimensions inches {mm}

A - Height above mounting plate

4 or 12

†

59.75 {1517.5} 59.75 {1517.5}

34 {863.6}

59.75 {1517.5}

34 {863.6}

65.75 {1669.9}

34 {863.6}

65.75 {1669.9}

34 {863.6}

65.75 {1669.9}

34 {863.6}

‡

B - Width

C - Depth

34 {863.6}

‡

D - Controller height

E - Controller width

F - Controller depth

Weight lbs {kg}

11.25 {285.75} 11.25 {285.75}

12.25 {311.15} 12.25 {311.15}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

Installed

Shipping

230 {104}

335 {152}

270 {122}

375 {170}

310 {140}

415 {188}

255 {116}

360 {163}

295 {134}

400 {181}

335 {152}

440{200}

Voltage Total amps

120V/1 phase/50-60 Hz

240V/1 phase/50-60 Hz

Compressed air requirements

Discharge valves

4.8

2.5

5.8

3.0

6.8

3.5

4.8

2.5

5.8

3.0

6.8

3.5

80 psi @ 0.2 ft³/min. {5.5bars @ 0.09 liters/sec}, 1/4 in. NPT fitting

40 psi @ 2 ft³/min. {2.8bars @ 0.94 liters/sec}, 1/4 in. NPT fitting

Compressed air feeder

SPECIFICATION NOTES:

Each bin compartment can support a 12-inch to 15-inch loader or vacuum receiver.

* Throughput rates are based on using no more than 2% additive or colorant material total in either the CAF3 compressed air or F03 auger

feeder. Always refer to the selection guide for specific throughput information.

†

The optional flow control valve adds 6.5 in. {165 mm} to the total height. We recommend using the flow control valve when mounting the

blender to a stand, surge bin or hopper.

Feeders will increase width and depth dimensions. Please refer to feeder specifications.

‡

One Conair Drive G Pittsburgh, PA 15202 G 412-312-6000 G FAX 412-312-6227 G www.conairnet.com

APPENDIX B

TPBS013/1199

SPECIFICATIONS

GRAVIMETRIC BATCH BLENDERS

AutoWeigh GB900 Series Models

GB920

FEEDER LOCATIONS

NOTE: Any one of the

feeders (A,B,C or D)can be

designated position 5 or 6.

GB940

GB960

SIDE VIEW

GB920/GB940

FRONT VIEW

GB920

SIDE VIEW

GB960

FRONT VIEW

GB940/GB960

CONTROL

MODELS

GB920

GB940

GB960

Performance characteristics

Batch size lbs {g}

19.8 {9000}

5200 {2359}

8.5 {240.7}

19.8 {9000}

3300 {1497}

6.7 {189.7}

3.6 {107.6}

19.8 {9000}

2124 {965}

3.6 {102.9}

3.6 {107.6}

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

MOUNTING INTERFACE

Number of additive feeders

Control software (# of components)

Dimensions inches {mm}

up to 4

4 or 12

up to 4

4 or 12

up to 4

IBO4

†

A - Height above mounting plate

74 {1880.7}

56 {1421.4}

34 {863.6}

74 {1880.7}

56 {1421.4}

34 {863.6}

74 {1880.7}

56 {1421.4}

34 {863.6}

‡

B - Width

‡

C - Depth

D - Controller height

E - Controller width

F - Controller depth

Weight lbs {kg}

Installed

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

480 {218}

600 {272.2}

480 {218}

600 {272.2}

480 {218}

600 {272.2}

SPECIFICATION NOTES:

Shipping

* Maximum throughput rates are based on 35 lbft³

pelletized material and using all dispense valves.

Use of feeders for minor ingredients will reduce

this rate. Refer to the selection guide for more

specific throughput information.

Voltage Running load amps

120V/1 phase/60 hz (control and mixer)

220V/1 phase/60 hz (control and mixer)

220V/1 phase/50 hz (control)

220V/3 phase/50 hz (mixer)

400V/3 phase/50 hz (mixer)

8.5

4.25

0.15

2.2

8.5

4.25

0.15

2.2

8.5

4.25

0.15

2.2

†

The optional flow control valve will add 6.5 in. {165

mm} to the total height. We recommend using the

flow control valve when mounting the blender to a

stand, surge bin or hopper.

