MAGUIRE FLEXBUS Lite Installation Operation & Maintenance Download Page 2

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Summary of Contents for FLEXBUS Lite

Page 1: ...der 4088 TSC MAGUIRE WEIGH SCALE BLENDER 4088 Touch Screen Controller FLEXBUS Lite Receiver Control System INSTALLATION OPERATION MAINTENANCE Original Instructions Manual Revision Date February 24 202...

Page 2: ...2 Use this space to record information about your Maguire Weigh Scale Blenders Serial Number Date of Purchase Model Number ID IP Address Notes...

Page 3: ...very person concerned with use and maintenance of the Maguire WSB it is recommended to read thoroughly these operating instructions Maguire Products Inc accepts no responsibility or liability for dama...

Page 4: ...____________________________________ 25 Example of Making Settings ______________________________________ 26 Entering Component Settings ____________________________________ 28 Setup Menu Brief Explan...

Page 5: ...________________ 82 Typical Problems _______________________________________________ 86 Mix Problems___________________________________________________ 88 Increasing Throughput________________________...

Page 6: ...6...

Page 7: ...Additive are dispensed as a of Natural or Materials are a of Total Batch Enable Disable Material Type Outputs Page 25 To Enable a component the TYPE must be selected as REGRIND NATURAL or ADDITIVE Eac...

Page 8: ...a safety interlock switch that prevents the mix motor from running and the slide valves from opening DO NOT disable or bypass safety switch HOPPER FINGER GUARDS Finger Guards are fitted into each Mat...

Page 9: ...CLOSED without warning 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 HAZARD ELECTRICAL Only qual...

Page 10: ...10 Blender Parts Key...

Page 11: ...e Load Cells 14 Safety Interlock Pneumatic and Electrical Safety interlock stops blender operating if door is opened 15 Weigh Bin Weigh Bin holds materials as materials are dispensed during a batch an...

Page 12: ...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 a...

Page 13: ...13...

Page 14: ...WSB 900 1800 51 7 8 1318 63 1 4 1607 56 1422 VTA Barrel Gaylord 36 914 8 203 8 203 43 1 4 1099 69 1 4 1759 57 1 4 1454 16 1 8 410 36 914 56 1422 36 914 15 381 15 381 15 381 STAND DIMENSIONS NOTE WSB...

Page 15: ...ontroller 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 t...

Page 16: ...o 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 The CONTROLLER and the WSB fra...

Page 17: ...del categories each with at least one sub model The model of the blender can be found on the red serial tag attached to the blender frame The possible models are Blender Model Batch Weight Grams Weigh...

Page 18: ...the password keypad screen Press 9 7 5 3 1 then press Display will show the Model Selection Screen displaying the Current Model and the model selection list Select The model series of your blender Mo...

Page 19: ...of the features of the earlier 6811 red display and 12 12 blue display controllers and easily installs on all existing Weigh Scale Blenders Retrofitting an earlier Maguire Weigh Scale controller requ...

Page 20: ...component Hoppers 9 12 The main Home Screen displays hoppers 1 through 8 Hoppers 9 through 12 are displayed on a second screen accessible by pressing this button To return to viewing hoppers 1 8 press...

Page 21: ...led diagnostics information scrollable back through a history of cycles printable to USB Print Center A menu screen of print related options including Totals Parameters Alarm History Events Cycle Hist...

Page 22: ...when available and then as a limited percentage of the entire mix ALL Components set to of Batch R or Mode set to of Total Batch If all components are set as of Batch R or the Mode of Operation is set...

Page 23: ...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...

Page 24: ...ion categories Press Modes of Operation Display will show the Modes of Operation screen Select General Mode of Operation General Modes of Operation are Blender Weigh Scale Blender WSB component blendi...

Page 25: ...changed if a different type designation is selected Press Component Type to select the component type designation Component Type selections are Disabled Turns off a component of Batch R Regrind Percen...

Page 26: ...egrind 300 0g 30 0 parts 2 Natural 679 6g 67 9 parts 3 Color 20 3g 2 0 parts Batch Total 1000g 100 parts Example 2 Blender WSB 100 Series with 1000g Batch Materials 30 Natural 70 Natural 3 Color Appli...

