batch or continuous rate controller installation and operation … · 2018. 9. 7. · electrical...

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Batch or Continuous Rate Controller Installation and Operation Manual

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Ver 6.11 October 2017

www.hartmansystems.com

http://www.hartmansystems.com/

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2 BRC623 Installation and Operation Manual

Contents BRC623 Physical Dimensions ............................................................................................................... 3 BRC623 Specifications .......................................................................................................................... 4 Overview: BRC623 Controller ........................................................................................................... 5 Installation ............................................................................................................................................. 6

Mounting considerations .................................................................................................................... 6 Control Panel Mounting ..................................................................................................................... 7 Control Panel Wiring .......................................................................................................................... 7 Power Connections ............................................................................................................................ 8 Feed Device Connections .................................................................................................................. 9 Optional outputs: ..............................................................................................................................13 Optional inputs: .................................................................................................................................14 Load cell Connections ......................................................................................................................16

Common Load cell Color Codes ....................................................................................................17 What is a Loadcell? .......................................................................................................................17

Startup Check list .................................................................................................................................18 System Operation .................................................................................................................................19

Main Menu Screen ............................................................................................................................20 Run Product in Batch Mode ..............................................................................................................21 Run Product Continuous Mode .........................................................................................................22 Scale Display ....................................................................................................................................24 Run Manual Mode ............................................................................................................................25 Batch Setup Password .....................................................................................................................26 Batch Setup ......................................................................................................................................26 History Table ....................................................................................................................................26 History Graph ...................................................................................................................................27 Product Totalizers .............................................................................................................................27 Enter System Setup Password .........................................................................................................28

System Setup .......................................................................................................................................28 Batch Sequence Setup .....................................................................................................................30 Batch Parameter Tuning Suggestions...............................................................................................34 Continuous Setup .............................................................................................................................38

Volumetric Calibration Instructions: ...............................................................................................38 Data point entry Instructions: .........................................................................................................38 Volumetric Calibration Automatic mode .........................................................................................39 Rate Calculation Troubleshooting page .........................................................................................40

Feed Device Setup ...........................................................................................................................45 Jog Input Setup ................................................................................................................................48 Mixer / Take Away Conveyor Setup ..................................................................................................48 Analog Setup ....................................................................................................................................49

Analog Output 2 Setup (2nd output on base unit) ...........................................................................49 Analog Input 1 Setup .....................................................................................................................50

Password Setup ...............................................................................................................................50 System Diagnostics ..........................................................................................................................51 Remote Communication Setup .........................................................................................................54 Scale Setup ......................................................................................................................................55 System Parameters / Restore Defaults .............................................................................................56 Screen Setup ....................................................................................................................................56 Clean Screen ....................................................................................................................................56

SCT20 Scale Indicator: .........................................................................................................................57

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BRC623 Physical Dimensions

Dimensions in Inches

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BRC623 Specifications Enclosure NEMA 4X Indoor Display Type 5.7” viewable color Touch screen Display View Area 4.72” x 3.5” [119.4 x 88.9mm] Touch screen

6 7 segment 0.8” digits Weight display Screen Pixels 320 x 240 Brightness 280 nits / 50,000 hours Touch Screen TFT (10-bit resolution, 1024 x 1024 touch area) Power 120-240 VAC @ 2Amp 1ph 50/60Hz (does not include product feeder)

Typical consumption 0.30Amp @ 120VAC (36W) Operating Temperature 32 to 120° F [0 to 50° C] Storage Temperature -4to 140° F [-20 to 60° C] Humidity 10 - 85% RH, non condensing Altitude 6500 ft [2000m] maximum Electrical Noise NEMA ICS 2-230 showering arc ANSI C37.90a-1974 SWC Level C

Chattering Relay Test Vibration 5 to 55 Hz 2 G for 2 hours in X, Y, and Z axes Shock 15 G for under 11 ms in X, Y, and Z axes Weight Depends on options installed – approx: 40lbs (18.2Kg) Loadcell excitation 5VDC ± 0.5VDC Number of Loadcells 8 x 350Ω or 16 x 700Ω

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Overview: BRC623 Controller The BRC623 was designed with flexibility in mind. This controller can be configured to dispense batches of product, or be configured to run at a continuous feed rate. Utilizing the setup features outlined in this manual you can select the features that will enhance the operation and use of this equipment. The touch-screen provides a convenient way to navigate the selections and also provides data for the operator to verify tolerance requirements and history of previous batches. An Analog output is provided to control the speed of the feeding device along with a discrete output used to start the feeder drive controller. In addition to the feed device control there are inputs and outputs available for remote start and stop, refill, batch monitor, take away conveyor, and mixer control. A “Gain in Weight” mode is provided for applications where a product is being fed on to a scale system such as a container setting on a floor / bench scale or weigh hopper on load cells. With this setting there are several other features that can be beneficial. The controller can verify zero setting between weighments, auto-tare the weight of a container, verify container is in position by referencing the container weight setting with a band value plus or minus to confirm an empty container is in place prior to starting the feeding device. A “Loss in Weight” mode is provided for applications where the feeding device is on load cells or a scale system of some type. This is used where one or more products need to feed into a process simultaneously and therefore all feeders can dispense product at the same time. A “Continuous Feed” mode is provided to continually feed product at a preset rate on a per second, per minute, or per hour basis. Refilling of the feed device can be automatic utilizing load cells or level sensor inputs without interrupting the continuous feed process. Analog input of target weight or rate from a remote PLC is available as an option. Included is one analog output that can be configured to represent weight or rate. A second analog output is available as an option to provide a second signal for weight or rate which can be interfaced to a DCS or other remote monitoring system

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Installation

Mounting considerations The BRC623 Control panel serves as both the system controller as well as the operator interface. Its location should be chosen such that it is within approximately 100’ of the feeding device and scale. It should also be located in an accessible location that is convenient for the operator. Remote operation of the controller is possible using the remote start and stop features, however system setup and configuration would still need to be performed from the touch screen on the front of the controller. It is recommended that the control panel be located at a comfortable height (approximately 49” from the bottom of the controller to the floor). It is preferable for the control panel to be within sight of the feeder and scale.

Whether you have a gain in weight system or a loss in weight system care should be taken when selecting the location and mounting of your scale. The primary concern when selecting a scale location should be the stability of the surface on which you are placing the scale. Excessive vibration or deflection of the supporting structure will adversely affect the weighing accuracy. The scale should be placed on support structure that is rigid and is isolated from mechanical noise and other vibration. The scale platform should be set so that it is level, and so that all of the loadcells are seeing a portion of the load. For example, in a 4 cell system you do not want the entire load sitting on two caddy-corner cells, with little or no load on the opposite corners.

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Control Panel Mounting The control panel can be mounted on any flat surface using the 4 mounting holes. ¼-20 bolts, with flat and lock washers, and ¼-20 nuts are recommended. The control panel should be mounted in an area free from excessive electrical noise. It is not recommended that the control panel be mounted directly adjacent to large variable speed drives, motors, or other devices that typically generate excessive electromechanical noise. All wires carrying current generate an invisible field of magnetism around them. The strength of this field depends on many factors including the amount of current, the voltage, the type and size of the conductor, etc. This magnetic field can cause induced currents in nearby devices and can cause sensitive devices such as scales and microprocessors to malfunction. This problem can be substantially reduced by avoiding close proximity to “noisy” electrical lines.

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Control Panel Wiring Most of the connections to the BRC623 controller are made to the terminal strip at the bottom of the control panel, inside the enclosure.

Power Connections All electrical connections should be made by qualified personnel and in accordance with all local codes and regulations. Failure to follow these practices may result in injury, death, and damage to equipment. Disconnect and secure all power sources that may be present. Always remember, “Safety First!” The BRC623 control panel requires 120-240 VAC 1PH 50/60 Hz power at 2 Amps. The power terminals are located at the left hand side of the interface terminal strip. 120 VAC is connected on the Fused terminal block. Ground is connected to one of the terminal blocks labeled “G”, and neutral is connected to one of the terminal blocks labeled “N”

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Feed Device Connections The BRC623 controller was designed to accommodate many different types of feeding devices such as screw feeders, belt feeders, vibratory feeders, butterfly valves, slide gates, bucket elevators, etc. All of these different feeding devices interface to the BRC623 controller in a similar way. The BRC623 controller provides a contact closure to enable the feeding device. If the feeding device is powered by a motor, as in the case of a screw feeder, or belt feeder, the contact closure would be used to enable the motor starter, or VFD (Variable Frequency Drive) that is connected to the motor. If the feeding device is a solenoid controlled butterfly valve or slide gate, then the enable contact can be used to energize a pneumatic solenoid. The enable contact closure occurs between terminals “1” and “O/0” In addition to the enable contact, the BRC623 controller provides an analog output signal that can be used to control the speed of the device. For a screw feeder or belt feeder this signal would typically be connected to a VFD. For a variable position butterfly valve, this signal would be connected to a proportional control valve. The analog output signal is a 4-20mA signal that represents 0-100% speed. When the controller wants to run at a minimum speed, the output will be set to near 4mA which would represent 1% speed. If the controller wants to run at maximum speed, it will set the output to be 20mA which would be 100%. The Analog output connections are made on terminals “O:1.0+” and “O:1.0-“ The analog speed signal is optional. If your feeding device does not have an input for a speed reference, then this signal can be left un-connected.