1.1

Compressed air requirements

‡

Discharge valves

80 psi @ 0.2 ft³/min {5.5 bars @ 0.09 liters/sec}; 1/4 in. NPT fitting

40 psi @ 2.0 ft³/min {2.8 bars @ 0.94 liters/sec}; 1/4 in. NPT fitting

Feeders will increase depth dimensions. Please

refer to feeder specification.

Compressed air feeder

Maximum loader sizes **

Number of 20 inch loaders

Number of 15 inch loaders

Each auger feeder requires an additional 1 amp @

120V or 0.5 amp @ 240V.

** Maximum loader sizes may be used only when the

loader is adjacent to loaders of a smaller diameter.

One Conair Drive G Pittsburgh, PA 15202 G 412-312-6000 G FAX 412-312-6227 G www.conairnet.com

APPENDIX B

TPS014/1199

SPECIFICATIONS

GRAVIMETRIC BATCH BLENDERS

AutoWeigh GB1840 and 1860 Models

FEEDER LOCATIONS

TOP VIEW GB1840

TOP VIEW GB1860

NOTE: Any one of the

feeders (A,B,C or D)

can be designated

position 5 or 6.

CONTROL

FRONT VIEW

GB1840/GB1860

SIDE VIEW

GB1840

SIDE VIEW

GB1860

MODELS

GB1840

GB1860

MOUNTING INTERFACE

Performance characteristics

Batch size lbs {g}

(4) 9/16 in. {14.3 mm}

diameter bolt holes

39.7 {18000}

4114 {1870}

6.7 {189.7}

3.8 {107.6}

39.7 {18000}

2566 {1166}

3.8 {107.6}

IB04

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

8 in. {203.2 mm}

square bolt pattern

4 in. {101.6 mm}

diameter

through hole

Number of additive feeders

Control software (# of components)

Dimensions inches {mm}

up to 4

4 or 12

up to 4

16 in.

{406.4 mm}

14.5 in.

{368.3 mm}

A - Height above mounting plate

93 {2362.2}

56 {1421.4}

34 {863.6}

93 {2362.2}

56 {1421.4}

34 {863.6}

†

B - Width

15 in. {381 mm}

20 in. {508 mm}

†

C - Depth

D - Controller height

E - Controller width

F - Controller depth

Weight lbs {kg}

Installed

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

SPECIFICATION NOTES

* Maximum throughput rates are based on 35 lb/ft³pel-

letized material and using all dispense valves. Use of

feeders for minor ingredients will reduce this rate.

Refer to the selection guide for more specific through-

put information.

730 {331}

850 {385.5}

730 {331}

850 {385.5}

Shipping

Voltage Running load amps

‡

110V/1 phase/60hz (control)

220V/1 phase/60hz (mixer)

220V/1 phase/60hz (control)

220V/1 phase/60hz (mixer)

220V/1 phase/50hz (control)

220V/3 phase/50hz (mixer)

400V/3 phase/50hz (mixer)

Compressed air requirements

Discharge valves

0.3

8.2

0.2

8.2

0.2

4.4

2.2

0.3

8.2

0.2

8.2

0.2

4.4

2.2

†

Feeders will increase width dimensions. Please refer

to feeder specification.

‡ Each auger feeder requires an additional 1 amp @

120V or 0.5 amp @ 240V.

§ Maximum loader sizes may be used only when

the loader is adjacent to loaders of a smaller

diameter.

80 psi @ 0.2 ft³/min {5.5 bars @ 0.09 liters/sec}

1/4 in. NPT fitting

Maximum loader sizes

Number of 20 inch loaders

Number of 15 inch loaders

One Conair Drive G Pittsburgh, PA 15202 G 412-312-6000 G FAX 412-312-6227 G www.conairnet.com

APPENDIX B

TPBS016/0700

SPECIFICATIONS

GRAVIMETRIC BATCH BLENDERS

WSBM Series models

CONTROL (REMOTE MOUNTED)

MODELS

WSBM22

WSBM131

WSBM140

MOUNTING INTERFACE

Performance characteristics

Batch size lbs {g}

0.882 {400}

Maximum throughput lbs/hr {kg/hr}*

Bin capacity - standard bins ft³{liter}

Maximum number of materials

97 {44}

0.4 {5.7}

111 {50}

0.4 {5.7}

132 {60}

0.4 {5.7}

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

4 or 12

27.25 {693}

21.75 {552.4}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

27.25 {693}

21.75 {552.4}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

27.25 {693}

21.75 {552.4}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

SPECIFICATION NOTES:

* Maximum throughput rates are based on

using all dispense valves dispensing no more

than 1.0% colorant or additive per each

micropulsing valve. Refer to the selection

guide for more specific throughput informa-

tion.

