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1. Page Number 48 Customizing A3 The A3 layout can be modified by the user The following are some of the customizable features e The Customer Name can be configured by selecting File Customer Name Once changed the customer s name will appear in brackets on the title bar menu As AJ System Management Softwar Perfect Plastics Inc File Edit View Tools Help seeaceee TIME 4 28 2003 10 03 42 AM start 5 customer name cha As 43 System Managem Page Number 49 e The Sheet Name can be modified by selecting File Edit Sheet Name Once changed the name of the sheet Plant Name will be changed to whatever the user has selected Commonly this is the location of the As AJ System Management Software Plant View e eenoneot TIME 4 28 2003 10 18 43 AM start 5 edit sheet name ch As A3 System Managem EXP 10 18 AM Page Number 50 Adding multiple sheets to the system A3 is capable of having up to 20 different sheets with up to 50 devices on each sheet To add a sheet select File New Sheet To delete a sheet click on the sheet and then select File Delete Sheet As AJ System Management Software Plant View File Sd eds eb es anle dide e e TIME 4 28 2003 10 25 13 AM 4 AW 10 25 AM Page Number 51 A3 options The A3 software also has many preference options that can be changed by the user To access the options menu sele
2. Legacy equipment with Hynet Driver md Loe Meter SERIAL SETUP far all units Monitor Running Recipe PMR Pauni Iw Change Recipe Ability Serial ID 1 255 4 pa r 1 Polling Time in milliseconds Number of Hopper i Ou Ii Include this device in Report 4 aximum Resend Atternps 10 Cancel OE Adding a Legacy Device As you can see you will need to enter a unique Serial ID for each device on your network You will also need to configure the number of hoppers for the device this is only necessary on the older proprietary blenders Leave the Polling Time at 100ms and Maximum Resend Attempts at 10 To configure the Serial ID on the actual blender Page Number 74 Step 1 From the main menu hit 5 and enter in your password P a WER at a ttt3 te ALARM 5 a il Ei cessa rTE Lorip Step 3 hit back up Page Number 75 Step 5 Em in Or ur to change Baud E I Backup The SERIAL SETUP section is the same for all proprietary devices on the network changing the settings here means changing it for all devices The COM Port should be set to whatever the USB RS422 485 is set to To check the USB RS422 485 port setting Page Number 76 A y Internet Explorer er L9 My Computer Owner E Command Prompt cA My Documents E Calculator ah Release Motes Explore Microsoft Visual Basic 6 0 Search Manage Shortcut to A3 exe Map Network Drive Dis
3. The approach to trouble shooting varies with the type of communications the device uses so this section is divided up into multiple sections Trouble shooting network problems with AEC AB OS OA blenders Problem You ve configured more than one Ethernet device and none of them are communicating Solution It is easy to trouble shoot when you have some devices communicating at least one but with none communicating you re going to have to start from the beginning otep1 Disconnect all of the blenders except for one Get this one working and then go to the next one otep2 Examine the DCOMM light on the PLC and ensure that it is on If it is off then remove the snap cover on the PLC and hold in the COMMS button until the DCOMM light turns on pe gm j le aj c u Page Number 114 step 3 Examine the Power light on the PLC s Ethernet module If it is not on then check the cable that connects the device to the plc and ensure that it is plugged in fully and is the correct cable 1761 CBL AMOO Also make sure that the power switch for the device is set to Gable step 4 Examine the FAULT indicator If the device is faulted then check that your subnet mask is 255 255 255 0 and that you have a valig IP e Chapter booting 4 for details It i but should turn off Wi Dis able af US ins BOOTP Jers ar Mits ubiz hi Dis pla Send Ethernet Module
4. eec BLEND amp RECLAIM amp RECLAIM A3 System Management Software Software Manual Bulletin number BF 4 600 2 Part number 882 00208 00 Date 11 14 2008 AEC Inc 1100 Woodfield Rd Suite 588 Schaumburg IL 60173 Phone 847 273 7700 Fax 847 273 7804 Page Number 1 Confidential Supervisory Manual Not to be released to floor operators Table of Contents ONECIE W siesta Sis M 4 PErequentuy Asked OTS ONS suede totu edu alee ale LM EM uu HMM E 7 uero arena reiner nie 1 Conii NC RE es seen nee ereignete 19 Running the Cables and Hardware to interconnect they system ueeeesssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennennnnnn 22 Networking instructions for the ACS Allen Bradley batch blender 220000000000BBBRnnnnnnnnnnnnnnnnneeneeeeeennnnn 24 Networking instructions for the older proprietary Hydreclaim embedded equipment seeeeesessuuuse 26 Networking instructions for the ACS Mitsubishi batch blender sssseeessssssssssseseeeeeeeee enn 28 Networkitie instructions Tor th Maguire WSB Blender za e oneal als naam 20 Configuring the Digi One IA or Digi One SP Ethernet Modules sss enne nnn 30 USINA A o es P 40 Application SCIENS ER T mc 54 Work no WIR
5. Page Number 14 Installing A3 Insert the A3 CD into the CDROM drive The installation software will automatically start If it doesn t then run Setup exe from the A3 CD A3 System Management Software Setup HEN A3 System Management Software Setup Welcome to the 43 System Management Software installation program etup cannot install system files or update shared files if they are in use efore proceeding we recommend that you close any applications you may step 1 Click OK Page Number 15 As System Management Software Setup E 13 System Management Software Setup Begin the installation by clicking the button below Click this button to install A3 System Management Software software to the specified destination directory Directory C Program Files 43 System Management Software Change Directory Exit Setup otep 2 Click the picture of the computer As System Management Sollware Setup a 13 System Management Software Choose Progr Setup will add items to the group shown in the Program Group box You can enter a new group name or select one from the Existing Groups list Program Group Existing Groups Accessories Axialis Programs cma Step 3 Click Continue Page Number 16 A3 System Management Software Setup A3 System Management Software Setup 43 System Management Software Setup was completed successfully Step 4 Success Click OK to complete Pag
6. Adding new A3 Device Objects simply right click in the blank white area of the sheet you wish to add a device to and select Add ACS Device You will then see the following dialog A3 System Management Software Plant View Device Type Communications Type OS Blender 052001 Blender DS or DA with AB Dri IP Address ann v Monitor Running Recipe T iai Change Recipe Ability Monitor Targets vs Actuals I Include this device in Report TIME 4 28 2003 10 21 57 AM Add New Device Dialog 1 Edit the Device Name Use whatever is appropriate for your blender 2 Edit Device Description if desired Any text that is entered here will pop up when the operator holds the mouse over the icon for the device This is commonly known as Tool Tips and can be used to give the operator location information of the device 3 Select the Device Type OS OA OL and OFC A picture is given for help 4 Select the Communications Type ACS AB BD blenders use the Allen Bradley Driver Older HydReclaim blenders and weigh hoppers use the Legacy Equipment with Hynet Driver ACS Mitsubishi blenders use the Mitsubishi Driver and Maguire WSB blenders use the Maguire Driver 5 oelect which features you wish to enable for this device These features are shown in the Available Features box and are self explanatory Page Number 70 Configuring a ACS Allen Bradley Batch Blender Device When selecting a newer AB
7. DATA ITEMS STATUS status status 1 enabled blender started 6 5 0 0 3 alarm number nl11 74 d plc version nz3 0 5 blender start request b3 0 11 b abort batch request ba 078 number of happers n3 3 B hap1 inventory 30 0 J hapz inventar 30 1 10 hop3_ inventory 30 2 11 hap4 inventory 30 3 1z haph inventor 30 4 12 enabled 13 hapb inventory 30 5 13 enabled 14 hop inventory 30 6 15 hope inventar E30 7 b batch inventor 30 35 1r hopl fractional inventory 30 15 16 hope fractional inventor 30 1 7 18 enabled 19 hop3 fractional inventory 30 18 19 enabled 2U hop d fractional inventery 30 13 21 hop5 fractional inventory E30 21 2e hopb fractional inventory 30 21 z3 hop fractional inventory 30 22 24 hope fractional inventory 30 23 4 enabled zh batch inventory decimal parts0 39 25 enabled 26 clear inventor ba 03 z2r pv1 hopl temp recipe value 20 0 z2u pvl hope temp recipe valuel20 1 zd p 1 hops temp recipe value z 3U pv1 hop4 temp recipe vwalue I2 3 3l pv1 hopb temp recipe value 20 4 3 enabled 3z pvl hopb temp recipe value 120 3z enabled 33 pv1 hop temp recipe value b5 34 pv1 hop8 temp recipe value l20 38 pv1l recipe enor message ng z Data Parameters Page The Data Parameters Page is accessed by selecting View Data Parameters from the dropdown menu This page shows all of the available data parameters for each device The status of each of these items is automatically config
8. Device Delete ALL ACS Devices Edit Selected ACS Device Ctri E TIME 4 28 2003 3 38 18 PM s Start Microsoft Word A3 i right click blank are As 43 System Managem Right clicking in the blank white area will bring up these dy AB 3 39 PM Page Number 46 As A3 System Management Software Plant View m x File Edit View Tools Help Blender 1 Edit Device Delete Device ae TIME 4 28 2003 3 33 40PM _ Start Microsoft Word 43 i right click device bm As A3 System Managem TEE sac Right clicking on a device will bring up these As A3 System Management Software Plant View File Edit View Tools Help Add Sheet Change Sheet Name TIME 4 28 2003 10 28 50 AM start add aec device war As A3 System Managem AW 10 28 AM Right clicking on the sheet name will bring up these Page Number 47 Status Bar on A3 The status bar is located near the bottom of the A3 main page A A3 System Management Software Plant View File Edit View Tools Help DAYS 0 20 48 10 UNTIL REPORT NEXT REPORT WILL GENERATE AT 4 23 2003 8 00 00 AM TIME 4 28 2003 11 11 50 AM Start report manager pag As 43 System Managem f 11 11 AM The status bar on the left shows when the next automatic report will generate the bar in the middle always shows the date and time and the bar on the right shows the countdown for the automatic report