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Typical Feeder Connections:

Typical VFDs require configuration to accept a 4-20mA signal. This is usually accomplished by using the buttons on the VFD to set the drives parameters. Consult you VFD owners manual for instructions on how to configure your drive to use 2 wire start / stop commands, and an analog input for speed reference. For some applications the supply voltage for the enable contact closure will come from this control panel. 24VDC may be connected to either side of the enable contact from the terminal labeled “24VDC”. If you application requires a 120VAC signal to enable your feeding device, one side of the contact closure can be connected to a “LS” terminal. The LS terminal has 120VAC present whenever the power switch on the front of the enclosure is in the ON position.

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Typical Feed Valve Connections: If your feed valve is only capable of being full open or full closed, the configuration below would apply. If the valve solenoid is 24VDC instead of 120VAC then terminals “24VDC” and “DCCOM” would be used instead of terminals “LS” and “N”

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Optional equipment connections In addition to the contact closure to enable the feeding device, there are 7 additional outputs which can be used to control additional equipment. Some examples are shown below. See the table below for a list of available outputs and their function.

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Optional outputs: Name Description Terminals Feeder Vibrator This output can be used to enable a vibrator mounted on the feeding

device. It is sometimes necessary to provide vibration to keep product flowing through the feeding device. This is particularly import on continuous feed applications.

VAC1 O/1 Contact closure

Refill This output can be used to enable a refilling device such as a slide gate or refill conveyor.


Alarm This output can be used as feed back to another system such as a DCS or be connected to an enunciator to attract an operator’s attention. This contact closes whenever the controller has an alarm condition.


Batch Complete This output can be used as feed back to another system such as a DCS or be connected to an enunciator to attract an operator’s attention. This contact closes whenever the controller is running in Batching mode and has completed a batch.

VAC4 * O/4 Contact closure

Batch in Process

This output can be used as feed back to another system such as a DCS or be connected to an enunciator to attract an operator’s attention. This contact closes whenever the controller is telling the feeding device to run.


Slow Speed This output can be used in batching mode for a two speed feeding device. Some feeding devices such as a 3 position slide gate have a means of reducing the flow of material using discrete control signals. This output is closed along with the Feeder enable contact while batching at fast speed. This contact opens when batching at slow speed.


Mixer / Take Away Conveyor

This output can be used to enable either a mixer, or a take away device such as a conveyor. If used as a mixer output, this contact can be configured to close at the end of a batch and remain closed for an adjustable period of time. This would be used to signal a mixer to run for preset period of time after a batch is dispensed. If Take Away Conveyor mode is used, this output turns on at the start of a batch and the contacts will remain closed for a preset period of time after the completion of a batch. This would be used if the batching feeder is emptying onto say a belt conveyor.

VAC4 * O/7 Contact closure * VAC4 is common to Outputs O/4 – O/7

Bag Flap 1 &2 For bulk bag discharge stands, bag massage paddles can be controlled to aid the flow of material out of the bulk bag. These outputs could be used to control any product flow aid

24VDC Outputs O/8 & O/9

Zero Scale This output can be connected to a Scale Indicator with a remote zero capability. If the SCT20 indicator is used, this output will be factory wired

24VDC Output O/10

Low Level Indicator

The low level condition detected by the Controller can be connected to an indicator light, or alarm

24VDC Output O/11

Current Weight / Current Rate / Last Batch

This analog output (4-20mA) can be set to represent either the currently displayed scale weight, the current feed rate (continuous applications) or the last batch weight (batching applications)

O:1.1+ O:1.1- 4-20mA

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Optional inputs:

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There are 5 discrete 24VDC inputs available for optional control features. The inputs all share a common DC common with the control panel. It is recommended that 24VDC be taken from terminal “24VDC” out to a contact closure on the device sending the input signal so that input signal is 24VDC in relation to the control panel common. The optional input signals are listed in the table below. Name Description Terminals Remote Start This input can be used to remotely start the feeding device. It is

expected that this is a momentary signal at least 500ms in length. In batching mode, this signal will start a batch. In continuous mode, this signal will start the feeder at the desired target rate. A maintained Start signal can be applied, however the signal must be removed and re-applied if a stop command is issued. If only a single wire control is to be used, the Remote Start input can be configured to operate as a remote enable signal. See the feeder setup section for additional information

I/4

Remote Stop This input can be used to remotely stop the feeding device. . It is expected that this is a momentary signal at least 500ms in length. In batching mode, this signal will pause a batch. In continuous mode, this signal will stop the feeder

I/5

Refill Low Level This input can be used to signal the controller that a refill of the feeding device is needed. This would typically be connected to a low level sensor in the feeder hopper.

I/6

Refill High Level This input can be used to signal the controller that a refill of the feeding device is complete. This would typically be connected to a high level sensor in the feeder hopper.

I/7

Mixer / Take Away Conveyor Feedback

If the Mixer / Take Away Conveyor output is used to start and stop either a mixer or a take away conveyor, this input can be used to monitor the Mixer or Take Away Conveyor. This would typically be connected to a zero speed switch, or to a proximity sensor set to pick up pulses as the mixer or conveyor was running.

I/8

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Load cell Connections The signal from a loadcell is typically between 0-30mV. This is a relatively small signal and therefore is susceptible to interference from electrical noise. Care should be taken when choosing the location and routing of the signal wire from the loadcell to the indicator in a single cell application or the summing junction box and the indicator in a multiple cell application. To minimize signal loss, minimize the number of connections between the loadcell and the weight indicator. 18Ga Stranded copper multi-conductor, shielded cable should be used to make this connection. If the cable length is greater than 100’ it is recommended that the sense lead be used. If the cable length is less than 100’ the sense leads can be omitted. Loadcell wire color code varies from manufacture to manufacture. Some common color codes are listed below. The loacell(s) are connected to the control panel by way of the terminal strip. These terminals have a removable plug connector to make wiring easier, and to aid the technician when troubleshooting.

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Common Load cell Color Codes

Wire Function Sensortronics, some Revere, Rice Lake, Vishey

BLH, Group 4, Revere (RTI), HBM, Toledo, Flintec

Rice Lake Single point loadcells, Tedea

+ Excitation (+EXE)

Red Green Green

- Excitation (- EXE)

Black Black Black

+ Signal (+SIG)

Green White Red

- Signal (-SIG)

White Red White

+ Sense (+SEN)

Blue Blue Blue

- Sense (-SEN)

Brown Brown Brown

Shield (SHLD)

Bare or Yellow Bare or Yellow Bare or Yellow

What is a Loadcell? A strain gauge loadcell is a machined metal block that consists of a very fine length of wire that is woven back and forth in a grid and laid on a piece of paper or plastic called its base. A common wire used is a copper-nickel alloy with a diameter of about one thousandth of an inch (.001"). The wire is zig-zagged to form a grid so to increase the effective length of the wire that comes under the influence of the force applied to it. Leads are attached to the ends of the gauge. Strain gauges can be made very small, sometimes as small as 1/64". These gauges are cemented to the strong metal block, commonly referred to as the load receiving element, to make up a load cell. The gauges are configured into a circuit called a Wheatstone bridge. As the block bends, the electrical resistance changes within the strain gauge bridge. This change in resistance is measured by the weight indicator and converted into a weight value.

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Startup Check list Once the control panel and feed equipment are installed and wired, the controller must be configured for use.

1. Scale Calibration The first thing to do when setting up your controller is to calibrate and configure your scale indicator. Configuration includes such tasks as setting the indicator units (Lbs, Kgs, g, etc.). The indicator configuration also sets the displayed scale resolution, filtering, and general scale operation. Calibration readies the scale to receive the weight signal from the loadcells and accurately convert that signal into pounds, or kilograms, or whatever unit is selected in during configuration. See the Scale indicator Configuration and Calibration section of this, or supplementary manual for additional instructions.

