Micro-Blender V2 Controller Control Description

The Micro-Blender V2 Controller receives pulses from the wild stream meter and blend stream meter
and ratios the two flows based upon the blend percentage set in Parameter # 010. The blend stream
control valve is directly controlled by the Micro-Blender V2 Controller electronics in order to maintain
that ratio. The wild stream flow is not controlled by the Micro-Blender V2 Controller electronics.

Control Valves
Micro-Blender V2 Controllers utilize two different types of control valves depending upon the
application. Some blenders use a globe or plug valve in which the product line pressure is used to
modulate the valve open and closed. The control valve is operated by cycling product pressure to
and from the control chamber on top of the valve. Other blenders utilize a hydraulic power-pak pump
and reservoir for valve actuation power. This method is typically used on ball valves or butterfly
valves. The valve is controlled by cycling hydraulic fluid to and from the actuator on the valve.

Solenoid Valves
To manage the flow of the actuation fluid to the control valve, electrically operated 2-way solenoid
valves are used. Two valves are required; a normally open (NO) solenoid controls the closing of the
control valve; a normally closed (NC) solenoid controls the opening of the control valve. When the
NO solenoid is pulsed, the control valve is closing. When the NC solenoid is pulsed, the control valve
is opening. This statement is true for both product actuated valves and hydraulic fluid actuated
valves. This method of using both NO and NC valves offers a fail-safe operation, in that upon power
failure the solenoid valves de-energize and the control valve goes closed.

Solenoid Plumbing
The position of the NO and NC solenoids on the control valve are different for product actuated
valves and hydraulic fluid actuated valves. Globe and plug style valves have the NO solenoid on the
upstream leg of the control loop and the NC solenoid on the downstream leg. Hydraulic actuated
control valves have the NC solenoid between the high pressure line from the power-pak and the
actuator. The NO solenoid is in the return line to power-pak reservoir. This is mentioned for
reference only and does not vary the operation or electrical connections.

Signal Description
Output number 1 on the Micro-Blender V2 Controller chassis (TB5-2) drives the normally open (NO)
solenoid. Output number 2 on the Micro-Blender V2 Controller chassis (TB5-3) drives the normally
closed (NC) solenoid. Lights on the front of the Micro-Blender V2 Controller module illuminate when
the output is on or energized. Thus, when output 1 is on, the normally open solenoid is energized
and is closed. When output 2 is on, the normally closed solenoid is energized and is open.

Control Valve States

There are six states that the blend stream control valve can be at:

Control Valve State Output 1 NO Solenoid Output 2 NC Solenoid

Closed Off Off
Fast Opening On On
Ramp Opening On Pulses
Locked On Off
Ramp Closing Pulses Off
Fast Closing Off Off

Solenoid Dwell
The Micro-Blender V2 Controller output circuit can energize the solenoids in two different ways. The
output can be turned on and held on continuously, or it can be cycled on-off-on-off. This cycling or
pulsing of the output is called dwell. The time period that the solenoid allows flow through it is called
active dwell and is controlled by Parameter # 030.

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Control Description (continued)

The time period that the solenoid prevents flow through it is called rest dwell and is controlled by
Parameter # 031. These time period values are in milliseconds.

Because the normally open solenoid allows flow through it when de-energized and the normally
closed solenoid allows flow through it when energized, the Micro-Blender V2 Controller treats active
dwell and rest dwell differently on output 1 vs. output 2. This difference is depicted in Figure 1 below.

Figure 1

Solenoid Dwell Default Values

Parameters # 030 and # 031 are defaulted to a value of 100 milliseconds. This means that when the
controller is pulsing the solenoid for ramp opening and ramp closing, the solenoids stay energized for
0.1 seconds and de-energized for 0.1 seconds.

Control Method
The Micro-Blender V2 Controller is a batch blender. It requires a permissive signal at the beginning
of the batch to zero the delivery totals for the batch and (optionally) resets the deviation count. When
permissive is removed at the end of the batch, a blend percentage is calculated for the delivered
volumes and compared to the target percentage for the purpose of alarm generation.

Located on the lower left area of the display is the deviation count. This value is a positive or
negative number that represents the error between the actual blend stream and wild stream volumes
vs. a perfect blend. The count is in wild stream pulses. Negative counts mean that the blend
stream is running behind target. Positive counts mean that the blend stream is ahead or too great.

