WPAK100 Batch Controller

Features

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• Configurable Recipe Storage, Typical setting – 100 recipes x 30 lines
• Named ingredients and recipes
• Clear and Informative LCD batching display
• Accurate Automatic & Manual weighing and flow metering of up to 16 ingredients
• Timers and Digital Interlocks for control of Mixing, Heating and other process operations
• Digital Input/Output Expansion Modules for complex process control applications
• Automatic Repeat Batching and Volume Batching
• Time and Date stamped batch report printing
• Stored Production Logs
• Material Stocks and Usage Data
• Serial network communications to a host PLC or PC system
• Off-line recipe and configuration editing software including upload/download facility

The WPAK100 Batch Controller is a single weigher, multiple ingredient, weigh controller that may be used in a variety of weighing, flow metering and batch processing applications. It offers the flexibility of high accuracy automatic ingredient weighing, metering and discharge, along with configurable timer/interlock functions for control of mixing, heating and other process operations from a single weigh controller. Operating from stored recipe data selected through its front panel or from a supervisory PLC or PC system.

It has been designed to be easily integrated into typical process control panels and can operate stand alone or with additional remote digital I/O modules to cater for more complex process control applications.

Using the large LCD display and alpha-numeric keyboard provided the WPAK100 Batch Controller supports named ingredients and recipes ensuring error free identification of materials and product formulations. It is also capable of displaying informative operator prompts during the batching process.

Recipe Based Process Control

The WPAK100 Batch Controller offers configurable recipe storage: typical setting – 100 recipes x 30 lines. The supported recipe instructions provide a flexible means of controlling both product formulations and process operations. The recipe instructions are sequentially executed and can include both weighing/flow metering control and process plant control functions. In many cases this eliminates the need for an additional PLC.

Where the process sequence is the same for all product formulations, a separate sequence program can be set up leaving the recipes to define material target weights only. This greatly simplifies the recipe data and minimises errors in the process sequence being introduced during recipe editing.

Recipes may be entered and edited directly via the front panel or alternatively they may be downloaded via the serial interface from a remote PC using a Configuration Editor package provided by Practicon.

The recipe execution can be started, held and when necessary aborted, either from the keyboard or remotely from digital inputs i.e. either under automatic control from other equipment or from external pushbuttons.

Automatic and Hand-Added Ingredient Weighing and Flow Metering

The WPAK100 Batch Controller is capable of controlling both automatic and hand-added ingredient weighing and flow metering of up to 16 ingredients.

It is able to connect directly to up to four strain gauge load cells fitted to the weighing system and has four pulse input channels available for connection to compatible flow meter devices.

Clear and Informative Batching Display

During recipe execution the batching screen displays: the active recipe, current batch number and status : STANDBY, RUNNING, or HELD. The recipe line is also displayed together with the live weight, shown in large numerals. The status of the current instruction, along with any alarm conditions are also indicated. Recipe based prompts are also displayed to inform the operator of process specific actions e.g. wearing the correct PPE (Personal Protective Equipment).

Automatic Repeat Batching and Volume Batching

In continuous repeat batching applications, an optional batch counter function can be used to set the total number of batches to be produced. A volume mode is available which allows the controller to determine the number of batches required to fulfil a given total quantity. In this case recipes are formulated for a fixed batch size. The total quantity may be defined in cubic metres or tonnes.

Printed Batch Reports

The WPAK100 Batch Controller is able to generate printed batch reports containing time and date stamped ingredient weighing and metering details for each batch produced.

Stored Production Logs

The WPAK100 Batch Controller stores batch production logs for a configurable number of the most recent batches. These logs comprise of the recipe number, completion time & date, batch number, ingredient target and actual figures. The production logs can be viewed on the display, printed, or accessed from a host PC/PLC system via the serial interface.

Material Stocks and Usage Data

The WPAK100 Batch Controller provides password code protected access to material stocks, deliveries, and usage records. Totals of all materials used during batching are recorded and may be viewed or printed. Material stock levels are automatically adjusted from final batch actual consumption figures and from material delivery entries. Provision is also made for manual stock adjustments.

Network Communication with Host Systems

The software configurable RS232/RS485 serial interface can be used for communication with host PLC or PC systems. The appropriate process data is available to be read, and written where applicable, using the SABus (simple ASCII commands) protocol.

Datasheets