Page 27: ...Series with 1000g Batch Materials 20 Regrind 50 Natural 30 Natural 4 Color 6 Additive Application Regrind is recycled next to the machine and therefore already has Color and Additive Color and Additiv...

Page 28: ...e blender If you are not sure what component number operates what hopper or feeder see Manual Operators to confirm components Press The Keypad To enter the desired setting for the selected Component A...

Page 29: ...WER ON The display should briefly show a power on splash screen followed by the main home screen Across the top of the home screen will display Model ID number Mode Date and Time The Home Screen displ...

Page 30: ...of the blender Devices 1 2 3 and 4 are counter clockwise starting with far left corner hopper FOR WSB 200 400 900 1800 SERIES On 2000 4000 9000 and 18000 gram SIX hopper systems facing the Controller...

Page 31: ...oad 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 display says INVALID after entering...

Page 32: ...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 EVER...

Page 33: ...d Press Component 5 or Component 6 Run until Auger Feeder is dispensing Press again to stop the feeder Press Weigh Bin This will empty the Weigh Bin Now you can CALIBRATE the material To do so Press t...

Page 34: ...meter to 00101 If overall blender throughput is too low you may increase the metering rate of each Micro Pulse device by adjusting the cylinder airflow control valves for higher flow rate This causes...

Page 35: ...mponent Second and 3rd digits are the cycle count Last 3 digits are the to increase current setting by Example 110100 Regrind 1 10 cycles increase setting by 100 Current setting 25 increases to 50 RLC...

Page 36: ...6 grams If PRN 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 colorin...

Page 37: ...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 than nor...

Page 38: ...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 RLC paramet...

Page 39: ...back to factory defaults Note During a firmware update it may be better to reset all settings back to factory This is because an update to the latest firmware from a much older version of firmware may...

Page 40: ...Then press Press System Configuration Display will show the System Configuration categories Press Resets Display will show the categories of System resets User Settings Factory Access Restore Factory...

Page 41: ...arm Create store edit and load up to 99 detailed RECIPES within the blender s onboard recipe database TAG information links all material usage data with an Operator Number Recipe Number or Work Order...

Page 42: ...ted 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 BATCH Mode W...

Page 43: ...pe button to delete the selected recipe Load Recipe Pressing an existing recipe in the recipe database table enables the Load Recipe button Press the Load Recipe button to load the selected recipe int...

Page 44: ...accounting number such as a job or purchase order number To set a work order enter a number ranging from 1 to 999999 then press SAVE Work Order and Operator numbers are for your TRACKING of informatio...

Page 45: ...e Dispense Count total back to zero Dispense Station Operation 1 Press the Dispense Station button to access the Dispense Station Screen 2 Set a Dispense Target Weight using the keypad pounds or kilog...

Page 46: ...en press Press System Configuration Display will show the System Configuration categories Press Preferences Display will show System Preferences categories Press Operator Access Display will show the...

Page 47: ...pt for a password admin default 22222 Then press Press System Configuration Display will show the System Configuration categories Press Preferences Display will show System Preferences categories Pres...

Page 48: ...are for PLCs and needed to communicate with the Maguire Weigh Scale Blender This legacy protocol is the method used by our G2 Software as well as the OPC Kepware Dimension Software and Software Toolbo...

Page 49: ...enter the number into the field highlighted in green To advance to the next field touch the field you want to edit and type the desired value Or click Enable DHCP to use DHCP for IP assignment MAC add...

Page 50: ...essed the password was entered and will also report the state of the level sensor uncovered or covered demand or no demand for material respectively When the operator has stopped the blender the STOP...

Page 51: ...imit WDF Operation Weight Reading Difference KDF Calibration Weight Reading Difference Components Parameters per component 1 12 RD Retry Limit Allow Weight Short RP Retry Limit Allow Percent Short AL...

Page 52: ...tion number Modbus Server enable disable Modbus TCP TCP IP Configuration Sets IP address Subnet mask gateway MLAN Serial Baud Rate Set baud rate of MLAN over serial Print Options Print Totals Prints t...

Page 53: ...ed into the following categories Control Times Vibration Control Weight Limits Components Regrind Control Mixer Control Parameters are covered on page 54 Setup is divided into two categories Blender C...

Page 54: ...800 3000 models full grams xxxxx 00010 10 grams PERCENTS are expressed in tenths for settings 0xxx x and full percent for other percentage references 00xxx Navigating Parameters Parameters are accessi...