F - Controller depth

Weight lbs {kg}

Installed

Shipping

60 {27}

80 {36.3}

60 {27}

80 {36.3}

60 {27}

80 {36.3}

APPLICATION NOTE:

Voltage Running load amps

120V/1 phase 50/60 hz

220V/1 phase 50/60 hz

Compressed air requirements

Handfill unless otherwise specified.

1.0

0.5

1.0

0.5

1.0

0.5

If you will be using this blender for central

blending applications, it will be necessary to

use a flow control valve with an air solenoid.

40 psi @ 1 ft³/min { bars @ 0.47 liters/sec}

1/4 in. NPT fitting

Material filling options

Self-contained vacuum loader

Central vacuum receiver

Hand-fill

ML8

DL8

flat lid

One Conair Drive G Pittsburgh, PA 15202 G 412-312-6000 G FAX 412-312-6227 G www.conairnet.com

APPENDIX B

TPBS001/0700

SPECIFICATIONS

GRAVIMETRIC BATCH BLENDERS

WSB 100 and 100R Models

Top View

Top View, R Model

CONTROL

Side View

Front View

Side View, R Model

Front View, R Model

MODELS

WSB122

WSB131

WSB140

MOUNTING INTERFACE

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

10 in.

{254 mm}

square

IB04

2.2 {1000}

200 {91}

1.0 {28.3}

2.2 {1000}

280 {128}

1.0 {28.3}

2.2 {1000}

450 {204}

1.0 {28.3}

8 in. {203.2 mm}

square

bolt pattern

Number of discharge valves

Number of micro pulsing valves

Control software (# of components)

Dimensions inches {mm}

A - Height above mounting plate

B - Width

C - Width R (removable bins)

D - Depth

E - Controller height

F - Controller width

G - Controller depth

Weight lbs {kg}

(4) 9/16 in.

3 in. {76.2 mm}

diameter

through hole

{14.3 mm}

diameter

bolt holes

4 or 12

†

38.9 {989.6}

33.2 {843.3}

30.2 {766.3}

31.4 {797.6}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

38.9 {989.6}

33.2 {843.3}

30.2 {766.3}

31.4 {797.6}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

38.9 {989.6}

33.2 {843.3}

30.2 {766.3}

31.4 {797.6}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

SPECIFICATION NOTES:

R model has removable bins with verti-

cal valves. Removable bins can sup-

port an 8-inch loader or vacuum

receiver. Stationary bins can support a

12-inch loader or vacuum receiver.

Maximum throughput for a 140R model

is 437 lb/hr {198.2 kg/hr}. Minor ingre-

dient bin capacity is 0.7 ft³{19.8 liter}.

Installed

200 {90.7}

Shipping

300 {136.1}

* Throughput rates are based on bins

with each micropulsing valve dis-

pensing no more than 1% colorant

and/or additive material.

Voltage Total amps

120V/1 phase/50-60 hz

240V/1 phase/50-60 hz

Compressed air requirements

Discharge valves

Micro pulsing valves

2.0

1.0

2.0

1.0

2.0

1.0

†

The optional flow control valve adds

60 psi @ 0.2 ft³/min { 4.1 bars @ 0.09 liters/sec}; 1/4 in. NPT fitting

3.5 in. {88.9 mm} to total height.

One Conair Drive G Pittsburgh, PA 15202 G 412-312-6000 G FAX 412-312-6227 G www.conairnet.com

APPENDIX B

TPBS002/1199

SPECIFICATIONS

GRAVIMETRIC BATCH BLENDERS

WSB 220 and 420 Models

MOUNTING INTERFACE

14 in.

{355.6 mm}

IBO4

10 in.

{254 mm}

8 in.

{203.2 mm}

square bolt

pattern

(4) 9/16 in.