2. Feeder Setup Parameters After the scale calibration is complete the next step is to enter the settings using the touch screen to describe the type of feeder that you are using. Feeder settings include parameters, such as is this system a loss in weight or gain in weight system, whether the feeder will be automatically refilled, and if a feeder vibrator is used. See the Feeder Setup menu section for additional information for setting up the feeder parameters

3. Decide the best mode of operation for your application a. Batching Application

If this application is requires a specific amount of product to be dispensed in a discrete batch, then batching mode should be selected See the Batch Sequence Setup menu section for additional information on setting up the Batch mode parameters

b. Continuous Application * If this application requires a continuous stream of product to be dispensed at a controlled feed rate then continuous mode should be selected. See the Continuous setup section for additional information on setting up the Continuous mode parameters.

c. Batching with Rate Control * If this application requires specific discrete batches to be dispensed at a controlled Feed Rate, then Batching with Rate Control should be selected. In this mode, The feeder will run at the rate setpoint for most of the batch. When the target nears, the feeder will then slow down to the fixed slow speed to finish up the batch.

4. * If running in Continuous, or in Batch with Rate Control mode, Perform a Volumetric Calibration.

After setting the Continuous mode parameters a Dynamic Calibration must be performed. In Continuous mode the controller adjusts the feeder output to speed up or slow down the flow of product in an attempt to maintain a target feed rate. When the feeder is first started the controller uses a look up table to determine the best speed to start the feeder in order to achieve the desired target rate. This look up table is built during the dynamic calibration. See the Volumetric calibration section for additional information.

5. Save all of the system Parameters in case a restore is needed in the future. See System Parameters in the System Setup Menu

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System Operation Operation of the controller is achieved through the displays and controls located on the front of the control panel. The Touch Screen Interface allows the operator view system status and to enter system parameters The Power Switch turns control power on and off The Start – Run – Stop switch is a three position center returning selector switch that can be used Start and Stop the feeding device The Emergency Stop button is a maintained push button that will immediately stop all devices control by the system

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To begin operation turn the power selector switch to the on position. After the startup sequence is complete, the startup screen is displayed: The display program version and the PLC control program version are both displayed on this screen. The Operator would then press the Main Menu button to move to the main menu.

Main Menu Screen

After the initial startup sequence is complete, the operator may select any of the displayed options by pressing the appropriate button. Run Product- Readies the system to begin dispensing product Manual Mode- Provides ability to operate feeder, vibrator and refill outputs Scale Display- Displays the current scale information. Can be used when calibrating the scale, or using the weigh system as a simple scale indicator. History- displays either the batch history or the rate history depending on which mode of operation is selected (batch or continuous feed). Totalizers: Whenever product is being dispensed by the system, a running total of how much product has been dispensed is available on the totalizers screen. Batch Setup*- The Batch Setup button allows the operator to enter parameters relevant to the batching process. System Setup- button allows the operator to configure the system setup parameters, and to perform operations such as volumetric calibration. Screen Setup- Allows adjustment of contrast and select screen saver mode. Clean Screen- provides a safe place for the operator to wipe the screen without inadvertently pressing a button. *If the system is set to operate in batching mode there is a Batch Setup button. If the system is set to operate in continuous feed mode, The Batch Setup button is omitted.

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Run Product in Batch Mode The message indicator in top right corner alerts the operator if the E-Stop button is pressed in, or if the batch is paused or if some other alarm condition exists. Target Weight- This is the final weight you are looking to dispense. When set to run Batch with continuous mode, the Target Rate you want to run can also be entered. If set to run in simple batching mode, this entry field does not appear. If running in batch with continuous mode the current rate is also displayed. Current Batch and Last Batch indicate the how much weight has been dispensed so far in the current batch, and how much was dispensed for the last batch. Completed Batches- If batch counter is turned

on in “batch sequence setup” then the number of batches completed and remaining is displayed here. Batches to Run- Pressing this button allows the operator to enter the desired number of batches they want to run The status banner near the bottom of the screen displays 22 different messages depending on what features are enabled or disabled. Examples are “Batch Complete”, “Out of Tolerance” etc. This banner displays the current system status. OK- Press OK when you need to acknowledge an out of tolerance condition Refill On- When the refill option is enabled the system will automatically trigger a refill when a low level condition exists. To prevent this from happening you can turn the refill off with this button. Material change or last batch at end of day would be examples of when to utilize this feature. Abort- Pressing the stop button and then the abort button will take the processor back to the beginning The Bottom Right corner of the display shows the current Scale weight and status. If the weight is stable or in motion, the corresponding message will appear above the weight value. If the indicator is in Net or Gross mode, or if the indicator is within the zero window, the indicators below the weight will illuminate. Start Take Away / Start Mixer some applications require a take away conveyor, to be used, or a mixer to be used. In these applications it is sometimes necessary to have some manual control of the device from the run product screen. If Analog Input 1 is set to Target Weight (See Analog input setup section) the Target Weight set by Remote System message will appear. If operating in this mode, the target weight is being set by the remote system. If Analog input 1 is set to off, the operator will be able to set the target rate from this screen. If Remote Start / Stop signals are wired to the optional inputs, their status will appear as a message above the status bar

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Run Product Continuous Mode

The Message Indicator at top of screen alerts the operator if the E-Stop button is pressed in, Volumetric calibration is needed, and the current rate is too high or other alarm conditions as listed below. Target Rate- This is the desired feed rate you want to run. Current /Estimated Rate- This is the feed rate the feeder is currently running. If the rate is unknown, the Estimated rate is displayed until a known rate can be calculated. Start Take Away / Start Mixer- If enabled in the system setup, these buttons can be used to control take away equipment, such

as a conveyor, or a Mixer. The message indicator at the bottom of the screen displays different messages depending on what features are enabled or disabled. Examples are “Gravimetric Speed = 45% “Checking Feed Rate” etc. This banner displays the current system status Refill On/Off- When the refill option is enabled the system will automatically trigger a refill when a low level condition exists. To prevent this from happening you can turn the refill off with this button. Material change or last batch at end of day would be examples of when to utilize this feature. Target Rate Setup by Remote System – If Analog Input 1 is set to Target Rate (See Analog Input Section) then the target rate will be set by a remote device. When set to operate in this way, the operator cannot change the target rate locally. If Analog Input 1 is disabled, then the operator will be able to set the target rate on this screen. Analog input 1 can also be set to control the feeder speed directly. In this mode of operation, the Speed Set By Remote System message will flash to remind the operator that the feeder speed is being set remotely by the analog input. If Remote Start / Stop signals are wired to the optional inputs, their status will appear as a message above the status bar Alarm messages that may appear at the top of the screen: Alarm Number

Alarm Message Alarm Description

0 No Alarm conditions 1 Emergency Stop Button Pressed In The emergency button has been pressed, twist the

button to release. 2 Target Feed rate Too High. The target feed rate is set higher than the max feed

rate determined during the dynamic calibration 3 Dynamic Calibration Needed The Dynamic Calibration data is not valid and a

Dynamic Calibration must be performed 4 Current Rate Out of Tolerance. Shut

down in XXX seconds The current Feed rate is outside the entered tolerance window. Feeder shutdown is enabled and the feeder will shut down after the specified time delay

5 Check Mixer If the system uses a mixer and the appropriate mixer feedback is not seen on input 8

6 Check Take Away Device If the system uses a Take away device such as a conveyor and the appropriate feedback is not seen on

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input 8 7 Current Rate Out of Tolerance The current Feed rate is outside the entered tolerance

window. 8 Device on in Manual Mode One of the system devices has been turn on using the

Manual Mode screen 9 Remote Communication Failed Remote communication is being used and the

communication has been disrupted due to remote device failure, or a broken communication link

10 Refill Taking Too Long A feeder refill is taking longer than the specified window.

11 Refill Taking Too Long Shutdown in XXX seconds

A feeder refill is taking longer than the specified window, and Feeder shutdown on refill alarm is enabled.

12 Feeder Stopped because Refill Took Too Long

The feeder was stopped because a feeder refill took too long to complete

13 Scale Communication Error If the serial communication to the scale indicator has not transmitted a successful message in 2 seconds, the communication error message will be displayed Press the OK button on the touch screen to clear this alarm

14 Loss in weight detected on a gain in weight system

If the feeder is selected to be a gain in weight system and a loss in weight is detected while the feeder is running, this error message will appear

15 Gain in weight detected on a loss in weight system

If the feeder is selected to be a loss in weight feeder and a gain in weight is detected while the feeder is running, and a refill is not taking place, this error message will appear

16 A Scale Communication Error Occurred. Scale is Now Communicating Again.

If a scale communication error (see alarm14) occurred but the scale is presently communicating to the PLC, this message will be displayed. Press the OK button on the touch screen to clear this alarm

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Scale Display

The Scale display screen allows the controller to be used as a simple scale indicator. This can be useful when doing system maintenance, or if performing some manual operation. The weight is

displayed in real time. If the weight is stable or in motion, the corresponding message will appear above the weight value. If the indicator is in Net or Gross mode, or if the indicator is within the zero window, the indicators below the weight will illuminate. The Tare button will switch the indicator into Net mode, and load the current gross weight into the Tare Value. Alternatively, the Tare value can be entered into the indicator using the input button blow the Tare button. The switch to net / gross button can be used to toggle the indicator between net and gross modes. The zero scale button can be used to zero the scale indicator. This can be used to zero small amounts, however the indicator will limit the total amount

of weight that can be zeroed. If the indicator is more than this amount off of zero, then a zero calibration must be performed. Cycling power on the control panel will clear any weight that has been zeroed from this screen, and the scale will return to the calibrated zero. If the scale indicator is showing an over or under calibration error, a message will be displayed instead of the weight value. If this occurs, there is either a problem with a loadcell, or a scale calibration must be performed.