Page 55: ...X will exit the sequence at any time The purpose of each parameter is explained in detail in the following section Navigating and Making Changes to Parameters Press Display will prompt for a password...

Page 56: ...mmended SBO parameter setting is 10030 which would pulse a 1 10th second pulse every 30 seconds FUL 20000 FULL BATCH TARGET WEIGHT in Grams Change only for extremely light or heavy material Default va...

Page 57: ...Total Enables up to 5 additives to run as percent of total Each digit represents a component Components are 1 9 10 A 11 B 12 C 0 none This parameter only works under Mode of Operation of Natural PAR 0...

Page 58: ...oduced than consumed and override the current setting to use a higher amount This helps prevent material backing up in your grinder RHL 00000 REGRIND LEVELS HI LOW RHL has effect only if level sensors...

Page 59: ...time Silence Alarm button or next cycle resets the alarm Generates Monitor Cycle Time Alarm Code 23 PRT 00000 REPORT INTERVAL MINUTE interval between automatic print of TOTALS This parameter will caus...

Page 60: ...and no retries will be made RD is set with rate calibration routine also adjusts over time AL 00000 Last digit number of retries before ALARM 00001 to 00009 sound alarm hold process 00011 to 00019 sou...

Page 61: ...per setting limit Uses the component s decimal place for the decimal location 01000 disables upper limit SL 01000 SL SETTING LOWER LIMIT Set a lower limit on the setting When enabled the setting will...

Page 62: ...2000 2000 2000 2000 2000 2000 2000 PRC 10 10 10 10 10 10 10 10 10 10 10 10 STL 500 500 500 500 500 500 500 500 500 500 500 500 LCL 27 27 27 27 27 27 80 80 80 80 40 10 LCH 39 39 39 39 39 39 120 120 120...

Page 63: ...TI 1000 1000 1000 2000 1000 1000 1MI 01 01 1NC 10 01 1PT 00 00 1RP 10 10 1RD 500 300 100 1LA 40 16 16 40 1PO 00 00 3 4 7 8 VV 3 Rnd 2 x3 or 3 x 6 Slide Gates 3TY OFF OFF 3CS 00 00 3AL 04 04 3XT 00 00...

Page 64: ...press Press System Configuration Display will show the System Configuration categories Press Resets Display will show the categories of System resets User Settings Factory Access Restore Factory Defa...

Page 65: ...tion categories Press Resets Display will show the categories of System resets User Settings Factory Access Restore Factory Defaults Firmware Update Press User Settings Categories will have several pa...

Page 66: ...ures such as a sticking valve or weigh bin gate For more information see MCT the parameter on page 56 Component Types See page 25 Setup Blender Configuration Component Types Manual Operations See page...

Page 67: ...n this manner the software sneaks up on the target providing the maximum achievable accuracy possible When Progressive Metering is Enabled then a component is selected and Enabled the corresponding PT...

Page 68: ...damaged Dispense times will be based entirely on the WT and TI parameters Alternate Liquid Color Alternate Liquid Color allows automatic switch over from Liquid Color component 10 to liquid color com...

Page 69: ...ress Display will prompt for a password default 22222 Then press Press Blender Configuration Display will show the Blender Configuration categories Press Calibration Routines Display will show the Cal...

Page 70: ...d and additive settings are in 100ths of a percent xx xx Natural uses 4 digits with no decimal xxxx Print Center Options to print specific reports to USB including Totals Parameters Alarm History Alar...

Page 71: ...perator Mode Menu Bar Options Allows changes to the right side menu buttons Screen Options Screen Saver options Screen Brightness Screen Calibration and On Screen Options On Screen Options is informat...

Page 72: ...ts If you are using the MLAN Protocol to automatically gather data then each controller must have a unique address Valid numbers are 000 to 255 TCP IP Configuration Enable DHCP or set a static IP addr...

Page 73: ...2 Then press Press System Configuration Display will show the System Configuration categories Press Print Center Display will show System Print Options Press Print Cycle Options Display will show Cycl...

Page 74: ...dispensed weight of that material and its percentage of the blend In this example Regrind dispensed 400 grams 20 of the cycle full weight Natural dispensed 1538 4 grams Additive in component 3 dispens...

Page 75: ...e 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...