3 in. {76.2 mm}

diameter

through hole

{14.3 mm}

diameter

bolt holes

CONTROL

MODELS

WSB220

WSB221

WSB222

WSB420

WSB421

WSB422

Performance characteristics

Batch size lbs {g}

4.4 {2000}

8.8 {4000}

Maximum throughput lbs/hr {kg/hr}*

Bin capacity - each ft³{liter}

Maximum number of materials

Number of discharge valves

Number of additive feeders

Control software (# of components)

Dimensions inches {mm}

1239 {562}

2.0 {56.6}

575 {261}

2.0 {56.6}

540 {245}

2.0 {56.6}

1966 {892}

2.0 {56.6}

700 {318}

2.0 {56.6}

680 {308}

2.0 {56.6}

4 or 12

†

A - Height above mounting plate

48 {1217.9}

34.4 {873.8}

24.75 {628.6}

11.25 {285.75} 11.25 {285.75}

12.25 {311.15} 12.25 {311.15}

48 {1217.9}

34.4 {873.8}

24.75 {628.6}

48 {1217.9}

34.4 {873.8}

24.75 {628.6}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

54 {1370.3}

34.4 {873.8}

24.4 {619.8}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

54 {1370.3}

34.4 {873.8}

24.4 {619.8}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

54 {1370.3}

34.4 {873.8}

24.4 {619.8}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

‡

B - Width

C - Depth

‡

D - Controller height

E - Controller width

F - Controller depth

Weight lbs {kg}

Installed

8.19 {208.03}

220 {100}

325 {147}

260 {118}

265 {120}

300 {136}

405 {183}

245 {111}

350 {159}

285 {129}

390 {177}

325 {147}

430 {195}

Shipping

Voltage Total amps

120V/1 phase/50-60 Hz

240V/1 phase/50-60 Hz

Compressed air requirements

Discharge valves

4.8

2.5

4.8

2.5

4.8

2.5

4.8

2.5

4.8

2.5

4.8

2.5

80 psi @ 0.2 ft³/min. {5.5 bars @0.09 liters/sec}, 1/4 in. NPT fitting

40 psi @ 2 ft³/min. {2.8 bars @0.94 liters/sec}, 1/4 in. NPT fitting

Compressed air feeder

SPECIFICATION NOTES:

Each bin compartment will support a 12-inch to 15-inch loader or vacuum receiver.

* Throughput rates are based on using no more than 5% additive or colorant material total in either the CAF3 compressed

air or F03 auger feeder. Always refer to the selection guide for specific throughput information.

† The optional butterfly control flow control valve adds 3.5 in. {88.9 mm} to the total height. We recommend using the flow

control valve when mounting the blender to a stand, surge bin or hopper.

‡ Feeders will increase width and depth dimensions. Please refer to feeder specifications.

§ Each additional auger feeder requires an additional 1 amp @ 120V or 0.5 amps @ 240V.

One Conair Drive G Pittsburgh, PA 15202 G 412-312-6000 G FAX 412-312-6227 G www.conairnet.com

APPENDIX B

TPBS003/1199

SPECIFICATIONS

GRAVIMETRIC BATCH BLENDERS

WSB 240/440 and 240/440R Models

Top View

Top View, R Models

MOUNTING INTERFACE

14 in.

{355.6 mm}

IB04

10 in.

{254 mm}

8 in. {203.2 mm}

square bolt pattern

(4) 9/16 in.

3 in. {76.2 mm}

diameter

through hole

{14.3 mm}

diameter

bolt holes

Front View

Side View

CONTROL

Front View, R Models

Side View, R Models

MODELS

WSB240

WSB241

WSB242

WSB440

WSB441

WSB442

Performance characteristics

Batch size lbs {g}

4.4 {2000}

8.8 {4000}

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

993 {451}

3.5 {99.12}

678 {308}

3.5 {99.12}

0.5 {14.16}

518 {235}

3.5 {99.12}

0.5 {14.16}

1645 {748}

3.5 {99.12}

983{446}

3.5 {99.12}

0.5 {14.16}

704 {319}

3.5 {99.12}

0.5 {14.16}

Number of additive feeders

Control software (# of components)