9. Hoppers NN Include this device in Report Cancel Limitations with using the Maguire WSB Batch Blender e recipe can be monitored but not controlled e target vs actual batch data is not available These are limitations with the Maguire protocol and blender functionality and not A3 Page Number 80 Checking the Device your about to Add Once you ve configured your device you will be ready to hit OK on the Add a New Device dialog Before the device is added an automatic check is performed to see if the device is responding correctly If the unit is not communicating you will see the following message and should correct the problem before proceeding check your settings A A3 System Management Software Plant View 4 Plant Name Add a New Device r Available Features M Start or Stop Ability iv Clear Inventory Ability 052001 Blender 0S or 67 TN d EUH IP Address Unit is not responding Add anyways onitoi 192 168 015 Y v Change Recipe Ability No Monitor Targets vs Actuals fv Include this device in Report TIME 4728 2003 10 28 08 AM 2 start 5 edit device popup b A A3 System Managem Warning given when device is not detected Page Number 81 You should click No unless you know that the device is not hooked up your setting up the system before the network is in place If the device is communicating the icon will be added on the main pa
10. MAL Ace MesMame Prodat Name F odule La wertet eins ta Eanes ah wiat p a mil My Compe Piores Weisel fin ragi Selber 2007 pa ai My Softee Lr zl Dacre hence 4 mudewWindm Dini SP Coe Gama baig best hd Hl Lco cua eg cher on Hie ran Foe that el beers nr hen dica pea nhe HAC Adder F you davor n not steal ene Heart sl 15942 Tha EU LIT pei E re nct nies Bi ag Deine hp Double click on the unit you wish to program Page Number 35 Confanes Wetec Seelen Enter he jolang reftngt ro configuse tha Dsg Cres SP For oor re Tha raneccck gen can nU cacabiry heros hr ak pe velba apa nets peti T siens Cibi HP safire acbeenahe ally utin DELH Uns te Klang F tl he Ei us Y M Sube Mask ME ME MES 6 ONS Serer Heat Kama Configure the IP as shown above remember that the last digit i in the IP must be unique for each blender here that digit is shown as 11 Be sure that no other blender is using 11 before proceeding Select Scenaro Chick hrough te bet to find the scenano tat best descabes how you mi use your Dig Ore SP connections hom ESSN Tae TST Een Cher UDP Chet Devices pensi devices connect to each other devices to bridge seny data 4 rr p O Custom ress mad crie e Ore Pr e bins n To continue click Wet Click Incoming Connections then Next Page Number 36 u Poros to mote
11. Places L My Documents ig My Computer Details Local Area Connection LAN or High Speed Internet Enabled Intel R PRO 100 VE otep 2 Right click on your Local Area Connection and select Properties i Local Area Connection Properties General Authentication Advanced Connect using BEER Intel A PRO Z 100 VE Network Connection 2 This connection uses the following thems el Client for Microsoft Networks ja File and Printer Sharing for Microsoft Networks ml aas Packet Scheduler Internet Protocol TCP IP 5 en ne Install Uninstall Description Transmission Control Protocol lnternet Protocol The default Wide area network protocol that provides communication across diverse interconnected networks C Show icon in notification area when connected Step 3 Double Click on Internet Protocol TCP IP Page Number 20 Internet Protocol TCP IP Properties n General ou can get IP settings assigned automatically if your network supports this capability Othenwise you need to ask your network administrator for the appropriate IF settings Obtain an IP address automatically Use the following IP address IF address 132 168 Ij en Subnet mask 256 265 455 Use the following DNS server addresses Preferred ONS server Eee Alternate DNS server Step 4 Set your screen to look like this then click OK and OK again Remember that you need to have a
12. Silo 6 Repro Silo Recenvirng Production eoa 2 m u CT ep OP ee z 3 Clear Entire Database Page Number 97 To access double click on the icon of the device from the main page then click on Job Report Manager Blender 1 PLC Version 3 1 EY Made Recipe Change Recipe Batch Size 3 HOPPER 1 SES HOPPER 2 20 00 HOPPER 3 30 00 HOPPER 4 40 00 HOPPER 5 50 00 HOPPER 6 60 00 HOPPER 7 0 00 HOPPER 8 0 00 Inventory HOPPER 1 0 000 HOPPER 2 0 000 HOPPER 3 0 000 HOPPER 4 0 000 HOPPER 5 0 000 HOPPER E 0 000 HOPPER 7 0 000 HOPPER 8 0 000 TOTAL 0 000 CLEAR INVENTORS Current Alarms Alarm LNg Batch Log Blender Click to Start Stopped a Job Inventories Push to and logs will start or clear at this Stop point Job Number Job Report Manager Material Information Job Reference Number for Job that E53 1 will be saved with the tL Job report Click to p Information Finish a Job Resin Product Name and Number Resin F Humber Resin Location be sure to enter in all of dE 5620 Bareback Linear 77620 Silo H5 the data first 2 5621 Bareback Low Density 3521 4 Isitt amp The report 3 5653 Repro nda Repo Slo will be saved 54 ees EV e BM Reewng x v4 at this point p Cancel Done Page Number 98 Sample Reports using Automatic Generation All of the selected reports will
13. Telnet REC To continus chick Meat COM Tet ht t Ts Oe eg Dever Setup Wi Dig Device Setup Wie Click TCP Sockets then next Page Number 37 My Software a eat tt cn a hs hat rn e tate E D 8 Paty we S en 1 Fowadi t i Reference the documentation that came wth your senal device you don AJ know the port settings Te continue click Next 77 start w setup we ea Configure the baud rate to 19 200 for ACS Mitsubishi blenders Configure the baud rate to 1200 or 2400 for Maguire WSB blenders you should use 2400 and modify your blender settings to use 2400 to achieve the best throughput March 31 2000 version 00331X or newer amp ig Device Selup Wizard Mep dhe coria bor son ire upset hos ten deese Zl paises selina vell be peted belore the new pelimgs Mp apple Hii ionize E C ER RET ne The Dag Corm SP vais MAC ch ATE SED 273 34 d wl be coru vath tha laksang A geige Helvsak Satiraj IP Adde 092 188 0111 F 1 225 2850 Duel mit meom LOO DNS Server MAUD Dorman sone Hirtt arme cruoris Sena Pos 1 Incoming TEP Socket Corridor Cthet itleri deaa cona oss the n he I thee device allached In tha penal port Data can be send andescered Used lor Device Hanagement Alia kneem az TOP Server Smia Setinar Dud Aste 13200 Ta seve the conhiguistien report bo diak fer biure reference click has To save theee settings lo t
14. a specified location for either backup purposes or for distribution to others who have A3 and would like to look at the same data that you are Another new feature is the ability to load a configuration file from a specified location for restore purposes or to quickly program a new computer Tip of the Day Tip of the Day is a small window that is displayed when the program boots The operator can scroll through the tips by selecting Next Tip Enough information is given in these tips to train most operators on the software This feature can be turned off by deselecting the Show this at startup box If you desire to turn it back on just select Tip of the Day under the Help menu Page Number 9 What s new in version 2 0 Sterling SGB Communications Driver Now you can communicate with any SGB blender The limitations are the same as the with the AEC OS OA blenders Up to 1000 units can be networked over an Ethernet network The system can also communicate with both the AEC units and the Sterling units at the same time over the same network cable What s new in version 4 0 Central System Inventory Feature This new feature allows a manager to program a database with up to 1000 resin product names and 1000 resin locations such as silos Once programmed an operator can select these resins and locations from a drop down menu and the system will keep track of material usage for each ingredient and location giving you
15. be reproduced stored transmitted or distributed without the prior written consent of ACS 2003 Revised November 6 2008 Page Number 3 Overview The A3 System Management Software program is a Windows based program that allows you to control and monitor up to 1000 ACS devices Currently you can use A3 with the following devices e ACS Allen Bradley Batch blenders ACS Mitsubishi Batch blenders Older OS Blender HydReclaim Proprietary Controls Older OA Blender HydReclaim Proprietary Controls Older OL Blender HydReclaim Proprietary Controls Older OFC Weigh Hopper HydReclaim Proprietary Controls Maguire WSB Batch blenders When using the system to integrate older proprietary units you will need the optional USB RS422 485 module and must limit the number of devices to 255 this is a limitation of RS422 and not the A3 package e Monitor the status of all blenders started stopped alarming etc Control the status of all blenders start and stop Read and Write the recipes to all blenders Built in recipe book with unlimited number of stored recipes Built in Alarm log that will log up to 1000 alarms for each blender Built in Batch Data log that keeps track of actual weight for every batch up to 5000 batches Monitor the inventory of all materials in all blenders e Resin Name and Location Database allows user to create up to 1000 resin names and locations These entries are then available for selection through the d