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Run Manual Mode

Extreme Caution must be used when controlling devices in Manual Mode. Manual mode is intended to be used for trouble shooting purposes, and should not be used to control the system on a regular basis. Only qualified personnel with intimate system knowledge should use manual mode. If care is not taken, personal injury, death, or equipment damage can occur.

Start / Stop Feed Device- Pressing this button will toggle the feed device to run or stop depending on the state of the button. Feed Speed- Enter the desired speed that the feed device is to run. 0 – 100 % can be entered via the keyboard. This is only applicable if the feed device has variable speed capability. If the feed device is a valve that can only be fully open, or fully closed, then the speed value is not used. Start / Stop vibrator – Pressing this button will toggle the vibrator output to be on or off depending on the state of the button. Start / Stop Refill- When pressed the refill output will be toggled to on or off depending on the state of the button.

Start / Stop Mixer / Take Away Conveyor- This button toggles the mixer / take away conveyor output. This output can be configured in the system setup to run a take away device such as a conveyor or rotary valve, or it can be used to control a product mixer. Extend / Retract bag flaps will allow manual control of the bag flap outputs. Some buttons may not appear if those features have been disabled in the system setup menu. Note: If any of the outputs are enabled (on) the “exit” button on the lower right of the screen will disappear until the device is turned “Off”. This is to prevent the operator from leaving the manual mode with a device still enabled.

The Bottom Left corner of the display shows the current Scale weight and status. If the weight is stable or in motion, the corresponding message will appear above the weight value. If the indicator is in Net or Gross mode, or if the indicator is within the zero window, the indicators below the weight will illuminate.

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Batch Setup Password Entering the correct password will allow access to the “Batch Setup” parameters. This feature is enabled or disabled in the system setup section using the password setup screen. If enabled, the operator would need to enter the password to access preact setting and over-under tolerance values. If disabled, no password will be needed.

Batch Setup

Preact- Weight value entered here is subtracted from the “target” to determine the “stop feed” weight. Under Tolerance Amount- This amount is subtracted from the target weight. When batch is complete the amount dispensed is compared to the value. If weight dispensed is less than the target minus the value, the alarm output will energize and alert operator to acknowledge out of tolerance condition. Over Tolerance Amount- This amount is added to the target weight. When a batch is complete the amount dispensed is compared to the value. If weight dispensed is greater than the target plus the over amount the alarm output

will energize and alert operator to acknowledge out of tolerance condition.

History Table Depending on the mode of operation either the batch history or the rate history will be Graph- Takes you to the graph representation of the same data. Minimum- Minimum rate reading within this “group” or “entire history” depending on which is selected. Maximum- Maximum rate within this “group” or “entire history” depending on which is selected. Mean- Average of the group or history Std. Deviation- Amount of deviation from the setpoint plus and minus. 1 Sigma- Shown in percent 2 Sigma- Shown in percent Entire History-Current Group- Select between displaying the entire history of 200 points or the current group of 20 displayed on the screen

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History Graph

Table- Press to go to the table version of the same data. Are You Sure?- Prompts the operator to be sure they want to “clear” data. Yes No- Press the “Yes” button to clear the data or the “No” button to abort the clear operation.

Product Totalizers Whenever product is being dispensed by the system, a running total of how much product has been dispensed is available on the totalizers screen. If the system is configured to dispense batches of product, then at the completion of each batch the totalizers are updated to show the total amount of product dispensed by the system. If the system is configured to run in a continuous mode, the totalizer is updated every 10 seconds with the amount of product dispensed. There are two totalizers that both update at the same time. Typically one totalizer is used as a daily or working totalizer and the second is used as a long term accumulator. Similar to a trip meter

and odometer in a car, the first totalizer would typically be cleared more frequently. Pressing the totalizer button from the main menu will display the above screen; however, the operator will not have access to the Clear totalizer 2 button. If the operator logs into the system setup menu, and presses the totalizer button from there, the Clear totalizer 2 button will be available. Totalizer 2 is protected by the system setup password.

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Enter System Setup Password

Entering the correct password will allow access to the system setup parameters. Password is selected using the “password setup” screen. System Setup Batch Sequence- Advance to “Batch Sequence” screens. If the System is set to run in batching mode, the Batch sequence setup button will be available to allow the configuration of the batching sequence Continuous- Advance to “Continuous Setup” screens. If the system is set to run in continuous feed mode, the Continuous Run setup button will be available to allow the configuration of the continuous mode parameters. *Note: The System Type selected on the following page (System Setup page 2) determines which button selections appear on System Setup page 1.

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System Setup Menu Page 2 System Type- Select between Batch Mode, Continuous Mode, and Batch with Rate Control Mode. Feeder Setup- Advance to Feeder Setup screens Jog Setup- Takes you to the “Jog Setup” screen Analog Setup- Takes you to the screen to setup and test the analog output features of the controller. Mixer / Take Away Conveyor Setup- This allows the modification of the Mixer or Take away conveyor options. Prev- Take you back one screen Exit- Returns you to the “Main Menu” screen System Setup Menu Page 3 Password Setup- Takes you to the “password setup” screen to configure the password and enable or disable the “batch setup” password. Diagnostics- Takes you to the “diagnostics” feature to provide testing features for button and remote inputs as well as scale readings into controller. Totalizers- Takes you to the Product Totalizer screen. Remote Communications: Allows the operator to configure communication with remote PLCs or DCS systems. These features are only available if an optional communication module is ordered. System Parameters- Takes you to the screen for resetting the factory default settings, saving and restoring all parameters. Program Version- Displays the PLC and Display program version screen. This information is useful when conversing with the factory and tracking custom program modifications. Scale Setup- Displays the Scale setup screen

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Batch Sequence Setup Fast Speed (%)- Speed that feeder is to run when feeding product in the “fast mode” Slow Speed- Speed feeder is to run (if Optimization feature is not enabled below) when nearing the target weight. Slow Speed Amount- The amount of product that is to be fed at the slow speed. If optimization is enabled this value is automatically determined.

Batch Sequence Setup Page 2 Auto Tare- Enable or disable the Auto Tare feature. If enabled the controller will automatically set the scale in the net mode and tare the reading to zero at the beginning of each batch. Container Top off Mode- if enabled, for a gain in weight system, the controller will fill the container so that the gross weight of the container and contents equals the target weight. If disabled, the system will always get a starting weight (typically the container tare weight) and will fill to the target weight above the starting weight. Settle Delay (s)- Enter the number of second that you want at the end of a batch dispense to

allow time for settling or other delay needed. Auto Preact- Enable or disable the Auto Preact feature. If enabled this feature will automatically adjust the preact setting (material in suspension) to keep the final dispensed weight as close as possible to the target weight. In most “gain in weight” systems there is material in suspension between the control valve or feeder and the scale system. This preact adjustment fine tunes the setting to always deliver the requested amount by adjusting a percentage of the error from the previous batch. Preact Amount- Displays the amount of preact that is currently being used to compensate for material in suspension. This number can be adjusted on the “Batch Setup” screen available from the “Main Menu”

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Batch Sequence Setup Page 3 Tolerance Checking- Enable or disable tolerance checking. If enabled the tolerance settings are entered on the “Batch Setup” screen (available from the Main Menu). Tolerance can be set to be either a fixed unit of weight, or as a percentage of the target weight. If set to be a percentage, the upper and lower tolerance value will be calculated based on the current target weight. Auto Start- Enable or Disable the auto start. If enabled, the controller will automatically restart another batch provided all other conditions are satisfied. Operator only need press the start button once to get the system running. Batch Counter- Enable or disable the Batch

Counter feature. If enabled the operator can enter the desired number of batches to be run and the system will stop after the preset number of batches on the main Batch Run Screen

Batch Sequence Setup Page 4 Auto Jog- Enable or disable the Auto Jog feature. If enabled, the controller will enable the feeder run output for short “bursts” if the final stop weight is below the target weight until the target weight is achieved. Material Availability check- Enable or disable controller from checking to see if there is sufficient material in the feeder hopper for loss in weight systems before starting a batch. A batch will not start unless there is sufficient material to complete a batch.

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Batch Sequence Setup Page 5 Require Zero- Enabled this feature requires the controller to see a zero reading from the scale plus or minus the “Zero Low Limit” and “Zero High Limit” settings before moving to the next sequence.