Dimensions inches {mm}

4 or 12

†

A - Height above mounting plate

59.75 {1517.5} 59.75 {1517.5}

59.75 {1517.5}

34.4 {873.8}

32.2 {817.9}

65.75 {1669.9}

34.4 {873.8}

32.2 {817.9}

65.75 {1669.9}

34.4 {873.8}

32.2 {817.9}

65.75 {1669.9}

34.4 {873.8}

32.2 {817.9}

‡

B - Width

34.4 {873.8}

32.2 {817.9}

34.4 {873.8}

32.2 {817.9}

34.4 {873.8}

‡

C - Width R (removable bins)

D - Depth

‡

34.4 {873.8}

E - Controller height

F - Controller width

G - Controller depth

Weight lbs {kg}

Installed

11.25 {285.75} 11.25 {285.75}

12.25 {311.15} 12.25 {311.15}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

230 {104}

335 {152}

270 {122}

375 {170}

310 {140}

415 {188}

255 {116}

360 {163}

295 {134}

400 {181}

335 {152}

440 {200}

Shipping

Voltage Total amps

120V/1 phase/50-60 Hz

240V/1 phase/50-60 Hz

Compressed air requirements

Discharge valves

4.8

2.5

4.8

2.5

4.8

2.5

4.8

2.5

4.8

2.5

4.8

2.5

80 psi @ 0.2 ft³/min. {5.5bars @ 0.09 liters/sec}, 1/4 in. NPT fitting

40 psi @ 2 ft³/min. {2.8bars @ 0.94 liters/sec}, 1/4 in. NPT fitting

Compressed air feeder

SPECIFICATION NOTES:

R models have removable bins. The removable bins can support 8-inch loaders. Stationary bin compartments can support 12-inch to 15-inch

loaders.

* Throughput rates are based on using the F03 auger feeder dispensing no more than 2% per additive or colorant. Maximum throughput rates

for R models are: WSB240R with no feeders 864 lb/hr; with one feeder 619 lb/hr; with two feeders 483 lb/hr. For WSB440R model with no

feeder 1326 lb/hr; with one feeder, 864 lb/hr; with two feeders 640 lb/hr.

† The optional butterfly flow control valve adds 3.5 in. {88.9 mm} to the total height. We recommend using the flow control valve when mounting

the blender to a stand, surge bin or hopper.

‡ Feeders will increase width and depth dimensions. Please refer to feeder specifications.

§ Each auger feeder requires an additional 1 amp @ 120V or 0.5 amp @ 240V.

One Conair Drive G Pittsburgh, PA 15202 G 412-312-6000 G FAX 412-312-6227 G www.conairnet.com

APPENDIX B

TPBS004/1199

SPECIFICATIONS

GRAVIMETRIC BATCH BLENDERS

WSB 920, 940, 950 and 960 Models

NOTE: Loader

configuration is

the same for all

models.

CONTROL

MODELS

WSB920

WSB940

WSB950

WSB960

MOUNTING INTERFACE

Performance characteristics

Batch size lbs {g}

IB04

19.8 {9000}

5200 {2359}

6.7 {189.7}

19.8 {9000}

3300 {1487}

6.7 {189.7}

3.8 {107.6}

19.8 {9000}

2492 {1132}

6.7 {189.7}

3.8 {107.6}

19.8 {9000}

2124 {965}

3.8 {107.6}

up to 4

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 additive feeders

Control software (# of components)

Dimensions inches {mm}

up to 4

4 or 12

up to 4

4 or 12

up to 4

A - Height above mounting plate

74 {1880.7}

56 {1421.4}

34.4 {875.3}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

74 {1880.7}

56 {1421.4}

34.4 {875.3}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

74 {1880.7}

56 {1421.4}

34.4 {875.3}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

74 {1880.7}

56 {1421.4}

34.4 {875.3}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

†

B - Width

C - Depth

†

SPECIFICATION NOTES:

D - Controller height

E - Controller width

F - Controller depth

Weight lbs {kg}

Installed

* Maximum throughput rates are

based on using all dispense

valves. Use of feeders for minor

ingredients will reduce this rate.

480 {218}

† Feeders will increase width and

depth dimensions. Please refer

to feeder specification.

Shipping

600 {272.2}

‡

Voltage Running load amps

‡ Each auger feeder requires an

additional 1 amp @ 120V or 0.5

amp @ 240V.