16. blender models and software versions and controller info AB Mitsuibishi or Proprietary and the person that networked the devices when you call Page Number 6 Frequently Asked Questions How many units can A3 integrate 1000 units which 255 can be the older proprietary units What minimum software version do need to have on blenders and weigh hoppers in order to communicate with A3 ACS Allen Bradley Batch software gt 3 2 ACS Mitsubishi Batch software gt 1 2 Older Proprietary HydReclaim OS OA software gt 700A Older Proprietary HydReclaim OFC software gt 5 5A Older Proprietary HydReclaim OL software gt 10 5A Maguire WSB Software gt 80609A 4 14 1998 NOTE if being used with ACS Allen Bradley batch blenders you need to purchase the Ethernet option for each blender if it wasn t purchased when you bought the blender NOTE if being used with older proprietary equipment you need to purchase the USB RS422 485 Legacy Module for the PC which will allow you to communicate only one module required for entire system NOTE if being used with ACS Mitsubishi batch blenders you need to purchase the Ethernet option for each blender if it wasn t purchased when you bought the blender NOTE if being used with Maguire WSB batch blender you need to purchase the Ethernet option from ACS for each blender What are the system requirements for the PC PII 750MHZ minimum processor speed P4 recommended Windows XP
17. end to the blenders Overview This chapter is to give you information on screen access and details Page Number 54 Virtual Control Panel The virtual control panel is accessed by double clicking on the icon of the blender from the main page A A3 System Management Software Plant View Ele File Edit View Tools Help TIME 4 28 2003 10 25 46 AM TE start 5 new_sheet_added b As A3 System Managem 4 Tfi 10 25 AM Page Number 55 Blender Name and Software Version Recipe Entry Mode Push to change recipe Push to go to Recipe Book Current Recipe Values Push to Accept New Recipe Push to go to the Alarm Log Push to go to the Batch Log Indicates running or stopped Push to start or stop blender Push to immediately stop blender Blender 1 PLC Version 3 1 Inventory HOPPER 1 111 001 HOPPER 222 002 HOPPER 3 333 003 HOPPER 4 444 004 HOPPER 5 555 005 HOPPER 5 666 006 HOPPER zer 007 HOPPER 8 885 006 TOTAL 3996 036 Batch Size 3 HOPPER 1 HOPPER 2 20 00 HOPPER 3 30 00 HOPPER 4 40 00 HOPPER 5 50 00 HOPPER B 60 00 HOPPER 7 0 00 HOPPER amp 0 00 ACCEPT RECIPE Current Alarms Current CLEAR INVENTORY Inventory Push to clear Alarm Log the inventory Batch Log Blender stopped Fush to Start or stop Abort v Done Alarms Current Active The Virtual Control Panel
18. purchase a standard CAT5 cable that already has the ends connected and a standard hub or switch this can be purchased from Best Buy Circuit City CompUSA or Radio ohack At the blender power up the hub and connect the blender using the new cable to one of the middle ports on the hub say port 3 on a 4 port hub Examine the LINK light and if it is now clear then the problem is definitely in your original cabling This same test can be performed on the PC and PC cable All PC Ethernet cards have a LINK light as well Establish the LINK light on all devices before proceeding otep 6 If you have LINK lights on all units including the PC and no fault link lights on the PLCs but you still cannot establish communications then we need to check the PC s network properties If this computer resides on your plant network and was set up by your IT department then you will need to involve them for further assistance with your problem Instruct your IT department that the blenders must have a fixed IP but the PC can have a dynamic IP All subnet mask for the PC and the blenders needs to be 255 255 255 0 They might not have the startup script correct for your PC If the blenders and PC all reside on a separate network that has nothing to do with your plants LAN then we need to check the PC s network Page Number 121 properties see Chapter1 Networking instructions for the ACS Mitsubishi Batch Blender for step by step Problem You ve configur
19. tart we My Computer My Software p Programs e Digi Device Setup Wizard E33 Incoming Connection My cena device accept ancormng connection hore cher ya decem LI D u SideWinder DP COMM Di 1 Gem Your Vest hi e Hr omen Metauth Connector G Kecr e n fottiefek Welcome roa Tha B Discover Device Conhgue Device Co Reason COM Port Redirection Mir application requies COM pon to communicare wilh my sesal Grace Incoming Network Connection Othe m rie mA A rpm Device Data Colecten Server an Management To contiene chick Next Med of Honor AB Medal of Hone OB m out to Propet eon j be Dig Device Setup Wir Click Incoming Network Connection then next e sx Finnet Muertos to tether mehe act d Maroselt nn My btw Prog sra Income Network Connection Ohe aptherna devices connect to my vena denice uang nehotkang protocols En Digi tent detoweng PCP Socket Consection t m gt Fm Battlefield Welcome 190 Bef Welcom Ditcorm Device TEP Sockets Conliywe Derice Save Settings Dither potiti dieit on the damak Cie Vo ay til device ug Feushed TCP Sockets Other systnrnesdevices Connect reti the network to my senal device Dala can be tard wndrecaned Doce Manager TCP m C UDP Sockets nensi device necervez data hon he network re one or multiple syrtemt devicer on CO Telnet Other ud deve 215 leiet to Manual Ravera
20. to connect the blenders or PC to the uplink port on the hub or switch and to also use straight through cables Configuring the Digi One IA or Digi One SP Ethernet modules Page Number 33 Before the modules can be used they each need to be programmed with the IP Address You will need to have the module wired to 24VDC if it is DIN rail mount or plugged into the wall receptacle if a wall transformer has been provided You must also connect the module to your Ethernet network If you have a separate 24VDC power supply you can program these modules without installing them into the blender and they will retain the programmed address Locate and install the CD that came with your Ethernet module If this has been misplaced visit www digi com to download the installation program After setup starts you will see the following screen baad tin Setup Wizard TEPEE ALL ARE i tha bh Medi io tel up lel yet Spar pcena md Bre conbgunfion w N Hean yi conbra make rae The device in ROMS DINI DEM ania ill er TEE NEN DGE M pou have a vepelen1 device d ic recommended io Ariea Hh Eihera gorl or mahal deese conibguralon Ones er LAM Lr en thee whia label on Ha balks on aci Page Number 34 8 3 Internet onaz to Opre notv adent Mn uw M Compute ww Cm mn Discovem Device Locate you Dap device on the mach Met below select the Gece you eut doves baed 6 Here i mde ei oen kerap rte wo pr Car in ren Need n TT Found Des Wade
21. unique IP for all of your blenders and for the PC For example you could use the following scheme PC IP gt 192 168 0 1 Blender 1 IP gt 192 168 0 10 Blender 2 IP gt 192 168 0 11 Blender 3 IP gt 192 168 0 12 Page Number 21 Running the Cables and Hardware to interconnect they system Depending on your expertise and preference you can either purchase CAT5 cables to length with the connectors already attached to both ends This makes it somewhat difficult to get the connector into the blender panel because of the head on the cable but not impossible Either way you will need to have some sort of Hub Switch or Router to interconnect all of the blenders with the PC If you already have a plant LAN then you should just run drops to each blender and one to the PC from your main network If this will be a stand alone system then you can purchase a hub or switch to accomplish the same thing A 5 port hub cost around 40 and is shown below 5 port Hub Page Number 22 Uplink Port to Existig LAN optional 182 158 0 1 182 158 0 10 182 158 0 12 182 458 011 Sample network Be sure not to connect the blenders or PC to the uplink port on the hub or switch and to also use straight through cables Page Number 23 Networking instructions for the ACS Allen Bradley batch blender Installing the PLC hardware The first step is that you must install the Ethernet module and cable into every PLC You will need an
22. 168 0 12 etc Notice how I m only changing the last digit Each digit can be as high as 255 IP addresses are either Static or Dynamic Static means that the device will always have the same IP dynamic means that the IP will be given to the device by a DHCP server another computer The blenders IP is always static and cannot be dynamic when using with A3 Have your system administrator set aside a group of static IP addresses for you to use Page Number 25 Networking instructions for the older proprietary Hydreclaim embedded equipment Installing the required USB RS422 485 adapter on the PC The installation is very easy 1 Remove the USB adapter from the box and plug it into a free USB port on the PC 2 Windows will find the hardware automatically keep clicking next until you see finish Windows will find 2 separate items when you plug the adapter in so you will have to repeat this step a few times until it says that your new hardware Is ready to use Wiring the interconnection cables You will need to wire a Belden 8103 type cable 2 twisted pair shielded between the PC and the first blender then from the first to the third and so on until you reach the end This network cannot be a Star type network A Start type network is where you have several branches coming out of a junction box The distance between the Tap and each blender cannot exceed 1 foot The Tap is the location at which th
23. A Device ODI CCIS sc einem 69 Working withthe A3 RECIPE Book a a ae dena 84 Working withthe Rep rt Managers nee RN ei 92 Work he wiih the confteuratton II een ende 106 Workinbp withthe Ass yten Log Hle uui iue eeu theo ee arto ae 108 Trouble SDOOLIH Poe ere ei ese een kernel 111 SELVICE NOS esi Sars aee el Geant aia 124 SEVICE NOLES dede edid edendo seien 125 Page Number 2 Preface The information in this manual is based on current industry sources and believed by the author to be correct and as complete as possible at the time of printing It is possible that later changes have been made by the manufacturers of ACS equipment and are not included in this publication Although every effort has been made to insure total accuracy ACS cannot assume any liabilities for omission errors or changes that have occurred in the production of this manual It is not possible to anticipate all possible conditions in which this machinery may be utilized or maintained or serviced It is not possible to provide cautions for all possible hazards Operators and maintenance personnel should use standard and accepted operating procedures and precautions ACS accepts no responsibility for the damages resulting from the utilization of the information in this manual Please note that this is a service manual it is not appropriate for use by system operators Copyright The material in this publication was compiled for the use at ACS No part of this manual may