Page 76: ...ME 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...

Page 77: ...following 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...

Page 78: ...bration 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 ca...

Page 79: ...Cycle History Print Parameters Print Alarm and Events and the option to Print All to USB Press Display will prompt for a password default 22222 Then press Press System Configuration Display will show...

Page 80: ...ication Date 09 12 18 Time 14 57 55 Machine Number 1 WSB Model 220 Serial Number 123456 Empty Bin Tare Weight x x grams Weight On Display x x grams Signature ______________________ How to create a Wei...

Page 81: ...NDS or KILOS depending on your selection of weight unit A line is printed for each active component Each line shows component number type setting grand and current totals The GRAND totals will continu...

Page 82: ...section on VERIFYING LOAD CELL function to be sure that the load cells are operating correctly 7 For difficult problems we can provide the most help if we have a printout of the PARAMETER table and a...

Page 83: ...t in the weigh bin MAX parameter and cycle was aborted The Maximum Weight Alarm is enabled under Setup Blender Configuration Specialized Alarms Maximum Weight Exceeded Alarm ON OFF Also See MAX parame...

Page 84: ...lid digits Solution Determine cause of over dispense WAIT FOR RECIPE ALARM ALARM CODE 21 Problem Recipe Request option did not receive a recipe within the 2 minute timeout period When enabled the Reci...

Page 85: ...for previous cycle The G2F parameter is used in conjunction with the Get Totals command The Get Totals MLAN command can be sent with either a command code of 16 or 17 If Get Totals used command code 1...

Page 86: ...amp panel front fuse is blown 3 The NATURAL dispense valve continues to dump repeatedly even though the weigh bin has filled to overflowing The weight reading is still below target full weight The we...

Page 87: ...ons If TARE weights are not steady something may be physically interfering with free movement of the weigh bin and load cells 9 At the end of each cycle the MIX MOTOR runs for a fraction of a second o...

Page 88: ...f 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...

Page 89: ...the blades the air supply line is too small Lower the pile in the mix chamber to reduce torque requirements on the mix blade This is explained above Increase the MPO parameter from 122 1 2 second to...

Page 90: ...aterial for a few seconds while the Weigh Scale blender is making a new batch The 44 END FULL function will also correct this Here when the sensor is uncovered a completed batch is immediately availab...

Page 91: ...rams then something is wrong See Verifying Load Cell Function on page 93 If the ALARM flashes If the initial TARE weight is below 50 grams the Alarm will active with the Alarm Log message Tare Low and...

Page 92: ...e component that is causing the alarm will continue to retry the dispense To continue with the dispense sequence the requirements of the dispense must be satisfied or the dispense aborted with the Abo...

Page 93: ...t since this empty weight reading is tared at the start of a cycle The empty weight readings should be consistently within 1 or 2 grams of each other The addition of several pellets to the weigh bin s...

Page 94: ...This RAW COUNT number is converted to the proper gram readout based on load cell calibration information The RAW COUNT numbers are more useful in diagnosing load cell problems because they bypass the...

Page 95: ...the Blender is powered off 2 Save User Settings The area in memory where User Settings are backed up into when the Save User Settings function is used If User Setting were never backed up using Save...

Page 96: ...exists on the USB flash drive in a folder named maguire Exit this screen and enter again to refresh the display window Highlight the version in the white panel on the left and press PROGRAM Press To p...

Page 97: ...chamber and check to be sure the sensor LED does not go on when the mix blade passes near it WEIGH BIN DUMP VALVE The WEIGH BIN DUMP VALVE should be adjusted to close softly A needle valve is installe...

Page 98: ...ge 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 ful...

Page 99: ...gray pin E component 4 air solenoid purple pin M flow control air solenoid yellow pin F component 7 air solenoid red comp 5 comp 6 strobe and beeper opt alarm relay output mix motor outlet panel side...

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Page 112: ...112 FCA INSTALLATIONDIAGRAM...

Page 113: ...113 WSB 4088 IO wiring diagram 120V...

Page 114: ...114 D WSB E0001 Electrical Diagram WSB Export Single Phase...

Page 115: ...115 D WSB E0002 Electrical Diagram WSB Export 3 Phase...

Page 116: ...116 D WSB E0003 Electrical Diagram WSB Export 1800 3 Phase...