Control valve action is based upon the magnitude and polarity of the error. Stated simply, if the
count is negative, the blend control valve is opened. If the count is positive, it is closed. If the count
falls very near zero, the control valve is locked in its present position.

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Control Description (continued)
A series of control windows must be set up in the Parameter settings. Each control window value
establishes the outer limit in deviation count for that window. When the deviation count is inside that
window, the controller reacts in a specific way when controlling the blend stream control valve. The
deviation count value falling in a specific control window changes the active and rest solenoid dwell
values used.

Parameter 020 - Inner Control Window Limit

The Inner Control Window Limit establishes a distance from zero in the error count. When the count
value is less than this number, the control output from the controller is locked. No correction is made
to the blend stream control valve. This value effectively establishes the dead band in which the
error count can drift without correction. The dead band is plus or minus this value.

Parameter 021 - Second Control Window Limit

The Secondary Control Window Limit sets a distance from zero in the error count. This value should
be greater than Parameter 020 and less than Parameter 022. When the count value is greater than
the Parameter 020 value and less than this value, the controller uses one-half the active dwell
(Parameter 030) value and double the rest dwell (Parameter 031) value when controlling the blend
stream control valve.

Parameter 022 - Third Control Window Limit

The Third Control Window Limit sets a distance from zero in the error count. This value should be
greater than Parameter 021 and less than Parameter 023. When the count value is greater than the
Parameter 021 value and less than this value, the controller uses the active dwell (Parameter 030)
value and the rest dwell (Parameter 031) value when controlling the blend stream control valve.

Parameter 023 - Outer Control Window Limit

The Outer Control Window Limit sets a distance from zero in the error count. This value should be
greater than Parameter 022. When the count value is greater than the Parameter 022 value and less
than this value, the controller uses double the active dwell (Parameter 030) value and one-half the
rest dwell (Parameter 031) value when controlling the blend stream control valve.

The above control windows can be further visualized in figure 2 below:

Figure 2

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Control Description (continued)

Control Window Default Values

The Micro-Blender V2 Controller electronics is delivered with default values in all parameters. These
values are developed from the needs of the majority of our customers. Although they meet the
requirements for many customers, they may require adjustment to configure the electronics to
perform exactly as required by your needs. This is particularly true of the control window limit
parameters 020 023.

Parameter 020 is the Inner Control Window Limit and defaults to a value of 30. This means that a
deviation count range of -30 to +30 will result in the control valve being locked.

Parameter 021 is the Second Control Window Limit and defaults to a value of 100. When the
deviation count is within the range of -100 to -30, the control valve will be opened at the rate of one-
half the value of the active dwell and double the rate of the rest dwell. When the deviation count is
within the range of +30 to +100, the control valve will be closed at the rate of one-half the value of the
active dwell and double the value of the rest dwell.

Parameter 022 is the Third Control Window Limit and defaults to a value of 200. When the deviation
count is within the range of -200 to -100, the control valve will be opened at the rate of the value of
the active dwell and the rate of the rest dwell. When the deviation count is within the range of +100 to
+200, the control valve will be closed at the rate of the value of the active dwell and the value of the
rest dwell.

Parameter 023 is the Outer Control Window Limit and defaults to a value of 500. When the deviation
count is within the range of -500 to -200, the control valve will be opened at the rate of double the
value of the active dwell and one-half the rate of the rest dwell. When the deviation count is within
the range of +200 to +500, the control valve will be closed at the rate of double the value of the active
dwell and one-half the value of the rest dwell.

When the deviation count is less than -500, the control valve is sent a continuous open signal on
Outputs 1 & 2. When the deviation count is greater than +500, the control valve is sent a continuous
close signal. Additionally, during this time when the deviation count absolute value is greater than
500, the Control Failure Alarm is timing and will eventually cause an alarm condition if the count
does not return inside the outer control window limits.

Control Adjustment
Set up of the Micro-Blender V2 Controller consists of adjusting the four control window limits, the two
solenoid dwell times, and finally the two speed needle valves in the upstream and downstream legs of
the solenoid streams.

Initial settings
In addition to the previously mentioned default values for the controller parameters, the speed needle
valves need to be set. With the blender idle, run each of the speed adjustment needle valves fully
closed, then open them four complete turns. With these settings in place the blender will initially start
and run although operation may be erratic.