24. Access the Virtual Control Panel by double clicking on the device from the main page Click on Recipe Book Click on the AVAILABLE RECIPE that you want to load Click Load Click Accept Recipe and the recipe will be loaded only on the Newer AB OS OA blenders the recipe is already loaded at this point for the Older Proprietary blenders If the recipe is not correct an error message will be given that will prevent it from loading The following are error messages given when using the newer AB OS OA blenders Blender 1 PLC Version 3 1 Inventory HOPPER 1 111 001 HOPPER 2 222 002 HOPPER 3 333 003 HOPPER 4 444 004 HOPPER 5 555 005 3 HOPPER 1 BE HOPPER 2 20 00 HOPPER 3 111 00 HOPPER 4 40 00 Entry over HOPPER E 666 006 HOPPER 777 007 HOPPER 8 898 008 TOTAL 3996 036 CLEAR INVENTORY 100 HOPPER 5 50 00 HOPPER 5 60 00 HOPPER 7 0 00 HOPPER 8 0 00 Current Alarms Batch Log Blender Stopped Push to Start or Stop Entry over 100 error message Page Number 88 Blender 1 PLC Version 3 1 Inventory HOPPER 1 111 001 HOPPER 2 222 002 HOPPER 3 333 003 HOPPER 4 444 004 HOPPER 5 555 005 Batch Size 3 HOPPER 1 0 00 HOPPER 2 20 00 HOPPER 3 111 00 HOPPER 4 40 00 Total not HOPPER E 666 006 HOPPER rrr 007 HOPPER 8 855 008 TOTAL 3956 036 CLEAR INVENTORY 100 HOPPER 5 50 00 HOPPER 5 60 00 HOPPER 7 0 00 HOPPER 8 0 00 Current Alarm
25. C INC TIC IC CIC CIC ICT ICT NC CCCII ICT RN NS RN C Recipe Info report same for auto or manual just name would be different This log is generated every time the operator changes the recipe Once a recipe change is detected this log records the inventories and recipe just prior to the change Page Number 104 2003_04_28_13_00_00 Blender 1 batch data log log Notepad PEE File Edit Format View Help 4 28 2003 10 46 37 AM 1 002 1 9987 3 002 4 5 001 6 001 7 002 8 001 44 28 2003 10 47 16 AM 1 001 1 9888 3 002 4 002 5 6 002 a 4 28 2003 10 52 50 AM 1 2 2 9908 4 001 4 8008 G 7 8 44 28 2003 11 26 51 AM unos 2002 2 990 un 5 009 25 neg O pop eget Batch data report same for auto or manual just name would be different Page Number 105 Chapter Working with the configuration file This chapter explains e What is the configuration file Setting the system back to defaults saving the configuration Opening a previously saved configuration file The location of the configuration file Overview This chapter will help you understand how to manage the A3 configuration file What is the configuration file The configuration file is a file that is used by A3 to remember your preferences and settings This is what makes your system different from the next This file can be backed up so that if you purchase a new computer you can quickly configure your A3 s
26. Ethernet Module A0563939 1761 NET ENI and a Cable for the Module A0565898 1761 CBL AMOO per blender The module snaps in to the DIN rail just to the right of the Mixer Motor contact and the cable snaps into the module and PLC 3 Lou Es m f j o i E i OF E s uy D nu 9 yy 4 EM my my oe OE Tp vay We Cue 7 ar L i slo sues Canto fast Car Gata fae fe al klk i alolololo T ael jejejejejeje li Ei i 4 z LM 1 You will also need to make sure that you are running at least 3 2 blender software this can be found on the blender under Setup PV config The final thing to do on the PLC is to make sure that the DCOMM light is enabled If it is not then remove the snap cover from the PLC and hold in on the COMMS recessed switch until the DCOMM light is on Page Number 24 Configuring the PLC You will need to go to Network Setup found under Setup on the blender and set the appropriate IP address The SUBNET mask should be set to 255 255 255 0 Make sure the Ethernet gt enh is enabled dn 9 5 s i ar or Stop 6 HHH AA Dis able nu US ing BOOTE erz or Mitsubis Ha Dis lan Yo zt ena EEE Ethernet Ri reas Crane chanse virt take otep 3 set appropriately What is an IP address An IP address is a unique address for each device that is on your network The number can be any number other than 0 0 0 0 Some examples are 192 168 0 10 192 168 0 11 192
27. F Communications Pork COM E Communications Pork COM Pe Kontron LISB RS422 485 Part Coh Processors e Sound video and game controllers Step 3 Expand the Ports and observe the Kontron Port If you do not see the Kontron entry then see Networking instructions for the newer AB OS OA Blender Page Number 78 Configuring an ACS Mitsubishi Batch Blender Device When selecting SGB Blender under Device type you will be given a few extra entries to complete Add a New Device Device Mame Device Description gt Available Features Blender 2 Start ar Stop Ability m Monitor Inventory Device Type r Communications Type SGB Blender Clear Inventory Ability Log All Alarms le Monitor Running Recipe 192 168 0 10 Change Recipe Ability amp 4 4 4 amp I 4 Monitor Targets vs Actuals 4 Include this device in Report Cancel Page Number 79 Configuring a Maguire WSB Batch Blender Device When selecting Maguire WSB using Device Type you will be given a few extra entries to complete You will need to select the features you want as well as configure how many hoppers to show Add a New Device Device Name Device Description Available Features Blender Monitor Inventory Device Type Communications Type Magure Diver CU IF Address 192 168 0 10 Clear Inventor Ability Log All Alarms Monitor Running Recipe 41 SI i id I x Number of
28. ILO Number Uptime Percentage Manually Generated Inventory and Uptime Report Page Number 102 File Edit Format view Help 4 14 2003 8 08 24 AM HOPPER 7 Gut of Material 42 14 2003 9 15 32 AM HOPPER 7 Gut of Material CLEARED 4 14 2003 9 33 50 AM INVENTORY CHopl 12121 Hope 2323223 Hop3 343434 Hopd 454441 4 14 2003 8 33 50 AM Hop5 565656 Hop6 6676767 CHopr 78778 Hops 898989 TOTAL 10944412 i 4 14 2003 8 33 50 AM INVENTORY CLEARE Alarm Log same for auto or manual just name would be different It is important to note that whenever the inventory is cleared either at the blender or the PC an entry of what the inventory was prior to clearing is added If the data in the inventory and uptime report is short of what you expect then check the alarm log for the device to see if the inventory was cleared sometime into the report Page Number 103 BILE 4 23 2003 11 09 26 am Inventory Hopl 111 123 Hop2 23 Hops 123 Hopd Los Hops i Hope Hop Hops 0 TOTAL Q Recipe EZ Mode Batch Size Batch Size 2 2 2 Hapl Ton Hope Hops Hope Hops Hope Hopr Hops 0 00 TRACHEA eee ee ee eo a ee ee RR ET RE 4 23 2003 11 19 Inventory Hop Hope Hops Hope Hops Hope Hopy Q Hope n TOTAL Recipe EZ Mode Batch Size Batch Size 5 Hopl Run Hope HORS s Hope Hops Hope Hop Hope 0 00 UL C
29. OS OA device you will also need to enter in the IP Address for the blender This IP is a fixed IP and must be unique for every device that resides on the same LAN Ethernet Network Some examples are 192 168 0 10 192 168 0 1 192 168 0 2 etc You will also need to program the blender with the same IP address Below is a the blender s IP address and Subnet Mask under Network Setup EE ETE CLEA lb Disable if using BOOTP Serwers or Mitsubishi Display Yo st send the send data if you make qs changes De ehe change wi Fake Module sce Step 3 set appropriately Page Number 71 You will also need to set the SUBNET MASK for the blender This needs to be set to 255 255 255 0 Once configured you will need to make sure you have connected the Ethernet Module and Cable see Networking instructions for the newer AB OS OA Blender for details Finally touch Send Ethernet Config to Module and monitor the Ethernet module on the blender After about 30 seconds the fault light should stay off and the LINK light should be green Page Number 72 Here are some quick trouble shooting answers Power light on module is off Check that the Cable External switch is set to Cable and that you are using the correct cable see Networking instructions for the newer AB OS OA Blender The module gets power from the PLC Fault light on module is on Check to ensure that the DCOMM light on the PLC is
30. PM Autocan R14 pt M Microsoft Money 2002 All Programs gt o My Documents e My Pictures e My Music T My Computer a My Network Places B Control Panel O Help and Support Search 777 Run Keep in touch with HP PR Log OFF TO Turn Off Computer iE winxp_system_check step 1 Click start and left click on My computer A 4 amp 3 System Managem Page Number 13 T My Computer File Edit View Favorites Tools Help Bac gt d Pr Search is Folders Gi Files Stored on This Computer System Tasks a a 7 View system information Shared Documents Owner s Documents 15 Add or remove programs G Change a setting Hard Disk Drives Other Places amp My Network Places LJ My Documents Shared Documents Devices with Removable Storage H 314 Floppy A 43 Software D G Control Panel Details HP PAVILION C VD DVD Drive E Local Disk gt File System NTFS Free Space 81 6 GB Network Drives Total Size 107 GB L File Server on SERVER Ss Kpsoftware 2 Step 2 Click on C and examine Free Space in the lower left corner under Details It should be at least 30 GB You should also see that you have a working CDROM drive on this page If the system meets all of the requirements except the Service Pack 1 requirement then you will need to install the Windows XP Service Pack 1 from the A3 CD Follow the instructions
31. PPER 8 855 008 TOTAL 3956 036 CLEAR INVENTORY 100 HOPPER 5 50 00 HOPPER 5 60 00 HOPPER 7 0 00 HOPPER 8 0 00 Current Alarms Alarm Log Batch Log Blender Stopped Push to Start or stop Total not 100 error message Page Number 60 The following are error messages given when using the older proprietary blenders Blender 3 Inventory HOPPER 1 0 0 HOPPER 2 0 0 HOPPER 3 0 0 HOPPER 4 0 0 Batch Size 2 HOPPER 1 20 00 HOPPER z 20 00 HOPPER 3 20 00 Recipe Not HOPPER 4 40 00 otaling 100 TOTAL 0 0 CLEAR INVENTORY Current Alarms Blender Stopped Push to Start or stop Recipe Not Totaling 100 Page Number 61 The following is the successful message given when using the older proprietary blenders Blender 3 Inventory HOPPER 1 0 0 HOPPER 2 0 0 HOPPER 3 0 0 HOPPER 4 0 0 HOPPER 1 20 00 HOPPER 2 20 00 HOPPER 3 20 00 HOPPER 4 40 00 Transterred TOTAL 0 0 CLEAR INVENTORY Current Alarms Blender Stopped Push to Start or stop Recipe Transferred message Page Number 62 Recipe Book AMAILAB LE RECIPES click on one RECIPE DATA BE NUMBEROFHOPPERS 8 my recipe ar DEVICE TYPE OS OA4Blender vl RECIPE MODE EZ Mode Batch Size EE EN HOPPER 1 i HOPPER 5 HOPPER 30 HOPPER 4 5 HOPPERS 10 HOPPERS 5 HOPPER 2 HOPPER 2 E Delete Delete All Save Mew C