Batch Sequence Setup Page 6 Require Container- If this feature is enabled then a container will need to be placed on the scale prior to a batch being started. The controller will look for the weight of the container to fall within the “Container Weight” value plus or minus the “Container + - Tolerance” values. Note: This feature is helpful when filling pails or other containers on a scale system. If set for automatic start, and this feature is set, the operator will not need to constantly press the start button. This also prevents trying to “double fill” a container that has already been filled.

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Batch Sequence Setup Page 7 Fast Speed Optimization- Automatically determines the speed needed to optimize the throughput of product at fast speed. While running a batch the controller will make small adjustments to the feeder speed to determine if the new speed produces a higher or lower feed rate. If the rate is higher, the new speed will be used as the fast speed. Finding the ultimate highest throughput speed may take multiple batches to determine. Slow Speed Optimization- Enables the controller to automatically determine and keep

a setting that will slow feed the minimal amount of product required to provide the greatest throughput of product. If Slow speed optimization is turned on the controller evaluate the amount of time spent at the slow speed. It will always try and adjust the slow speed amount to achieve 5 seconds at slow speed. If you toggle the Optimize next batch, the controller will start the feeder at 1% speed at the start of the next batch. The controller will increment the speed slowly and evaluate the rate at each speed. The Ideal slow speed is as fast as possible while still being able to see each increment in the scale weight. If the scale is jumping by multiples of the smallest graduation, then less than optimal accuracy can be achieved. Once the fastest speed at which each graduation can be seen is determined, the controller will lock in on that value as the slow speed. Finding this value may take several batches depending on the feeder and the target weight that is set.

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Batch Parameter Tuning Suggestions When operating the system in Batching Mode, setting the various parameters may seem a bit daunting. Here are some tips and suggestions:

• Fast Speed – The initial speed for weighing material. Generally, you would want this to be set as fast as possible, without losing control of the material flow. If the fast speed is set too fast, you may overshoot your target. You want to balance the fast speed with the Amount of product to run at slow speed so that the feeder has time to transition from fast to slow, and then stop.

• Slow Speed – The final speed as the target weight is approached. This speed starts when the Target Weight minus the “Slow Speed Amount” is reached. The Ideal slow speed should be the fastest speed at which each graduation of weight change can be seen on the scale indicator. For example if the scale indicator is set to display .01 lb increments, then increase the feeder speed to the point at which you consistently see the weight increasing by .01 steps. If the slow speed is too fast, then the weight will tend to jump up multiple increments at a time. If the slow speed is too slow, there might be extended periods of time between each increment, or the product may stop flowing all together.

o Going over the target some of the time may indicate the need to have a slower slow speed, a larger slow speed amount, or a slower auto jog (See below). Start with the Auto Jog first. Otherwise, weights may have gone over as a result of a slow speed that is too fast, or a slow speed amount that is too small.

o Slow Speed Amount – The unit weight amount before the Target Weight when the Slow Speed starts. If you observe the batch, you should see each distinct stage. You should see the fast speed, you should see the feeder run at slow speed for at least a few seconds, and then you may see the auto jog. If you do not see the slow speed step, then the slow speed amount might be too small. If you make the slow speed amount larger, the feeder should switch to the slow speed sooner and have enough time to stabilize at the slower rate before reaching the cutoff weight. If the Slow speed amount is too large, then the feeder will transition to slow speed prematurely and the batch may take too long to complete.

• Preact Amount – The unit weight amount before the Target Weight when the Slow Speed stops. o The ideal preact weight would always stop the feeder just short of the target, and then

with 0, 1, or 2 auto jogs get it right on. o If the feeder is consistently overshooting the target, this would suggest that the preact is

not set large enough. Making the preact larger will stop the feeder sooner. If there is no auto jogging, then make the preact larger. If it is running at fast speed, then slow speed then stopping, then the preact adjustment should correct this problem. If the feeder is running at fast speed, then slow speed, and then auto jogging some number of times to get to the target and then overshooting it, then the auto jog speed is too fast, or the auto jog duration is too long. The auto jog speed is often set very close to the slow speed. The auto jog time is ideally long enough to get enough product to fall off of the feeder and cause the weight to increase by one scale graduation.

o If the feeder stops too soon, that’s ok, the auto jog will bump the weight up to the lower tolerance window.

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o If the preact is too large, then the feeder will cut off too soon, and the auto jog will work too many times / too long to get the weight up to within the tolerance window. (which is ok for accuracy, but might take too long)

• Auto Jog – If disabled, the weighing process stops when the Preact Amount is reached. If enabled, the weighing process continues with jogging to the Target Weight minus the Under Tolerance Amount.

o Ideally, the jog should be 0, 1, or 2 times. o The auto jog will continue to jog until the actual weight is within the lower tolerance

window and then stop. If there are too many auto jogs (therefore taking too long) then reduce the preact so that it stops the feeder sooner.

• Auto Jog Speed – The speed for weighing material in the auto jog mode. o If the target weight is exceeded some of the time, then a slower slow speed or a slower

auto jog may be needed. Weights may go over as a result of the auto jog – in which case a slower auto jog speed, or a shorter auto jog time might help.

• Auto Jog Duration – The length of the jog time in seconds. • Tolerance Checking – If disabled, the weighing process is complete after reaching the Target

Amount minus the Lower Tolerance Amount. If enabled, the weighing process is complete if the final weight is between the lower tolerance and the upper tolerance. If the final weight is over the upper tolerance, the weighing process pauses for the operator.

• Upper Tolerance Amount – The highest acceptable weight is the Target Weight plus the Upper Tolerance Amount.

• Lower Tolerance Amount – The lowest acceptable weight is the Target Weight minus the Lower Tolerance Amount.

o When a final weight is consistently under the Target Weight, the lower tolerance can be made smaller. A smaller lower tolerance will force the system to auto jog more to get the weight closer to the target.

o Making the lower tolerance tighter than what is actually needed will force the system to bump the weights up closer to the target.

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Here are some examples of the batching process. In these examples the red line represents the various batch steps. The blue line shows the batch weight relative to the current step.

In this example the finished batch weight was over target weight. This graph would suggest that the feeder ran at fast speed, then it went to slow speed, and then stopped. So making the preact larger should stop the feeder sooner. If the feeder stops too soon, that’s ok, the auto jog will bump the weight up to the lower tolerance window. If you make the preact too big, the feeder will have to auto jog a lot of times. (which is ok for accuracy, but might take too long) The ideal preact would always stop the feeder just short of the target, and then 0, 1, or 2 auto jogs to get it right on. If you are always over weight and you are not auto jogging, then you should make the preact larger. If the feeder was auto jogging, we would see some pulses in the batch step number on the graph between slow speed and discharge.

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In this example the feeder ran at fast speed, then at slow speed, and then there were 7 auto jog cycles. Although this may have produced an accurate batch weight, it might be possible to complete this batch in a shorter period of time while maintaining accuracy. In this case making the preact amount smaller would let the feeder run for a longer period of time at slow speed and should require fewer auto jogs at the end. Some products, especially “chunky” dense products may have a variety of piece sizes in the mix. The preact would need to be set at least as large as the weight of the largest piece in the mix. In these instances some, or even most, batches may have more auto jog cycles than desired, but on the event that there is a large chuck of product right at the end of the feeder after the slow speed stops, a single auto jog could complete the batch. Systems with a mix of product piece sizes are often challenging to tune for optimum batch time. Settings that catch the worst case scenarios often tend to be a bit conservative the rest of the time. A decision would have to be made to either tolerate slower batch times, or have the occasional over tolerance batch.

A graph showing the batching steps can be accessed from System Setup -> Diagnostics menu -> Batch step

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Continuous Setup Time Base- Select time base of Seconds (wt./sec), Minutes (wt./min), or Hours (wt. / hr.). Multi State Indicator- Displays the rate time base as Seconds, Minutes, or Hours. Volumetric Run Time-This is the time that the feeder will run in a volumetric mode before beginning to start tracking the target rate. This is also the time used for running the Volumetric Calibration as outlines below. Volumetric Calibration- See Volumetric Calibration screen below. Number of Rate Samples to Average- Number entered here is the number of rate averages that are used to create the

average rate used in controlling the rate. A smaller number provides faster update and a larger number provides a slower update of the rate number. The points in average status bar describes how many points are currently in the average queue.

Volumetric Calibration Instructions: In continuous mode when the feeder is first started, the controller uses a lookup table to determine what feeder speed is needed to achieve the desired target feed rate. This table is developed by performing a volumetric calibration. You can perform a volumetric calibration in one of two ways. You can have the controller automatically run the feeder and determine the feed rates at various speeds, or you can manually enter the feed rates using the data entry mode. This screen allows you to select between running the feeder to determine feed rates at 10% speed intervals or progress to the next screen to enter known data points representing 10% speed increments for the

feed system. Data point entry Instructions: Enter the known feed rate for 10% speed increments. Enter values in “rate per second” . Press the “USE DATA” button then press “View Data” to advance to the next screen. To enter this data you must know what the feed rate of the product is when the feeder is running at 10% speed, 20%, 30% and so on. If this data is not known you can either run the feeder using manual mode to determine the feed rate, or use the volumetric calibration automatic mode.