Normal Operation
When the blender is running normally, the deviation count will cycle above and below zero. It does
this because of the digital nature of the valve control method. It will rarely hold near the zero
deviation count. The objective when tuning the blender is to minimize the swings of the deviation
counts, and keep the deviation count in the dead band established by the Inner Control Window Limit
for as long as possible.

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Control Description (continued)

Many factors interact to determine the ideal tuning of the Micro-Blender V2 Controller electronics. For
this reason, it is impossible to predict what the parameter and needle valve settings will ultimately be.
These factors include the differential pressure across the blend control valve, the pressure of the wild
stream, the type of control valve, etc. It is possible to observe the operation of the blender and
optimize each of the settings accordingly. The following paragraphs explain this process.

Tuning Set up
The first objective is to adjust the control window limits very wide in order to give room to observe the
deviation count fluctuations. Leave Parameter 020 set to 30 initially. Set Parameter 021 to 35
counts, 022 to 1250 counts, 023 to 1500 counts. This effectively forces the blender to use equal
active and rest dwell during initial tuning steps. Turn off the Control Failure Alarm by setting
Parameter 310 = 0.

Establish flow through the blender and allow the control valve to swing to its extremes several times,
noting the plus and minus extreme counts. The count must change direction within 1250 counts. If it
does not change direction within 1250 counts initially, widen the windows further.

Needle Valve Speed Adjustment

If the deviation count consistently goes more positive than negative, slightly close the speed
adjustment needle valve nearest the normally closed solenoid valve. (Downstream solenoid on a
globe valve, pressure side of a hydraulically actuated valve.) Start out closing it by turns until a
noticeable change is effected, then smaller adjustments until the positive and negative deviation
swings are equal.

If the deviation count consistently goes more negative than positive, slightly close the speed
adjustment needle valve nearest the normally open solenoid valve. (Upstream solenoid on a globe
valve, vent side of a hydraulically actuated valve.) Start out closing it by turns until a noticeable
change is effected, then smaller adjustments until the positive and negative deviation swings are
equal.

The purpose of the adjustment above is to correct for variations in Cv or flow of fluid through the two
different solenoid valve types and to equalize the opening and closing times. Lock the speed
adjustment needle valves in these positions.

Dwell Adjustment
Slowly increase BOTH Parameter 030 and 031 by increments of about 20 milliseconds while
observing the deviation count swing extreme numbers. As the dwell value is increased, the peak
value of the deviation count will decrease. At some point, the count swing will start back upward.
The ideal setting for dwell is the point at which the deviation count swing is smallest.

Second Control Window Limit Adjustment

Change Parameter 021 from 35 to 1000 (higher if the swing is greater than this value). Allow the
deviation count swing to stabilize positive and negative again and note the peak value. The setting
for the Second Control Window Limit Parameter 021 should be one-half the peak deviation value.
Thus, if the blender was swinging from -725 to +725, set Parameter 021 to 363.

Third Control Window Limit Adjustment

Change Parameter 022 from 1250 to 150% of Parameter 021. Thus if Parameter 021 was set to 363
in the step above, 150% of 363 = 545.

Outer Control Window Limit Adjustment

Lastly, change the value in Parameter 023 from 1500 to 200% of Parameter 021. In our example,
021 = 363 times 200% = 726.

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Control Description (continued)

Optimization
The blender is now set to control equally over its widest range of conditions. However, tuning may be
improved upon if additional steps are taken. These steps take considerable flow observations and
may not be practical unless repeated blending batches are undertaken.

In an attempt to minimize the swing of deviation counts, the following observations and adjustments
can be made:

Note the extreme deviation count values. Reduce the value in Parameter 021 by 10% and then
recalculate and set Parameters 022 and 023 by the 150% and 200% amounts previously used.
Again observe the extreme deviation count values. Did the value decrease? If yes, then an
improvement has been accomplished. This process can be repeated as needed. Take small steps
when reducing the value in 021, keeping them 10% or smaller. Remember to recalculate and set the
values for 022 and 023 each time. At some point the optimum setting will be passed and the extreme
deviation count value will begin to increase again. The value in Parameter 021 should be increased
back toward the previous setting.

Closely observe the counts during start up and shut down of the blender. If the deviation count is
exceeding the value in Parameter 023 for more than a few seconds during this time, the value in this
Parameter should be increased. The value in Parameter 311 should be double the number of
seconds that the count remains above the value in Parameter 023.

Lastly, remember to turn on the Control Failure Alarm by setting Parameter 310 back to 2.

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