32. Page Number 115 step 5 If all of the previous steps have been satisfied then examine the LINK light on the Ethernet module It should be green If it is not then first make sure that the Ethernet cable is hooked up at both ends Remember that you must use straight through standard CAT5 cables when going between the blender and a hub or switch If you are trying to go directly from the blender to a PC without using a hub or switch l d then you need to use a Crossed Ethernet cable At this point you more than likely have a cable problem and should test this To test purchase a standard CAT5 cable that already has the ends connected and a standard hub or switch this can be purchased from Best Buy Circuit City CompUSA or Radio Shack At the blender power up the hub and connect the blender using the new cable to one of the middle ports on the hub say port 3 on a 4 port hub Examine the LINK light and if you have it now then the problem is definitely in your original cabling This same test can be performed on the PC and PC cable All PC Ethernet cards have a LINK light as well Establish the LINK light on all devices before proceeding Step 6 If you have LINK lights on all units including the PC and no fault lights but you still cannot establish communications then we need to check the PC s network properties If this computer resides on your plant network and was set up by your IT department then you will need to involve them for furthe
33. Push to go back to the main display Page Number 56 Current Recipe Current Inventory Push to clear the inventory Current Alarms Push to go to the Alarm Log You can operator the buttons as if you were in front of the real Blender Name and Software Version Strobe Flashes control during Alarm auti 1 Software Version 10924A Recipe REGRIND 16 0 eile Blender Thumbwheels ADDITIVE 32 8 Stopped update as operator changes the recipe VIEW RECP BTCH FAST Inventory 4 w 3 REGRIND 0 S E NATURAL 0 e ri COLOR O REG HERNE 0 NAT u 4 C 5 COL oO C E B 5 g u r N TOTAL 0 ADD R 8 x C CLEAR INVENTORY o CE HOLD DUMP D 2 Curent Alarm MIX ALRM Job Report Manager The Virtual Control Panel for Maguire Blenders 4 larm Log LED readout shows what the real blender shows Page Number 57 Blender Name and time of log Blender 1 PLC Version 3 1 ALARM LOG 4 28 2003 11 27 25 AM NVENTOR Y Hop 111 NVENTOR Y Hop5 555 iM INVEN iM INVEN OPPER 1 Out o teria OPPER 1 Out o terial l 222 Hop3 333 Hop4 444 008 Hop2 Hop6 666 Hop 777 Hops Alarm History up to 1000 alarms per blender Push to clear the log Click to send log to the printer PRINT SAVE Click to go back to Click to save the log to a specific location Virtual Control Panel
34. The Alarm Log EZ Mode Recipe Batch Size 5 HOPPER 1 HOFFER Z 120 00 HOPPER 3 30 00 HOPPER 4 140 00 HOPPER 5 150 00 HOPPER E 160 00 HOPPER 0 00 HOPPER 5 0 00 Change Recipe Page Enter new values and hit Load or cancel to quit If a box shows 777 then this is the automatically calculated entry and does not need to be entered On newer AB OS OA blenders you then need to hit Accept from the Virtual Control Panel to finish loading the recipe Page Number 58 If the recipe is not correct an error message will be given that will prevent it from loading The following are error messages given when using the newer AB OS OA blenders Blender 1 PLC Version 3 1 Inventory HOPPER 1 111 001 HOPPER 2 222 002 HOPPER 3 333 003 HOPPER 4 444 004 HOPPER 5 555 005 HOPPER 1 sees HOPPER 2 20 00 HOPPER 3 111 00 HOPPER 4 40 00 Entry over HOPPER 6 666 006 HOPPER 777 00 HOPPER 38 898 008 TOTAL 3996 036 CLEAR INVENTORY 100 HOPPER 5 50 00 HOPPER 5 60 00 HOPPER 7 0 00 HOPPER 8 0 00 Current Alarms Batch Log Blender Stopped Push to Start or Stop Entry over 100 error message Page Number 59 Blender 1 PLC Version 3 1 Inventory HOPPER 1 111 001 HOPPER 2 222 002 HOPPER 3 333 003 HOPPER 4 444 004 HOPPER 5 555 005 Batch Size 3 HOPPER 1 0 00 HOPPER 2 20 00 HOPPER 3 111 00 HOPPER 4 40 00 Total not HOPPER E 666 006 HOPPER rrr 007 HO
35. a useful report at the end of the day or whatever interval you specify Maguire WSB Communications Driver Now you can communicate with Maguire WSB batch blenders Up to 1000 units can be networked over an Ethernet network The system can also communicate with all available brands at the same time Page Number 10 Chapter 1 Installing A3 This chapter explains how to install A3 from your CD to your hard drive e System requirements e Step by step installation instructions e Starting and exiting A3 software Overview A3 software installs directly from the CDROM to your hard drive The CD also contains the Windows XP Service Pack 1 drivers for the USB RS422 485 Legacy module required when integrating older proprietary equipment Internet Explorer 6 0 upgrade and this manual System requirements PII 750MHZ minimum processor speed P4 1 8GHZ recommended Windows XP operating system service pack 1 must be installed Internet Explorer 6 0 30GB minimum hard drive space 60GB recommended 128MB minimum RAM 512 MB DDR Ram recommended CDROM drive CD RW recommended Video card capable of 1024x768x16bit color 32bit color recommended 10Mbps Ethernet 100Mbps recommended 1 USB slot otandard Ink Jet Printer if you are going to print the reports Page Number 11 Installing A3 Before you start the installation you will need to be logged in as the administrator and you will need to close all programs that are runnin
36. allation problem Problem During the installation of the A3 software you receive a message saying that some of the files on your PC need to be updated and then asks you to reboot After rebooting and running the installation again you receive the same message Solution The problem is that your PC does not have Windows XP Service Pack 1 installed This is an update from Microsoft and must be installed first See Chapter 1 Installing A3 for a detailed solution At this point you should thoroughly read Chapter 1 and follow every step Hemember to always check that your PC meets the requirements or you could be wasting time Problem After inserting the A3 CD into your PC the installation program does not automatically start Solution Auto Play is not turned on for your PC To run the installation just click Start then click My Computer double click on your CDROM drive where the A3 CD is inserted and the installation will then run Problem You receive a message Unable to Read Disk after attempting to run the installation from the A3 CD Solution Try the CD in another computer If it runs on another computer then there is a problem with either your PC or CDROM drive If it doesn t and you have checked that you are running Windows XP then it is possible you have a defective disk Consult the factory to receive a replacement CD Page Number 112 How to trouble shoot a PC problem Problem Your software installation went
37. ancel v Recipe Book The recipe book can store an infinite number of recipes only limited by your hard drive size see Working with the Recipe Book Page Number 63 Batch Data Log STATISTICAL DA Se AERE SHOW THESE HOPPERS MIN MAX AVERAGE STANDARD DEVIATION Refresh OPPER1 0998 1 002 10000 X 00073 OPPER2 1 998 2002 1 9998 0 00171 OPPER3 2398 3002 30003 000200 OPPER 4 4 000 4002 40008 000095 OPPER5 4998 5002 50003 X 0073 OPPER amp 5 998 6002 60003 34m o OPPER 7 000 7002 70008 00096 OPPER8 8 000 8002 s0008 000095 HH 2 an fa g co oO m 5 an wD w 2 22 24 25 28 Batch Data Page The Batch Data Page shows the actual weight of every component of every batch made up to 5000 batches Clicking on the Show these Hoppers boxes only effects what is displayed and does not effect the data in the log The graph is automatically scaled for the hoppers you have chosen to be displayed To reload the graph click Refresh If the recipe hasn t been changed then the STATISTICAL DATA section can be very useful in determining the performance of your blender and for trouble shooting Page Number 64 Umit Uptime Percentage Blender 1 50 EN Blender amp 0 estar Blender 3 0 alculation Uptime Data Page The Uptime Data page is accessed by selecting View Uptime Data from the drop dow
38. be saved in the path selected under the Report Manager The name of the report will be date amp time stamped for reference Below are some sample reports System Inventory Resin Product Hame Resin Location Amount Hb43 Hexene LLDPE 547 699 Silo 1 547 699 5640 Liner LDPE 32 046 Silo 2 232 046 5655 Clarity LOPE 44 147 Silo 3 44 147 MH RM MME MME MRE MRE MEEKER RE KHENHENSENSEN Silo H4 36 906 5660 ctene 36 906 Silo 5 696 8 PRINT 5620 Bareback Linear 696 9 Silo 6 13 526 REPORT 5621 Bareback Low Density 13 526 Repro Silo 34 44 5653 _ Repro 34 44 Receiving 66 054 a B635 EWA 66 054 Production 0 5545 Slip 5540 Anti Block 5537 Pink Anti Stat 8535 Clear Anti Stat 5536 Amine Free FAS Abe Matallacine 5495 Dark Green 5496 Black 5500 Medium Blue p501 Baby Blue 5503 Carolina Blue 5505 Brown 5510 Buff 5515 Red 5520 white 5525 Leaf Green 8530 Yellow 5532 Blue VL 5534 Clear VEI 5533 Yelow WEI 5539 Sunblack Ul 5550 Mint Green 5555 Pink 5560 Orange 5565 Grep oo oy yo oyoyoyyoy yoy oyoy oy yoyjyoayoay yoayoyo mm Total System Inventory 1972 418 Page Number 99 7 My Reports Directory File Edit View Favorites Tools Help File and Folder Tasks EJ Make a new Folder c Publish Ehis Folder to Ehe Web Other Places ae File Server on SERVER Kpsoftware Zi My Documents Shared Documents My Computer a My Network Places Details My Reports Directory Fi