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Volumetric Calibration Automatic mode Start- Press the “Start” button to begin the volumetric calibration of the system. The system will cycle through 100% down to 10% in 10% increments. Building the Volumetric table is important to establish the feed rate characteristics of the feeder. Once this table is established the controller will utilize this table to start out so only minor adjustments will be needed to maintain rates desired. Stop- Stops the volumetric calibration Note: The graph built here should be a straight as possible. If gross discrepancies are found we suggest running the calibration again. Please be certain there is sufficient material in

the feeder hopper to complete the test or adjust the “Volumetric Run Time” on previous screen to limit the time feeder will run at each speed. Typically a 20 – 30 second volumetric run time is sufficient for an accurate calibration.

Continuous Setup Page 2 The feeder speed is controlled using a PID controller. The PID loop tuning parameters can be adjusted here to achieve the most responsive, yet stable control of the feeder. Correction Proportional Gain - This gain parameter is the proportional gain, ranging from .1 to 100. Set this gain to one-half the value needed to cause the output to oscillate when the Integration Time and Derivative gain are set to minimum. Correction Integration Time - This parameter is the Integral gain, ranging from .1 to 100 minutes per repeat. Set the Integration time equal to the natural period measured in the above gain calibration. A Proportional Gain

value of 1 adds the maximum integral term into the PID equation. Correction Derivative- This parameter is the Derivative term of the PID equation. The adjustment range is .01 to 10 minutes. Set this value to 1/8 of the integration time. Fully understanding PID Loop calibration can be a difficult task. Experimentation can used to get the parameters set reasonably close. Start with the minimal values of 0.1 for the proportional gain, 0.1 for the Integration time, 0.01 for the Derivative and a loop update time of 0.1. Then increase the Proportional gain to make the feeder more responsive. Increase the integration time to make the feeder more stable. This screen includes some tools for troubleshooting problematic applications. Pressing the displayed actual weight at the top of the screen will display the rate calculation troubleshooting screen.

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Rate Calculation Troubleshooting page The display shows the values used by the PLC to calculate the current feed rate. When the feeder is running in rate control mode, weight samples are taken and used to calculate the current feed rate that

is displayed on the run product screen. In applications that are prone to scale disturbances resulting from equipment in the area, wind, or other mechanical interference with the scale, this screen can be used to help identify the problem. If excessive mechanical noise is present, the displayed feed rate will appear erratic. It will have the tendency to take large jumps up and down, which may cause the feeder speed to jump, adding to the instability. The sample window is the length of time in between weight samples. The longer this window is, the more weight will have left the scale (or gained in a gain in weight system) The larger the weight change is from one sample to the next, the less significant small weight disturbances become. Each weight sample

results in a calculated feed rate that is added to the Rate queue. The entire 30 point queue is displayed on this screen so that you can see what the last 30 weight samples were. Another parameter allows you to select the number of points from the queue to use in the average calculation. The rate queue is arraigned in 3 columns. The first column contains samples 1 to 10. The second column contains values 11 to 20 and the third column contains samples 21 to 30. Values that are to be included in the average calculation are shown with a black box around them. Once the point has been included in the average the box will turn blue. Looking at the blue boxes will show which values from the queue are currently being averaged to calculate the displayed feed rate. Adjusting the sample window size, and the number of points to include in the average can have a significant effect on how stable the resulting feed rate will be. As the feeder is running, the current sample is shown in green at the end of the sample window time, this value will be added to the queue. If at the end of sample time this value is outside the limits shown in the green box, the system will consider this reading a scale disturbance and will place the feeder into a volumetric hold and will clear the data from the queue and begin to rebuild it. The values in the queue are always in whatever weight units the scale is set for, per second. If the unit is configured to run in say tons/hr the current target rate is shown at the bottom of the screen. For convenience the equivalent target in tons / sec is shown. In an ideal system, the current sample should build throughout the sample window time up to the target feed rate in weight units / second and should match the value at the bottom of the screen.

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Pressing the scale display at the bottom of the screen will display the scale history screen. In some cases, the scale display may be bouncing as a result of outside influence and mechanical noise. Capturing this disturbance on a graph may help the process of identifying or at least quantifying the amount of the disturbance. In an ideal system this graph should show an nice smooth down sloping line for a loss in weight system, or an up sloping line for a gain in weight system. If small spikes of increased weight are seen on a predominately downward sloping line, you may see a fluctuation in the displayed feed rate. The magnitude and frequency of these disturbances can in many cases be filtered out, however, it is always preferable to eliminate them from the system. The controller can only calculate the current feed rate based on the data it receives from the scale. If the scale is not stable, then chances are, the displayed feed rate will not be stable. There are 3 zoom levels to adjust the y axis scaling. No zoom will show values from 0 to 2000. Zoom level 1 will show 0 to 1000. Level 2 will show 0 to 500 and Level 3 will show 0 to 250. The last 90 minutes of the scale readings are shown at a sample rate of 1 minute. If you set the Zoom level from -4 to -1, the same Y axis scaling options are available, however the X axis will show the last 90 seconds with 1 second updates

Pressing the Current Rate at the bottom

of the screen will display a graph of the current Feed rate. The Zoom level can be used to adjust the range of the Y axis. Negative Zoom levels will display the X axis in seconds, Positive values will Display the X axis in Minutes.

Pressing the status bar below the graph will display a graph of the Feeder command speed. This is the speed the controller is sending to the feed device. A negative 1 zoom level will display the X axis in seconds and a value of 0 will display the X axis in minutes.

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Continuous Setup Page 3 Rate Tolerance Checking Enabled / Disabled- if enabled, the system will check the current feed rate to see if it is in or out of the specified tolerance. If disabled, the system will not check to see if the current feed rate is within the tolerance. Low Rate Alarm Limit- Rate at which the alarm output will trigger. High Rate Alarm Limit- Rate at which the alarm output will trigger The Rate tolerance can be set to be fixed units or as a percentage of the target rate. Alarm Delay (s)- Delay time in seconds where the low or high level limit has been exceeded

before the alarm output is triggered Rate Units:- Simply displays the rate units selected on another screen as reference.

Continuous Setup Page 4 Disturbance Sensitivity (# of Grads)- The number of graduations entered here will represent the number of graduations of the weight display that will need to fluctuate before the controller will go to the volumetric mode. This should be adjusted to reflect more major fluctuation in weight as opposed to minor wind fluctuations etc. Rate History Update (s)- The value entered here will represent the number of seconds that are to elapse before storing a rate reading to the history record. Startup Speed (%)- Speed at which the feeder is to start from a stopped position. Typically

used for vibratory feeders where initial speed is required to get the product to flow. Startup Time (s)- Amount of time feeder will run at the “Startup Speed” listed above before changing to gravimetric mode.

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Continuous Setup Page 5 When the Feeder is running in continuous mode, the controller calculates the current feed rate based on the data that it receives from the scale indicator. The controller will get a weight, then wait for a period of time, and then get a second weight. It then calculates the difference between the two, divides by the length of time between the two samples in seconds, to calculate an instantaneous feed rate. That rate is then added to an averaging queue, and evaluated to calculate the current displayed feed rate. The length of time in between weight samples can be very critical when the feed rate is very low in proportion to the current scale resolution. For example, say the target feed rate is 50 lbs/hr. That’s equivalent to .0139 lbs/sec. If the scale

resolution was set for say 0.1 lb increments, then at 50 lbs/hr you would have to run for almost 10 seconds before the weight on the scale indicator would change by one graduation. The Sample Window Size parameter allows you to set the length of time between weight readings that the controller will wait. For very low feed rates, with course scale resolution, more time must be allowed to pass to allow the scale to see the change in weight. The Larger the sample window, however, the slower the system is to respond to changes in the material flow. If the sample window is set very large, say 30 seconds, then the controller will only update the current feed rate once every 30 seconds. The Sample window can be set to be either Fixed, or Sliding. If fixed, the window size will stay at whatever value is entered on this screen. For some applications where a large range in feed rates are used, the sample window can be set to slide along with the target feed rate. If a sliding weight sample window is used, then the sample window size will automatically adjust from the longest window to the shortest window as the target rate is changed. In the example above, the sample window will be as long as 10 seconds when the target rate is 50 lbs/hr, and will shrink to 3 seconds as the target rate is increased to 2500 lbs/hr. The sample window size is calculated as a linear function and is limited to the longest and shortest times entered. This means that if the target rate is set lower than the Lowest Rate parameter, the controller will set the sample window to the longest value, and no longer. Likewise if the target rate is set larger than the Highest Rate the sample window will adjust to the shortest window, but will go no shorter. Consultation with a factory trained representative is recommended to find the best settings for a specific application. Environmental conditions, such as electrical and mechanical noise, loadcell selection, feeder type, etc. all come into play when selecting values for these parameters. For most applications a fixed sample window of 3 to 5 seconds is usually sufficient for calculating a stable rate that is still lively and responsive.

