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VOLUMETRIC BLEND SYSTEM OPERATION MANUAL

YARGUS MANUFACTURING 12285 E MAIN STREET MARSHALL IL 62441

PHONE: 217-826-6352

FAX: 217-826-8551

LARRY D YARGUS PRESIDENT

MIKE WHEELER PRODUCTION MANAGER

CHRIS WHITE ENGINEERING

RANDY DAVISON PARTS

VIST US ONLINE AT WWW.YARGUS.COM

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OVERVIEW SYSTEM OVERVIEW

The LAYCO volumetric blend system is designed to accurately blend free flowing

materials with very high accuracies. The Mitsubishi VFD obtains these accuracies

through precise calculations. The input to the VFD’s is a 4-20ma signal derived from

floating point math calculations from the 205 PLC. Also with the scale option, the system

can accurately enter in bulk densities for the materials, which you will be using, by only

entering in the cubic inches of the container used. These values can be automatically

entered or manually entered through the operator interface panel. This is the heart and

soul of the LAYCO blending system and how we can obtain such high accuracies.

Through the following setup procedures, the system can be up and running within an

hour. Once set up, all the operator will have to do is enter in the desired poundage of

each material. The system will automatically calculate the correct blend ratios and speed

for each rotary valve. Simply pressing the START key after each batch run can then

make multiple batches of the same blend.

Ease of setup and operation with built in protection to prevent a bad batch from ever

coming out is what is behind the LAYCO blend system.

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MAIN MENU SCREEN

The main screen is where you can navigate to any of the

other screens. Pressing the MENU button in the opening

screen accesses this screen. By touching the screen, the

following screen is displayed.

HOPPER WEIGHTS SCREEN

Pressing the HOPPER WEIGHTS button on the main

menu screen accesses this screen. This screen displays

all the weights entered in for each hopper. You can

change the batch weights for any of the hoppers by

touching the desired hopper weight and entering in a

new weight.

Pressing the EXIT button takes you back to the Main

Menu.

HOPPER SETUP MENU SCREEN This screen is accessed from the HOPPER

BATCH WEIGHT SCREEN. When this screen

is displayed, you can select which hopper you

wish to view.

Pressing the EXIT button takes you back to the

MAIN MENU.

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TURN OFF DELAY SCREEN This screen is accessed from the HOPPER

SETUP SCREEN. When this screen is displayed,

you can set the delay shut off time for the

Underbin Auger and the loadout conveyor. On

this screen you can also adjust the System

capacity to match your output requirement.

Pressing the EXIT button takes you back to the

MAIN MENU.

HOPPER SET UP SCREEN

This screen is the same screen for all hoppers.

The hopper you are looking at is displayed at the

top left of the screen. This screen display’s all

the information to that particular hopper. Set

batch weight is where the desired weight for that

hopper is entered. Set bulk density is where you

can manually enter the Bulk Density or

automatically enter it by filling the bulk density

container with the material, setting it on the scale

and then pressing the ON button located next to

the display. The set volume constant is a

calculated value that is determines the characteristics of the rotary valve and how much

material the valve will dispense. The set batch delay is the number of seconds it takes the

material to flow from the previous valve. The empty hopper is that you can manually start

the rotary valve to empty the hopper. Pressing the button again will stop the valve.

ROTARY VALVE CALIBRATION (VOLUME CONSTANT)

1. First have several thousands of pounds of material in the hopper to be tested.

2. Have available a weigh hopper or a means of preciously weighing 2000 pounds of

material on certified scales.

3. Set the weight for this hopper to 2000 pounds with a volume constant of 34700.

4. Enter in the correct bulk density for this material by the scale method if possible.

5. Set all other hoppers batch weight to 0 (zero).

6. With a weight hopper in place to catch the material, press the START key.

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7. The system will turn on and dispense 2000 pounds of material, or close to it, into

the weight hopper.

8. When the system shuts down, and all material has dispensed is in the weight

hopper, use the following formula to calculate the new volume constant.

((material dispensed) / (material wanted))*volume constant used = new volume

constant

((weight on scale)/(2000))*34700 = new volume constant

2000 = target weight

34700 = volume constant used

9. Enter in the new volume constant and run the test again.

10. This time the dispensed weight should be within 2% of the target weight. If off

more than 2%, calculate the volume constant again using the same formula again to

get a new volume constant. Remember to use the volume constant used in the test,

in the formula instead of the previous.

Follow the same procedure for calibrating all rotary valves.