39. connect Network Drive Package amp Deployment Wizard z Show on Desktop LEIH Autocan R14 x M Microsoft Money 2002 All Programs gt Keep in touch with HP JP Loa Off Turn Off Computer untitled Paint A 4 amp 3 System Managem Step 1 click start right click on My Computer then click P m 1 33 PM roperties System Properties System Restore Automatic Updates Remote General Computer Name Hardware Advanced Add Hardware Wizard Ed The Add Hardware Wizard helps you install hardware Add Hardware Wizard Device Manager The Device Manager lists all the hardware devices installed on your computer Use the Device Manager to change the properties of any device Hardware Profiles Hardware profiles provide a way for you to set up and store different hardware configurations Hardware Profiles C Step 2 Click the Hardware tab and then click Device Manager Page Number 77 Device Manager File Action View Help Ed E eb EP mu STATIONI 3 Computer Tw Disk drives E Display adapters DYDICD ROM drives Floppy disk controllers A Floppy disk drives Human Interface Devices IDE ATAJ ATAPI controllers x IEEE 1394 Bus host controllers 28 Keyboards t Mice and other pointing devices L5 Modems E Monitors B8 Network adapters Ports COM amp LPT
40. ct Tools Options Options F Closing the 43 program Deleting any 43 Data Object Starting or Stopping a device Changing the recipe of a device Deleting 4 stored recipe Cancel Cleaning Inventory Clear L earing any Log Dk Options VetivngActon Sec Stop saving data when Hard Drive Space is less than the following 2000 ME Cancel OF Options Veting cion Had Dive Operator must enter USER PASSWORD for the following actions Closing the 43 program Masher Password Changing 43 setup User Password Starting or Stopping a device Changing the recipe of a device Deleting or Saving a stored recipe Cancel Cleaning Inventory Clear L earing any Log Dk Page Number 52 Verify Action Options These options enable or disable the Are you sure prompts after certain operations Hard Drive Options This option allows the user to configure the minimum allowed hard drive space to allow saving The minimum value that can be entered here is 2000 MB 2 GB Security Options These options enable or disable password protection on certain operations Once password protection is enabled the operator must enter in the user password in order to perform the operation You will be asked to enter in the master password in order to access this tab The default Master Password is 3145348 and the default User Password is 5413 These can be modified to whatever you desire If you change either
41. e Number 17 Starting and exiting A3 To start A3 1 From the Start menu click Programs 2 Select ACS Software and click A3 System Managem 4 Internet WeatherBug Explorer LUE H9 My Computer ar Windows Catalog Windows Update Set Program Access and Defaults Winzip New Office Document Open Office Document Accessories ATI HydraVision ATI Multimedia Center Detto IntelliMover Owner Command Promp Calculator hp center HP RecordNow hp tools InterVideo WinDYD Microsoft Works My Movies My Photo Center E Release Notes Microsoft Visual Basic A E Shortcut to A3 exe Quicken Financial Center Real Startup Studio Version 7 Package amp Deployme Wizard WeatherBug gag amp ggggmgSggggSsS vnseees25 WordPerfect Office 2002 4 D oe Ies Acrobat Reader 5 0 EMusic amp M Encarta Online Deluxe Internet Explorer BB MarketBrowser Y Microsoft Money 2002 Paint All Programs To exit A3 Microsoft Works Move Your Stuff WA MSN Explorer 5 Outlook Express y Remote Assistance windows Media Player Fi AutoCAD R14 Fi AutoCAD R14 0 Uninstall e Codemasters Fi ExpressPCB MM McAfee Fi Micro Cap Evaluation 7 Fi Microsoft Hardware Fi QuickTime Fi Rockwell Software T WinRAR e Winzip fm ACS Software e Automated Solutions Activex Fi Axialis Programs e Cimquest m GMS INGEAR ActiveX Controls e Microso
42. e cable passes by the blender before proceeding to the next blender To connect the cable to each blender you will need 1 DB9 Male solder type connector To connect the cable to the PC you will need 1 DB9 Female solder type connector The Tap can be made in several different ways Some solder 2 wires into each solder cup this is difficult and can easily be done incorrectly while others solder 1 set of wires to the DB9 Male and connect these wires to 2 other sets using a standard terminal block 4 connections that is inside of a j box The third method is to purchase pre made Taps from Black Box Corporation part number FA149A cost around 22 each and can be ordered from www blackbox com Page Number 26 The pin outs for the cables are as follows PC to 1st BLENDER PIN9 PIN4 PIN1 PINS PIN2 PIN8 PINS PIN9 BLENDER to BLENDER PIN4 PIN4 PINS PINS PIN8 PIN8 PIN9 PIN9 It is best to ring out every pin on every connector to ensure that it is wired correctly and that there aren t any shorts prior to connecting the cables to each blender Damage to your blenders can occur if you ve wired this incorrectly ALL CABLES MUST BE RAN IN CONDUIT Page Number 27 Networking instructions for the ACS Mitsubishi batch blender Installing the PLC hardware The first step is that you must install the Ethernet module and cable into every PLC You will need the Mitsubishi FX2N 232 BD board added to each blender an Digi One IA Ether
43. e linked together through the World Wide Web system will handle up to 1000 blenders up to 255 older units can make up the 1000 units e System can be custom configured with the customers name plant locations and blender line names LIMITATIONS FOR LEGACY HYDRECLAIM DRIVER e Alarm name and logging not available e Target vs Actual data not available LIMITATIONS FOR MAGUIRE WSB DRIVER e Recipe can be monitored but not controlled e Target vs Actual data not available These are limitations due to these blenders and not A3 Page Number 5 Who should use this manual Use this manual if you are responsible for system integration of machinery in your facility You should have a basic understanding of Allen Bradley or Mitsubishi PLC Ethernet networking and Windows XP If you do now contact the appropriate personnel to obtain information before proceeding Your IT personnel or outside networking consultants should be involved in the installation of this software package Purpose of this manual This manual provides information on the installation operation and trouble shooting of the A3 System Management Software Technical support If you have questions or problems using the A3 software or need help with installation questions please refer to this manual first If you cant find the answer your looking for contact ACS Technical Support ACS Technical Support 800 423 3183 Please have your purchase date software version
44. e name of the device and the name of the log Page Number 101 Sample Reports Here are some sample reports All number are only shown as an example 2003_04_28_13_00_00 Blender 1_inventory_and_uptime_log log Notepad E E X File Edit Format View Help TOTAL INVENTORY 3996 036 Hopl 111 001 Hope 222 002 Hops 333 0 03 Hop 444 004 Hops 7 555 005 Hope 666 0065 Hop 777 007 HopB8 888 008 Uptime Percentage 7 0 Automatically Generated Inventory and Uptime report 2003 04 28 16 19 34 JOB 14717723 Blender 1 inventory and uptime log log Notepad Sele TOTAL INVENTORY 7 0 JOB STARTED 2003 04 28 16 18 034 JOB FINISHED 2003 04 28 16 19 34 Hopi 7 0 Hopl Material Reference PET Lot Number 1044 SILO Number 9 ism uro NN Hop2 Material Reference Titanium pioxide Lot Number 332a SILO Number 4 Hobs 4 0 Hops Material Reference PCR Regrind Lot Number 205 SILO Number n a Hop4 0 Hopd Material Reference Uv Stabilizer Lot Number 550 SILO Number 7 Hiper TE Hops Material Reference Lot Number SILO Number Msn gt a Hope Material Reference Lot Number SILO Number ope oe a Hop Material Reference Lot Number SILO Number Hons i Hops Material Reference Lot Number S
45. ecipe Book The A3 Recipe Book is a book that is stored on your PC that allows the user to create delete edit print and recall stored recipes This book has nothing to do with the local recipe book that each machine might have and it is suggested that you use one or the other not both to store your recipes These recipes are used to load recipes to each device from a central location that can be managed by one person easily Page Number 84 Accessing the Recipe Book The recipe book can be accessed by selecting Tools Recipe Book using the dropdown menu or can be accessed by double clicking on a device and from the Virtual Control Panel clicking Recipe Book Recipe Book AVAILABLE RECIPES click on one RECIPE DATA default adr ez recipe a3r NUMBER OF HOPPERS D my recipe ar DEVICE TYPE 057 04 Blender RECIPE MODE Percentage Made The stored List of Batch Size recipe s data available stored recipes Click to Delete a recipe Click to Delete all the stored recipes Delete Delete All Click to save an entered stored recipe Save Mew g Click to print the entire The A3 Recipe Book Recipe Book Page Number 85 Creating a stored recipe 1 Edit the RECIPE DATA fields to appropriate values 2 Click Save New and enter in a name in the File Name box and click Save Viewing a stored recipe Click on an AVAILABLE RECIPE and the RECIPE DATA fields will sh
46. ed This log will automatically log up to 5MB of data before starting over Page Number 109 The location of the file The A3 system log file is always named a3 system log txt and is located in the installation path By default the file will be found in c program files a3 system management software a3_system_log txt and can be as large as 5 MB in size depending on the number of entries iv C Program Files A3 System Management Software File Edit View Favorites Tools Help Q ack r d yo Search Folders BER a3 system config cFq File and Folder Tasks AW CFG File j k 244 KB mij Rename this File iy Move this File MESS system log tet Drivers ved M Virtual device driver Copy this File _ B 30 KB g Publish this File to the Web Igpktx irf read me txt E mail this File Setup Information Text Document KB 5 EB Print this File x Delete this File I STEUMNST LOG tipofday txt Text Document Text Document b EB Other Places IS Program Files E My Documents Page Number 110 Chapter 9 Troubleshooting This chapter explains e How to trouble shoot a software installation problem e How to trouble shoot a PC problem e How to trouble shoot a communications problem e Where to go for further help Overview This chapter will help you understand how to properly trouble shoot the A3 oystem Management Software Page Number 111 How to trouble shoot a software inst