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Continuous Setup Page 6 On loss in weight continuous feed systems there is a Feed Speed Skewing feature that can be used to compensate for changes in feeder speed due to changes in product head load. In some applications the feeder may need to run slightly faster when the feeder is nearing its low level. This speed increase is needed to maintain the target feed rate. When the refill occurs, the current feeder speed is held during the refill. At the completion of the refill the feeder speed is turned back over to the gravimetric controller. The gravimetric control logic will have to adjust the speed back down to a slower speed to keep the product flowing at the desired feed rate. This cycling of the feeder speed during a refill can sometimes cause the feeder to over feed slightly during and right after the refill. If the product being dispensed has these characteristics, the BRC623 controller can automatically compensate for this shift in speed. To enable this feature simply toggle the enable button to Refill Feeder Speed Skew Enabled. Once enabled, you can choose to limit the maximum amount that the controller can adjust the feeder speed. This value can be set from 0 to 100% but is typically set for less than 10%. Once enabled the controller will monitor the feeder speed when the supply hopper is full, and when it reaches its low level set point. It will then automatically adjust the feeder speed during the refill to compensate for the change in material flow characteristics. This feature can be disabled if not needed, or left enabled. If the material flow characteristics are the same whether the feeder is full or empty, then the controller will see this and not skew the feeder speed during the refill. This feature is only available on a loss in weight, continuous feed application.

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Feed Device Setup Feeder Refill-Select if refill is enabled or disabled Refill Trigger- If Feeder Refill is enabled; the refill can be controlled by weight or by low and high level sensors. Refill can be triggered by weight only if the system is a loss in weight system. Low and High level sensors can be used for either loss in weight or gain in weight systems. If level sensors are used, they must be wired to the Refill High and Low terminals as explained in the interconnections section of this manual. If refill by weight is selected enter a weight value for “Low Level” and High Level” which will trigger the refill output.

When the scale weight is below the low level value, the refill output will be energized. When the scale weight is equal to or greater than the high level value, the refill output will be de-energized. The refill output can be wired to whatever device is refilling the feeder. This could be a slide gate, butterfly valve, screw feeder, or some other kind of conveyor. Refill Taking Too Long Alarm Delay- When a refill is started, a timer begins timing the refill. If the refill takes longer than the time delay entered here, an alarm condition occurs. The operator is notified on the run screen that the refill is taking too long, and the alarm output is energized. If Feeder Shut Off on Alarm is enabled, then a second timer begins at the completion of the first timer. If the refill has not completed by the time the second timer has completed, the feeder will be stopped. The feeder can be restarted by pressing the start button, or by issuing the remote start signal.

Feed Device Setup Page 2 Hopper Vibrator- Select between the following: Off: Vibrator will not run at any time. Fast Speed: Vibrator will only run when the feeder is in fast mode and will stop before the controller goes to slow speed. Fast and Slow Speed: Vibrator will run the entire batch time both in fast and slow modes. Pulsed by time: Vibrator will run for specified duration at specified frequency whenever the start button is pressed. Typically used in the continuous mode of operation. Pulsed by Batch: Vibrator will run for specified duration at specified frequency while batching only. Duration (s)- Enter the duration in seconds that the vibrator should run when it runs.

Frequency- Enter the time in seconds that the vibrator should remain OFF. If a zero is entered for the off time, the vibrator will run continuously while the feeder is running. Start Weight- If the controller is set to run in batching mode, you can specify the starting weight of the vibration sequence. The vibration will begin when the batch weight has reached the starting weight. Amt Before Target to Stop- If the controller is set to run in batching mode, you can specify when the vibration should stop. For batching accuracy it is usually desirable to stop the vibration before reaching the target. The amount of product before reaching the target can be specified using this parameter. For example if the amount

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before target to stop is set for 10 lbs, and the target batch weight is 100lbs, then when the batch weight has reached 90lbs, the vibration will be turned off.

Feed Device Setup Page 3 Feeder Type- Select between “Gain in Weight” and “Loss in Weight”. A gain in weight system is one in which product is being added to the scale when the feeding device is running. A loss in weight system is on in which product is leaving the scale when the feeder is running. Start Delay (s)- Enter a value in seconds for the delay before starting the feed. Weight Change Alarm (s)- Enter a time in seconds to delay the no change in weight alarm. If the feeder is running and there is no change in weight, the controller will start the alarm delay timer. When the time expires the alarm output will energize. This alarm can alert the operator that material is running low, clogged, or not available.

Feed Device Setup Page 4 Installations that require a bulk bag discharge stand often include bag flaps that can be used to massage the bulk bag to allow product to flow out of the bag. Bag Flaps: Can be either enabled or turned off. On Time: If the bag flaps are enabled, the length of time that the flap(s) are extended can be set here in seconds.Off Time: If the bag flaps are enabled, the length of time that the flap(s) are retracted can be set here in seconds. If no off time is desired, set this value to zero. Unison / Sequential: If enabled the bag flaps can be set to operate one at a time in an alternating fashion, or they can be set to operate together.

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Feed Device Setup Page 5 The process, either batching or continuous can be started using remote start and stop signals. The Remote start and stop feature can be enabled or disabled. If Enabled they can be utilized as two separate signals hardwired in inputs four and five. If desired, the system can be configured to use only the start input, which would then be treated as a feeder enable signal. If the signal is present on the start input, the feeder would run, and if removed, the batch would be placed in a paused state, or if in continuous mode, the feeder would be stopped.

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Jog Input Setup Jog Button Speed %- This is the speed that the feeder is to run when in the “jog” mode The jog mode is entered when either of the two optional jog inputs are used. Jog Vibration- Enable or disable this parameter to determine if the vibrator output is energized when in the jog button is pressed

Mixer / Take Away Conveyor Setup

In some applications, when the feeder is running it is necessary to control a take away device. A take away device may be needed to transport the product away from the feeder and into the container or process. This take away device can be controlled automatically by using the Mixer / Take away output. In other applications, the feeder is dispensing batches of product into a mixer. In this case, it is desirable to run the mixer for a set period of time after the batch has been dispensed. Depending on which type of function is selected, the controller will control the Mixer / Take

Away output accordingly. If Take Away conveyor, Lid or Gate is selected, the output will be turned on at the start of a batch, and run for the duration of the batch. A delay off or clearing delay can then be entered to turn off the take away device. If Mixer mode is selected, the output will be energized at the end of a batch and remain on for the specified mix time. In either mode, a feedback input may be utilized to prove that the mixer or take away device is operating correctly. There are two options available for the feedback input. It can be set as either maintained or pulsed. If maintained is selected the controller expects to see a constant input when the mixer or take away device is on. This would typically come from a zero speed switch, or from an auxiliary contact on the device motor starter. If Pulsed mode is selected, the controller expects the input to pulse on and off. This would typically come from an encoder, or a proximity switch monitoring a sprocket, or rotating flag. If the feedback is not seen by the controller the operator will be notified and the current batch will be paused, or if this is a continuous feed application, the feeder will be stopped. If no feedback is desired, this parameter can be set to None.

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Analog Setup Analog Out 1 of analog output board provided on all units is always set for feeder speed control and cannot be changed. Output 2- Allows access to setup second output on analog output provided on all units. Output 3- Optional Analog output board. Allows access to change signal to represent weight or rate. Input 1- Optional Analog Input board. Allows access to setup the analog input parameters to represent target weight or target rate depending on how controller is configured. Exit-Returns to “System Setup” screen

Analog Output 2 Setup (2nd output on base unit) Output Type - Can be set for current scale weight, current rate, or the last batch weight. If set for weight, the output represents whatever weight is currently displayed on the scale indicator. If rate is selected, the output represents the current feed rate. If set for last batch (only in batching mode) the analog output represents the last batch weigh. Minimum Value-This is the value the weight or rate will be when a 4ma output is transmitted with this output. Maximum Value- This is the value the weight or rate will be when a 20ma output is transmitted with this output.

Current Output- Pressing this button will allow the current weight or rate mA signal to be transmitted to the output for testing 4mA Output- Pressing this button will transmit a 4mA output to the receiving device for testing 20mA Output- Pressing this button will transmit a 20mA output to the receiving device for testing Tweak- Up Dn When in the 4mA or 20mA modes you can tweak the output to fine tune the signal going to the receiving device by using the “up” and “down” buttons Exit- Returns you to the “Analog Setup” Screen If the optional output 3 module is installed, the analog output 3 setup menu is the same as the output 2 menu.