120V/1 phase/60 hz (control and mixer)

220V/1 phase/60 hz (control and mixer)

220V/1 phase/50 hz (control)

220V/3 phase/50 hz (mixer)

400V/3 phase/50 hz (mixer)

Compressed air requirements

Discharge valves

8.5

4.3

0.15

2.2

8.5

4.3

0.15

2.2

8.5

4.3

0.15

2.2

8.5

4.3

0.15

2.2

§ Maximum loader sizes may be

used only when the loader is

adjacent to loaders of a smaller

size.

1.1

80 psi @ 0.2 ft³/min {5.5 bars @ 0.09 liters/sec}; 1/4 in. NPT fitting

40 psi @ 2.0 ft³/min {2.8 bars @ 0.94 liters/sec}; 1/4 in. NPT fitting

APPLICATION NOTE:

Compressed air feeder

We recommend using a flow con-

trol valve when mounting the

blender to a stand, surge bin or

hopper.

Maximum loader sizes

Number of 20 inch loaders

Number of 15 inch loaders

One Conair Drive G Pittsburgh, PA 15202 G 412-312-6000 G FAX 412-312-6227 G www.conairnet.com

APPENDIX B

TPBS005/0700

SPECIFICATIONS

GRAVIMETRIC BATCH BLENDERS

WSB 1840, 1850 and 1860 Models

Note: loader

configuration

same for all

models

CONTROL

MODELS

WSB1840

WSB1850

WSB1860

MOUNTING INTERFACE

Performance characteristics

Batch size lbs {g}

(4) 9/16 in. {14.3 mm}

diameter bolt holes

IB04

39.7 {18000}

4114 {1866}

6.7 {189.7}

3.8 {107.6}

39.7 {18000}

3160 {1433}

6.7 {189.7}

3.8 {107.6}

39.7 {18000}

2566 {1164}

3.8 {107.6}

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}

8 in. {203.2 mm}

square bolt pattern

4 in. {101.6 mm}

diameter

through hole

16 in.

{406.4 mm}

up to 4

4 or 12

up to 4

14.5 in.

{368.3 mm}

A - Height above mounting plate

93 {2362.2}

56.25 {1428.8}

34.4 {873.8}

93 {2362.2}

56.25 {1428.8}

34.4 {873.8}

93 {2362.2}

56.25 {1428.8}

34.4 {873.8}

15 in. {381 mm}

†

B - Width

†

C - Depth

20 in. {508 mm}

D - Controller height

E - Controller width

F - Controller depth

Weight lbs {kg}

Installed

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

11.25 {285.75}

12.25 {311.15}

8.19 {208.03}

SPECIFICATION NOTES:

* Maximum throughput rates are based

on using all dispense valves and 35

lb/ft³pelletized material. Use of feed-

ers will reduce this rate.

730 {331}

Shipping

850 {385.5}

† Feeders will increase width and depth

dimensions. Please refer to feeder

specifications.

Voltage Running load amps

‡

110V/1 phase/60hz (control)

220V/1 phase/60hz (mixer)

220V/1 phase/60hz (control)

220V/1 phase/60hz (mixer)

220V/1 phase/50hz (control)

220V/3 phase/50hz (mixer)

400V/3 phase/50hz (mixer)

Compressed air requirements

Discharge valves

0.3

8.2

0.2

8.2

0.2

4.4

2.2

0.3

8.2

0.2

8.2

0.2

4.4

2.2

0.3

8.2

0.2

8.2

0.2

4.4

2.2

‡ Each auger feeder requires an addi-

tional 1 amp @ 120V or 0.5 amp @

240V.

§ Maximum loader sizes may be used

only when the loader is adjacent to

loaders of a smaller diameter.

80 psi @ 0.2 ft³/min {5.5 bars @ 0.09 liters/sec}

1/4 in. NPT fitting

Maximum loader sizes

Number of 20 inch loaders

Number of 15 inch loaders

One Conair Drive G Pittsburgh, PA 15202 G 412-312-6000 G FAX 412-312-6227 G www.conairnet.com

APPENDIX B

APPENDIX C

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Alpine V12 AccuClass D MRD M1005 User Manual
Canon DM GL1 User Manual
Canon Optura 500 User Manual
Casio NP20 User Manual
Datexx DS 700 User Manual
DXG Technology DXG DXG 506V User Manual
Hitachi VM E455LA User Manual
Hitachi WL 201 User Manual
iSimple Car Stereo System User Manual