47. ed Status connection 204 Nat Adanker E 1394 Net Adapter E Intel R PRO 100 VE N Set up a home or small ah Repair MT oe Bridge Connections Disable this network e bac device Create Shortcut Repair this connection Te mi Rename this connection Rename view status of this connection Change settings of this connection Other Places G Control Panel My Network Places L My Documents ig My Computer Details Local Area Connection LAN or High Speed Internet Enabled Intel R PRO 100 VE otep 2 Right click on your Local Area Connection and select Properties i Local Area Connection Properties General Authentication Advanced Connect using BEER Intel A PRO Z 100 VE Network Connection 2 This connection uses the following thems el Client for Microsoft Networks ja File and Printer Sharing for Microsoft Networks ml aas Packet Scheduler Internet Protocol TCP IP 5 en ne Install Uninstall Description Transmission Control Protocol lnternet Protocol The default Wide area network protocol that provides communication across diverse interconnected networks C Show icon in notification area when connected Step 3 Double Click on Internet Protocol TCP IP Page Number 31 Internet Protocol TCP IP Properties n General ou can get IP settings assigned automatically if your network supports this capability Othenwise you need to ask your network administra
48. ed more than one Ethernet device and some are communicating but others aren t Solution It is easy to trouble shoot when you have some devices communicating at least one The quickest way to resolve the problem is first examine the lights on the PLC and Ethernet module for a device that is working Compare this with one that isn t working and then read the section on the prior page You can also simply swap cables and modules until you figure out what is causing the problem and then focus on the problem Where to go for further help Contact ACS service at 800 229 2919 Page Number 122 Notes Page Number 123 Other service problems or questions can be answered by contacting the ACS Service Department Service Notes Page Number 124 Service Notes Page Number 125 Parts Department Call 847 273 7700 Parts shipped from the New Berlin WI facility available for Next Day Air shipment only up to 3 pm CST The ACS Parts Department at ACS Inc is ready to provide the parts to keep your systems up and running Application Engineering replacement parts ensure operation at design specifications Please have the model and serial number of your equipment when you call Consult the Customer Parts List included in your information packet for replacement part numbers Service Department Call 8am 5pm CST 847 273 7700 Emergencies after 5pm CST call B47 439 5655 ACS has a qualified service department ready to help S
49. ed under law Tip of the day The gu a window will appear and will show you a Tip of the ae As AG inn manaesinat Software Plant View 4 Plant Name As Tip of the Day g Did you know od Sab nitor and control up to 1000 It will work with both AB 05 04 Here as ad ir all of Ru eet equipment Older Q5 04 and OL blen well as single OFC i ee IV Show Tips at Startup m T ME 4 28 200395306AM a Start untitled Paint A A3 System Managem PI 9 59 AM Deselecting Show Tips at Startup will prevent the Tip of the Day from appearing the next time the program starts Also you can scroll through Page Number 41 many random tips by hitting Next Tip Hitting OK will close the Tip dialog Page Number 42 Drop down menus A3 has many drop down menus that can be selected A3 A3 System Management Software Plant View AG Edit View Tools Help Set Config to Default Open and Load Config file Save Config Save Config file as New Sheet Ctrl D Delete Sheet Ctrl x Edit Sheet Name Customer Name Exit NEXT REPORT WILL GENERATE AT 4 30 2003 8 00 00 AM TIME 4 29 2003 1 23 17 PM s DAYS 0 18 36 43 UNTIL REPORT start Microsoft Word A3 ff read me txt Notepad fg Z PUBLIC Projects g new project select As A3 System Managem Sy AB 1 23 PM A A3 System Management Software Plant View m File aig Vie
50. ervice contracts are available for most ACS products Sales Department Call 847 273 7700 Monday Friday 8am 5pm CST ACS products are sold by a world wide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Contract Department Call 847 273 7700 Monday Friday 8am 5pm CST Let ACS install your system The Contract Department offers any or all of these services project planning system packages including as built drawings equipment labor and construction materials union or non union installations and field supervision AEC Inc 1100 E Woodfield Road Suite 550 ochaumburg IL 60173 847 273 7700 G roup Hours 8 00 am to 5 00 pm CST PROCESSING SOLUTIONS WORLDWIDE Page Number 126
51. fine but your PC crashes intermittently Solution A3 software has been testing on multiple computers from multiple manufacturers If your PC is crashing then the problem is either that the PC doesn t meet the minimum requirements see Chapter 1 Installing A3 or your PC has a separate issue that must be addressed by your local PC company Running other applications on the PC along with A3 can also cause problems see Chapter 3 memory status ACS does not perform PC repairs or installations of A3 software Problem You receive a message Hard drive is about out of space or Hard drive is out of space Solution The hard drive mentioned is either approaching or has reached the minimum allowed free space see Chapter 2 A3 Options for the minimum allowed space You need to delete some of the log files from these drives before other files will be saved A warning is given when you only have 25 space left When you reach the limit all saving including the configuration file will be prevented until the problem is resolved Problem Your receive printer error messages when the printer is hooked up Solution A3 works with all printers that work with Windows XP Use the control panel right click on the printer and select properties and then click Print Test Page If the printer doesnt print from here then the problem is with the printer or printer installation Page Number 113 How to trouble shoot a communication problem
52. ft Developer Network Microsoft Reference Click Exit from the File Menu ent Software mx amp Microsoft Access gt Microsoft Binder x BS Microsoft Excel 4 Microsoft Outlook amp Microsoft Photo Editor Microsoft PowerPoint b WY Microsoft Word gt Wa Windows Install Clean Up gt gt gt gt b gt gt gt gt gt A 3 System Management Software gt B Read Me 43 System Management Software b b R 2 19 PM Page Number 18 Configuring the PC lf your PC is part of your plants LAN then you will need to have your system administrator configure the IP settings for the PC If the PC isa stand alone system then you will need to configure the network properties Step 1 Click Start then right click on My Network Places and click on Properties Page Number 19 s Network Connections File Edit View Favorites Tools Advanced Help Q Back Q wi P Search ig Folders fsi LAN or High Speed Internet Network Tasks 1394 Connection ocal 4rea Connection Disable 4 d new Enabled nabled Status connection 204 Nat Adanker E 1394 Net Adapter E Intel R PRO 100 VE N Set up a home or small ah Repair MT oe Bridge Connections Disable this network e bac device Create Shortcut Repair this connection Te mi Rename this connection Rename view status of this connection Change settings of this connection Other Places G Control Panel My Network
53. g Checking your PC You should first check that your PC meets the requirements To check the operating system requirement processor and RAM ES Command Prompt E Calculator ah Release Notes Microsoft Visual Basic 6 0 Manage Shortcut to A3 exe ont Map Network Drive Disconnect Network Drive Package amp Deployment elp Wizard Show on Desktop R ear AutoCAD R14 Li roperties un M Microso ft Money 2002 Keep in touch with HP All Programs gt d Log Off O Turn OFF Computer 5 untitled Paint A A3 System Managem e Cli H My Computer and select Step 1 Click start then RIGHT CLICK on My Computer and selec Properties Page Number 12 System Properties Automatic Updates Remote Computer Name Hardware Advanced Sustem Restore General System Microsoft Windows F Horne Edition Version 2002 Service Pack 1 Registered to Manufactured and supported by Hewlett Packard Pavilion Intel Fi Pentium R 4 CPU 1 80 Hz 1 79 GHz S12 MB of RAM Support Information Apply Step 2 Examine the above and ensure that you see Microsoft Windows XP Service Pack 1 at least 750MHZ and at least 128MB or RAM Next you will need to check the hard drive ES Command Prompt E Calculator fa Release Notes Microsoft Visual Basic 6 0 Shortcut to A3 exe Package amp Deployment Wizard il Auto I
54. g the reports The user can specify the location where all reports will be saved using the following Report Manager un Do m x zu Report Options ing Automatically Print Report W Enable Reports quency Sayin y Print Ren Seen Inventories Save Report to the following Select a directory by clicking select directory goto Select Directory the directory then click save Cancel Path where all reports are saved to Saving the Reports To select the location click Select Directory go to th desired directory and then click Save The path will automatically be calculated for you Page Number 96 Using Manually generated Reports Job Report Manager First step is to create the System Inventory Resin Database This database can hold up to 1000 resins and 1000 resin locations Resin Database Manager Of In CTT ee ee Resin Product Mame 5643 Hesene LLDPE 5640 Liner LOPE 5655 Clarity LOFE FBO Uctene 5620 Bareback Linear B62 Bareback Low Density FESS Repro 5635 EVA 5545 Slip 5540 Anti Block 5537 Fink amp nti Stat 5535 Clear Anti Stat AAS Amine Free PAS Abe Metallac ne 495 Dark Green 5496 Black SO Medium Blue S81 Baby Blue 5503 Carolina Blue B505 Brown 5510 Buff 5515 Hed 5520 white p525 Leal Green 5530 Yelow 5532 Blue Will 5534 Clear VLI m m Resin Location a SM SS SS SE mE Silo 1 Sila Hz Silo 3 Cancel Sila 4 Silo 5