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Analog Input 1 Setup Analog Input 1- Can be selected as “off” or “target weight” or “rate” depending on which mode the controller is in. If controller is set in the batch mode the input here will be target weight. If the controller is set to continuous mode the input here would be rate. If the system is being used in continuous mode, the analog input can also be set to be the feeder speed set point. In this mode, the remote system will set the feeder speed. The controller will provide rate feedback, but it will not change the feeder speed. Minimum Value- This represents the value when a 4 ma signal is sent to this input. Example: A “0” will represent “0” rate for

continuous or “0” pounds if set for batching. Maximum Value- This represents the value when a 20ma signal is sent to this input. Example: A value of 200.00 when in batch mode represents a target weight of 200.00 pounds. When in rate mode a value of 200.00 would represent 200.00 pound per minute or pounds per hour etc. Tweak 20 ma This feature allows fine tuning of the signal being sent into the controller. You can select “Tweak 20ma” or you can select “Tweak 4ma” Tweak- Up Dn- Utilize the Tweak “Up” and “Down” button to fine tune the signal watching the display in the lower left corner to verify the results. Exit- Returns you to the “Analog Setup” screen

Password Setup System Setup Password- Enter a password number between 0 – 65,535 up to 5 digits. If changed to a number other than “0” the password will need to be entered to be able to access the “System Setup” screens. Protect Batch Setup- Enable or disable the need for a password to enter and change “Batch Setup” parameters such as Preact and Tolerance. If “ON” then you can enter a password of 5 digits with any number between 0 and 65,535. Exit- Returns to “System Setup” screen Caution: Once Password is entered please record in a safe place. If Password is forgotten please call for assistance.

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System Diagnostics

Current Weight- Displays the current weight reading from the scale indicator Packets per Second- Displays the number of packets read from the scale per second. The scale type and data string are displayed below the packets per second. The Controller supports 2 different data strings depending on the scale indicator selected for the application. Standard scale Tare, switch to Gross and Zero scale functions are available for testing and trouble shooting scale functionality. Next- Advances to the Diagnostics screen for testing Discrete Outputs.

Exit- Returns to “System Setup” screen Batch Step- If the controller is configured for batching mode, the batch step will indicate what step in the batching process the controller is currently on. This can be useful when talking to the factory for trouble shooting purposes. Likewise if the controller is setup to run continuously, the Cont Step will indicate the current continuous mode step number. Pressing either the Batch step or the continuous step displays will show a graph of the step number which can be used for tuning parameters.

Diagnostics Page 2– Discrete Outputs To test any of the outputs press the button for the device you want to test. The device will remain on until the button is pressed to stop the output. To test the feeder a speed must be selected before the feeder will run. Be certain to turn off any device turned on while on this screen. This screen is for testing purposes only and is not designed to be used with any automatic control. Starting and stopping equipment is controlled by the person pressing the buttons.

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Diagnostics Page 3– Discrete Outputs To test any of the outputs press the button for the device you want to test. The device will remain on until the button is pressed to stop the output. To test the feeder a speed must be entered before the feeder will run. Be certain to turn off any device that was turned on while on this screen. This screen is for testing purposes only and is not intended for automatic control. The person pressing the buttons controls starting and stopping equipment. Diagnostics 4 – Discrete Inputs E-Stop- When E-Stop button is pressed the button on the touchscreen will change state to indicate “pulled out” or “pushed in”. Start Button- “ON” Should appear when switch is turned to the start position. Stop Button- “ON” should appear when switch is turned to the Stop position. Jog Button- “ON” should appear when the Jog fast input is energized. Remote Start- “ON” should appear when the “remote Start” input is activated. Remote Stop-“ON” should appear when the “remote Stop” input is activated. Low Level- “ON” should appear when the Low Level Sensor is activated.

High Level- “ON” should appear when the High Level Sensor is activated.

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Diagnostics 5– Discrete Inputs To test any of the inputs toggle the device used to provide the input signal. Proof switch on slide gates, level sensors etc. can be tested by looking for the input state to change when the device is activated.

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Remote Communication Setup If communication over AB Ethernet IP is desired, Remote Ethernet Communication can be Enabled. If enabled, the user can specify what to do if that communication is interrupted. If the feeding device is running and communication is lost and feeder shutdown is enabled, the controller will stop the feeder and place an alarm message on the screen. If Feeder shutdown is disabled, the controller will continue to run the feeder at whatever target was last communicated.

In order to verify that the communication with the remote device is active, a toggling bit used as a heartbeat can be enabled or disabled. If enabled, the system will echo back on N200:0/7 whatever it sees on bit N200:4/7 the remote device would respond by toggling the N200:4/7 bit back and forth. If the bit stops toggling for more than 5 seconds the controller will sense that the communication has stopped and will display a Communication lost message, and if feeder shutdown is enabled, it will stop the feeder. When using a remote device to control the unit, you can select whether the controller should use the target set by the remote device, or the target entered on the local touch screen.

Address Description Read / Write N200:0 Status Bits Read N200:0/0 Feeder Running Read N200:0/1 Feeder Refilling Read N200:0/2 Feeder Alarm Read N200:0/3 Feeder Ready Read N200:0/4 Totalizer 1 Cleared Read N200:0/5 Low Level Input

Active Read

N200:0/6 Spare Bit Read N200:0/7 Communication Heart

Beat Echoed back to Remote Device

Read

N200:0/8-N200:0/15

Spare Bits Read

N200:1-3 Spare Words Read N200:4 Command Bits Write N200:4/0 Run Feeder

Command Write

N200:4/1 -N200:4/3

Spare Write

N200:4/4 1 = Clear Totalizer 1 Write N200:4/5 Discharge Weigh

Hopper Write

N200:4/6 Spare Bit Write N200:4/7 Communication Heart

Beat from Remote Device

Write

N200:5-7 Spare Words Write F201:0 Scale Weight Read F201:1 Current Feed Rate Read F201:2 Current Feeder Speed Read F201:3 Totalizer 1 Read F201:4 Totalizer 2 Read F201:5 Last Batch Weight Read F201:6 Current Batch Weight Read F201:10 Target Weight / Rate Write

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Scale Setup The Scale setup page allows the operator to adjust parameters related to the scale indicator. When batching it is often important to know when the scale weight is stable. The Stability grads sets the

number of scale graduations that the weight must move in order for the motion indicator to be set. For example if the stability grads is set for a value of 4, and the scale resolution is .01 lbs then the scale must move more than .04lb before the motion indicator will be set. Certain applications require the sale to be considered empty before the next step is allowed. The Zero Low and High limits define what the scale controller is allowed to consider empty. The weigh units can be set by pressing the Weight units button. This button will cycle through the various weight unit options. These units are displayed in various places on the touch screen and should match the units that were used to calibrate the scale indicator.

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System Parameters / Restore Defaults Restore Factory Defaults- Pressing this button will restore original setting in this controller when the unit was shipped. All operation settings will need to be re-entered. Using this option is not recommend in most circumstances, and should only be used if instructed to do so by qualified personnel. Once a system has been configured and is working properly, all of the system settings can be saved. To save the current system setup, press the Save Current Settings button to store the units current settings. Saving the current settings will overwrite the last saved profile.

Restore Saved Settings if a known good profile has been saved, the saved settings can be restored by pressing the Restore Saved Settings button.

Screen Setup Adjust Contrast- Used to adjust the contrast of the touch-screen. Press the “up” arrow to brighten the display and the “down” arrow to dim the display. A setting of 100 is typically a good setting. Activate Screen Saver- Pressing this button will cause the display to go blank. Touching the display while blank will make this screen re-appear. Exit- Press to go back to the “Main Menu”

Clean Screen

Periodically the touch screen will need to be cleaned. By nature, it is sometimes difficult to clean a touch screen without accidentally pressing buttons displayed on it. Enabling this button provides a safe cleaning screen. Wipe the screen with a soft damp cloth. To leave the clean screen display, press exit button the specified number of times.

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SCT20 Scale Indicator: The BRC623 utilizes Rice Lake weighing system’s industry recognized and tested digital weight indicator to collect and display the scale information. The SCT20 is a single channel digital weight indicator. The indicator front panel consists of a seven-segment LED display and four-button keypad.

The complete SCT20 User manual is included after this document and describes the calibration and use of this unit. In order to set the SCT20 for use with the BRC623 controller the rS-485 parameter in the Serial menu must be set to Hdr 1P All other parameters can be left at their default values of baud = 9600, parity = none, stop = 1.

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Adjusting the Touch Screen Time and Date To adjust the time and date displayed on the touch screen display, follow the steps below

batch or continuous rate controller installation and operation … · 2018. 9. 7. · electrical...

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