HOPPER BATCH DELAY

The batch delay is the amount of time it takes for the material dispensed from hopper to get

to the rotary valve, which you are setting up. In other words, if you are setting up hopper

#2, then the time you enter here is the time in seconds that it takes material to reach hopper

#2 from hopper. Hopper is the reference point so each hopper is set up with a batch delay

time for material to reach each hopper from hopper. This time insures that that the blend

remains constant through out the blend. Normally this time is preset and you will not have

to adjust it. You can test if the time for each hopper is correct by turning on the blend auger

and dropping a tennis ball in hopper auger point at the same time the start button is pressed

and see if each rotary valve starts when the tennis ball gets to each hopper. To set the time

press the SELECT key when this screen is up and the following screen will be displayed.

ADJUST SCREEN This screen is accessed from the MAIN MENU

SCREEN. When this screen is displayed, you

can adjust the contrast of the touch screen or

activate the screen saver.

Pressing the EXIT button takes you back to the

MAIN MENU.

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CONDITION SCREEN This screen is accessed from the MAIN MENU

SCREEN. When this screen is displayed, you

can set the max cut off amperage for each

conditioner. On this screen you can also adjust

the amount of time that will pass before current

monitoring will begin. This is used to allow the

motor to reach full RPM.

Pressing the EXIT button takes you back to the

MAIN MENU.

SCALE CALIBRATION SCREEN

The scale calibration screen is where the scale

calibration is preformed. To zero the scale, make

sure the scale is clean and the bulk density

container is empty and clean. Place the bulk

density container on to the scale. Put the

analogic board switch to calibration position and

press zero scale calibration button. If the scale

calibrated ok, then the scale-zeroed indicator will

display. If there was a problem calibrating the

scale, then the zero failed indicator will display.

If this happens, press the reset button and try

again. To calibrate the span, place the test weight on the scale and press the span scale

button. If the scale spanned ok, then the scale-spanned indicator will display. If you see

the span failed indicator, then press the reset button and press the span scale again. The

scale is now calibrated. Be sure to place the calibration switch back to run mode on the

analogic board or the scale will not display weight.

Pressing the EXIT button takes you back to the MAIN MENU

TEST WEIGHT SCREEN

This screen is to enter in a test weight that you

will be using to span the scale. To enter in a test

weight press the calibration test weight button.

Enter the test weight. You must enter in the bulk

density container’s cubic inches on this screen.

This is the number used to calculate the bulk

density.

Pressing the EXIT button takes you back to the

MAIN MENU

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BINDICATORS

LOW LEVEL INDICATOR

Each hopper is equipped with 2 bindicators. The bindicator in the main hopper is a LOW

LEVEL indicator. When this trips, the indicator light will illuminate on the main control

panel and will remain on until the hopper is refilled. To reset the panel alarm, press the

RESET ALARMS button on the SYSTEM RUN screen. If the problem has been

corrected, the alarm will go out.

BRIDGED INDICATOR

The bridged indicator is right above the rotary valve. This bindicator is to sense a bridged

condition. As soon as this condition is detected, the system goes into an emergency

shutdown condition. All rotary valves as well as the main auger will shut down

immediately. This prevents the batch from being corrupted and maintains the integrity of

the batch. To fix this condition, the operator must rap the side of the bin with a rubber

mallet. When the bridge has been broken. Pressing the RESET ALARMS button can reset

the Alarm. Once reset, the START button can be pressed to resume the batch cycle.

ROTARY VALVE INDICATOR

Each rotary valve is equipped with a proximity switch that senses if the valve is turning

when the system is running. If for some reason the valve stops during a batch cycle, the

system will go into an emergency shutdown. Once the problem has been corrected, and the

Alarm has been reset on the main panel, the START button can be pressed to resume the

batch cycle.

UNDER BIN AUGER INDICATOR

The Under Bin auger is equipped with a Zero Speed switch, which senses if the auger is

turning when the system is running. If for some reason the auger stops during a batch cycle,

the system will go into an emergency shutdown. Once the problem has been corrected, and

the Alarm has been reset on the main panel, the START button can be pressed to resume

the batch cycle.

LOAD OUT CONVEYOR INDICATOR

The Load out Conveyor is equipped with a Zero Speed switch, which senses if the auger is

turning when the system is running. If for some reason the Conveyor stops during a batch

cycle, the system will go into an emergency shutdown. Once the problem has been

corrected, and the Alarm has been reset on the main panel, the START button can be

pressed to resume the batch cycle.

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Valve Alarms An * denotes alarm will not stop a run or prevent a blend from being made

Alarm Diagnostic Solution

Standard Volumetric Valve Bridged Indicates that there is no material that is ready to be distributed by the valve.

Usually caused by an air pocket or clumped/stuck material to hopper.