Page 117: ...117 D WSB E0004 Electrical Diagram WSB Export Maxibatch...

Page 118: ...118 D WSB P0001 Pneumatic Diagram WSB with Non Removable Hoppers...

Page 119: ...119 D WSB P0002 Pneumatic Diagram WSB with Removable Hoppers...

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Page 121: ...1 5x28x51 5 in 1054x711x1308 mm 470lb 214kg WSB 440R 41 5x28x51 5 in 1054x711x1308 mm 345lb 157kg WSB 460 41 5x28x51 5 in 1054x711x1308 mm 355lb 161kg WSB 940 46 5x28 5x60 in 1181x724x1524 mm 420lb 19...

Page 122: ..._________ 123 Flexbus Setup and Configuration ______________ 123 Flexbus Pump Assignment ____________________ 126 Receiver Assignment _________________________ 128 Receiver Configuration _____________...

Page 123: ...tion and numeric assignment of each Flexbus pump and receiver is setup within the Flexbus Lite through the order that the receiver is turned on and discovered during the Pump Assignment routine and th...

Page 124: ...e Maguire Weigh Scale Blender Press Display will prompt for a password default 22222 Then press Press System Configuration Display will show the System Configuration categories Press Preferences Displ...

Page 125: ...t password is 22222 Press to confirm password This enters the Setup screen This screen contains several setup specific options Pump and Receivers Setup Buttons Pressing PUMP or RECEIVERS enters Setup...

Page 126: ...several setup specific options To setup Pumps PRESS Press the large Pumps button on the far left of the screen This enters the PUMP assignment screen This gray screen contains any previously assigned...

Page 127: ...you can go straight to setting up Receivers without re entering the password PRESS To enter the Receivers assignment screen See Next Page for Receivers Assignment instructions Otherwise to exit SETUP...

Page 128: ...no Receivers have been assigned Turn on your Flexbus Receivers in the order that you want then to be assigned Your receivers will appear on the screen and be numbered in the order that they were turne...

Page 129: ...and allows the receiver to be turned OFF or ON The receiver symbol can display the following states Pressing the Receiver symbol toggles receiver OFF or ON This symbol indicates that the receiver is t...

Page 130: ...Time will increase the number of pulses Purge Time The time in seconds that the purge valve will open to purge the convey line Purge time follows Load time LEVEL SENSOR Level Sensor Enables the use o...

Page 131: ...a pump in this overview screen will open the Pump s Configuration screen The pump that you are configuring is identified by the pump s ID label on the pump s image on this screen You can select anoth...

Page 132: ...he pump to be turned OFF or ON The pump symbol can display the following states Pressing the pump symbol toggles the pump OFF or ON Message will display PUMP OFF This symbol indicates that the pump ha...

Page 133: ...lt Time Interval is 5 1 400ms IDLE TIME The time in minutes that the pump runs after the last convey request before shutting off BYPASS The time delay in 10ths of seconds 0 50 zero seconds to 5 second...

Page 134: ...rs A device must be turned off or communication must be disconnected to remove the device When a device is turned off or communication to the device is disconnected the loader or pump icon will show a...

Page 135: ...ort Press this Update button Press the green check to start the update The firmware update will be copied from the flash drive to the Pumps and Receivers that require the update up to date firmware wi...

Page 136: ...ion Switch the WSB Home Screen Setup Enters password protected setup screens Receivers Setup of all Receivers Pump Setup of Pump Live Status Panel In the Live Status Panel the receivers will display t...

Page 137: ...is off or a disconnected communication wire Receiver is inactive Receiver is alarming Virgin material filling receiver Regrind material filling receiver Demand for material Material discharging Virgi...

Page 138: ...138 Flexbus Lite Wiring Diagrams...

Page 139: ...139...

Page 140: ...140 Flexbus Lite Component Map...

Page 141: ...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 fu...

Page 142: ...sylvania PREPAID Please note that we always strive to satisfy our customers in whatever manner is deemed most expedient to overcome any problems they may have in connection with our equipment EXCLUDED...

Page 143: ...il info maguire com Web www maguire com Maguire Europe Tame Park Tamworth Staffordshire B775DY UK Tel 44 1827 265 850 Fax 44 1827 265 855 Email info maguire europe com Maguire Products Asia PTE LTD Ma...

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