Low Level Hopper * Material in hopper is below sensor level Fill hopper before it runs out of product

Valve Motion Valve is not turning Something is preventing valve from moving or is a VFD issue

Blend Ratio One or more weights is too low or high VFD's cannot turn valves slow enough to compensate for weight, adjust blend

E-Stop Emergency Stop Button was pressed. Pull out E-stop and reset alarms

BE Pressure Switch Spout is plugged Unplug the spout and reset alarms

Bucket Elevator Zero speed switch detects no motion or not enough RPM's

Make sure conveyor is running/running at required speed

The Touchscreen is locked. Sign out of the HMI to have touchscreen control

Declining Weight/Gain-Weight Master GSE Lost Connection lost to GSE Cycle Power

Weight in Tank There is already a weight in a tank Empty tank or switch tanks so blends are not mixed.

GSE Menu Mode GSE is in MENU mode Cycle Power

HMI Bad Batch Number Number does not exist Re-enter the number

HMI Connection Lost No connection to HMI Reset connection

HMI- Information Will Not Be Saved Running from Touchscreen Ignore, can log back into HMI to transfer control

Chemicals Needed are Not Loaded

HMI cannot find chemicals in correct hopper

Check/setup HMI hopper configuration

Short Run Time* The run time is too short to run in gain/weight mode

Switches to volumetric mode

Impregnation IM Flowrate AL Cannot Reach GPS Flowrate Check connection

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12285 EAST MAIN STREET

MARSHALL, IL 62441

217-826-6352

WWW.YARGUS.COM

VOLUMETRIC AND

DW MANUAL

SENSORS AND

ADJUSTMENT

PROCEDURES

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Volumetric and DW Manual Sensors and

Adjustment procedures

1. Sensor Adjustment

a. Low Level and Bridge Sensor To adjust the low level or bridge sensor, first, empty the hopper and

verify that there is no build up of any kind on the sensor well.

If there is it must be removed. Once this is done, use a small

screwdriver to find the set point of the sensor. The set point of

the sensor is found by rotating the adjustment screw in & out

until you find the point that the

red light on the sensor turns on and off. Tightening the

adjustment screw should make the light come on, and

loosening the screw should make it go off. Once the set point has been reached loosen the adjustment screw two full turns, once this is complete

no further adjustment is necessary. Weekly maintenance should be performed on this sensor in the form of a visual inspection of the sensor

well and cleaning of caked on product from it.

b. Proximity Motion Sensor and Target Wheel After initial setup the Target wheel

and Proximity sensor should not

require any adjustment. The distance

from the Proximity Sensor to the

target wheel should not exceed one-

eighth inch. To check the proximity

sensor for proper operation, watch the

small yellow light located on the

sensor it should be on when a tooth on

the target wheel passes the sensor and

off when nothing is close to it.

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Fig. 3

c. Zero Speed Switch and Disc Zero speed switches are located on the tail roller of all conveyors, the boot of bucket

elevators, and on the shaft of Augers.

The Zero Speed Sensor is factory

preset. No adjustments should have to

be made after installation. When

correctly installed the gray plastic

sensor should be centered on the white

line located around the pulser disc.

The sensor face should be about 1/8

inch to ¼ inch from the face of the

pulser disc.

d. Binful Switch If your Volumetric Blender has a Bucket Elevator transport system, then there will be a

Binful pressure switch located in the

Head of the Bucket Elevator. In the

event that the Down spout on the

Bucket Elevator becomes plugged and

product backs into the head of the

Bucket Elevator the Binful Pressure

Switch will shut power off to the Leg

and prevent it from running until the

down spout can be emptied. There are

no adjustments or calibrations for this

sensor.

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2. VFD Reset Information If a Frequency drive over loads or faults out for any reason, record the code displayed on the

display of the drive, then shut off the

circuit breaker located next to the

frequency drive. Wait until the

frequency drive powers down

completely, this can take up to thirty

seconds. Once power down is

complete the breaker can be turned

back on and the drive will reset

itself. In the normal operating mode

the drive should display “0.0” in the

display and the run light should be

on. As displayed in the picture.

Note: When foreign matter is

introduced into a volumetric valve

(hammer, screwdriver, or 2x4) it is

normal for the valve to overload, the

above procedure should be used to reset the valve.

No regular maintenance is required for the VFD or breaker, but it should be inspected weekly to

make sure the fiberglass box is closed and latched, and that there are no air leaks allowing

fertilizer to gain entry into the panel.

3. Routine Valve

Maintenance The Volumetric valve (like any

other equipment moving fertilizer)

will require periodic cleaning. It is

necessary to remove the cover and

inspect the Volumetric Valve cups

weekly in order to maintain an

accurate blend system.

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