55. ge As A3 System Management Soffware Plant View m F File Edit view Tools Help Blender 1 Y E TIME 4 28 2003 10 25 46 AM 5 start 5 new_sheet_added b As 43 System Managem 9 AB 10 25 AM Device Type Icons Each device type has a unique graphic icon associated with it Blender 1 Blender 1 Blender 1 BD SGB OS OA OL OFC MAGUIRE Page Number 82 Device States Each icon has different states to indicate the conditions of the device Blender 1 Y Blender 1 Device is communicating and is not in the Run mode Device is in the Run mode Blender 1 r state flashes Device has an alarm active at the unit Blender 1 v Device is not communicating with A3 Editing an existing device SUL Right click on the device and select Edit If you make changes hit OK when done Deleting a device Right click on the device and select Delete Device You can also chose to delete all devices using the Edit Delete all ACS Devices from the dropdown menu Page Number 83 Chapter 5 Working with the A3 Recipe Book This chapter explains e What is the A3 Recipe Book Accessing the Recipe Book Creating Stored Recipes Viewing a stored recipe Editing existing Stored Recipes Deleting Stored Recipes Printing the Recipe Book The location of the Recipe Book Loading a stored recipe into a device Overview This chapter will help you understand how to use the A3 Recipe Book What is the A3 R
56. gram customer configuration loaded 4 28 2003 03 PM Operator has chosen to add a sheet aA 28 2003 EE PM Operator has chosen to add a device 4 28 2003 UE PM operator has chosen to edit Blender 1 4 28 2003 03 PM Operator has chosen to add a device 4 28 2003 C4 FM operator has chosen to delete Blender 1 4 28 2003 04 PM A3 program started 4 28 2003 04 PM A3 program customer configuration loaded 4 28 2003 04 PM operator has chosen to edit Blender 2 4 28 2003 Far PM As program started 4 28 2003 tog PM A3 program customer configuration loaded 4 28 2003 potis PM Operator has chosen to delete Blender 2 A 28 2003 x EN PM Operator has chosen to delete a sheet 4 28 2003 729 PM operator has chosen to add a device 4 28 2003 230 PM operator has chosen to edit Blender 1 4 28 2003 d0 PM A3 program started 4 28 2003 40 PM 23 program customer configuration loaded 4 28 2003 dr PM 43 program started 4 28 2003 S2 PM A3 program customer configuration loaded A 28 2003 iga PM operator has chosen to edit Blender 1 aA 28 2003 744 PM operator has chosen to add a device 4 28 2003 744 PM Operator has chosen to add a device 4 28 2003 1 00 00 FM Automatic Report Generated The A3 System Log It is normal that when the program is started you will see communication alarms for several devices This is normal while the devices are initializing and as long as the alarms clear quickly you should not be concern
57. he Report Manager The A3 Report Manager is a utility that allows the user to generate reports for each device that contain e Inventory Usage information e Uptime Percentage information the percent of time that the device has been in the Run mode Alarm Log information stores up to 1000 of the device s alarms e Recipe Info Log stores up to 1000 recipe changes along with the recipe values and the inventory when the recipe was started e Batch Data information the actual weight of every component of every batch created up to 5000 batches These reports can be automatically printed and will be automatically saved to a location specified by the user From the Report Manager you can also clear all inventories and logs with one click using Clear All Logs and Inventories Accessing the Report Manager The Report Manager can be accessed by selecting Tools Report Manager using the dropdown menus Page Number 93 Automatic vs Manually generated reports The report manager can be configured to either automatically generate reports based on a time interval from 1 8760 hours or manually generate reports based on Jobs This option is up to the user and can be configured using the following or Report Manager ur Ue Report Options Savin Automatically Print Report Enable Reports Inventories Device Report Options System Inventor Report Options Generate Device Reports using the Job Report Ma
58. he device click Hast Page Number 38 From this screen click Next to save the configuration to the Ethernet module Save 5elbingr The conhaguahron n bern savod lo you Dag One SP sins hee rer SE a Me a Please war while the configuration is saved to the device The configuration will begin to be saved and then the system will reboot the Ethernet Module This takes about a minute Tig Device Setup Wicard Comp ota vant Pou have maceria camel pha Dog Devin Stars aed Vacante Fe met ce Lo aree ard marha the Dig Dre SF Toast then vd tench the Lo orto eh ech ba ade Fra ar go toe SIR Th iarsan ird Galea puma inc mihi Finreard dee IT ETT T ede et FH ee Deg DRE Setup we Deselect Register and click Finish to complete Page Number 39 Chapter 2 Using A3 A3 software uses menus windows status bars and right click menus as do most Windows applications This chapter covers e The application window Status bar info Drop down menus Right click menus Tip of the Day Setting up the A3 options Customizing A3 Overview When A3 starts you will see an introduction screen Page Number 40 Group PROCESSING SOLUTIONS WORLDWIDE WARNING This software is protected under copyright laws and international treaties Any unauthorized reproduction or distribution or this program or portions of it may result in criminal penalties and will be prosecuted to the maximum extent allow
59. information will be included in each report by enabling or disabling the following check boxes also what is cleared Report Manager M en ann Can SEE OO ET a eS Be Frequenc Savin Automatically Print Repot i Enable Reports Report Options g y en ae Inventories Select what data to include in the report Automatic Report Features iv Total Inventor Information Automatically Clear the Device Inventory after Report Hopper Inventory Information Automatically Clear the System Inventory after Report iv nclude Uptime Percentage info iw Restart Liptime Downtime after Report Cancel Iv Include Alarm Lag in Report v Automatically Clear the Alarm Log after Report iv All Recipe Information iw Automatically Clear the Recipe Info after Report Include Actual Batch info iw Automatically Clear the batch data after Report Hs Report Options You should select to have all reports automatically clear and restart so that the system does not exceed the limitations of each report size The system can accumulate the following Up to 999 999 999 Lbs or Kgs of total inventory for each device Up to 1000 alarms per device Up to 1000 stored recipe changes per device Up to 5000 batches of actual weight data per device These limitations are limitations to each report If these logs are set to Auto Clear after each report doesn t effect the generated report then these limits should never be reached Page Number 95 Savin
60. ing string exactly into HyperTerminal be sure to set the blenders ID to 1 for this test see Chapter 4 Cntrl b 01T Cntrl c 45 make sure caps lock is on don t type the commas Page Number 118 You should see a response on the screen from the blender that looks something like 01TOOBTest String 6C If this works than communications is working Try starting the blender and then perform the same test If when the blender is running this test fails then the problem is noise from within the blender consult service If this test fails and you see scrolling junk on the screen then the problem is that you have noise on the com cable The cable s shield should only be connected at the PC end and not at the blender end When the cables are unhooked there shouldn t be continuity between the hoods on any of the cables If there is fix the problem If you ve fixed the shields and are still seeing noise then start unhooking blenders If when you unhook a blender the noise goes away then check the blender consult service If the blenders aren t causing the noise and you ve ran the cables in conduit if not then you must then some external device is creating the noise Begin shutting electrical devices off one at a time until you find the problem Sometimes this issue can be caused by weak ground circuits To resolve a weak grounding grid in the plant you have to drive a copper spike through your floor into earth ground near the source of noise
61. le Folder Date Modified Today April 28 20053 12 54 PM Automatically generated reports The date and time stamp is as follows and cannot be changed Year month day hour in military time minutes seconds This is followed by the name of the device and the name of the log Page Number 100 Sample Reports using Manual Generation Job Reports All of the selected reports will be saved in the path selected under the Report Manager The name of the report will be date time and job number stamped for reference Below are some sample report 7 My Reports Directory File Edit wiew Favorites Tools Help sack r P d pP Search fer Folders EHE 2 2003 4 78 13 00_00 Blender 1 alarm lag lag File and Folder Tasks T Move the selected items ID Copy the selected items Publish the selected items to Ehe Web i 2003 6 E mail the selected 3 2003 04 28 15 19 34 JOB 14717723 Blender 1 recipe infa log log Items 2nu3 n4 28 16 19 34 JOB 14717723 Blender 1 inventory and uptime log lng x Delete the selected items Other Places File Server on SERVER Kpsaftware Z G My Documents IS Shared Documents ap My Computer amp J My Network Places Details 2 items selected Total File Size 1 14 KB Manually generated reports in blue The date time and job number stamp is as follows and cannot be changed Year month day hour in military time minutes seconds JOB job This is followed by th
62. lender Refer to Maguire for software upgrades CHANGING THE BAUD RATE ON THE MAGUIRE TO 2400 RECOMMENDED FOR A3 You must have software dated March 31 2000 version 00331X or newer if not contact Maguire for update From Maguire controller hit then 22222 if you haven t modified the password Next hit 95 If the software is new enough you will see baud 1200 or baud 2400 hit to change then hit exit twice Reboot the Maguire controller if you ve changed it Besure to save your new configuration to the Maguire EEPROM see side of Maguire controller for details Follow the instructions on page 30 to setup and configure the Digi One SP Ethernet Module Page Number 29 Configuring the Digi One IA or Digi One SP Ethernet Modules The first thing to complete is configuring the PC for Ethernet Configuring the PC If your PC is part of your plants LAN then you will need to have your system administrator configure the IP settings for the PC If the PC isa stand alone system then you will need to configure the network properties Drian Panagem then right click on My Network Places and click on Properties otep 1 Click Start Page Number 30 s Network Connections File Edit View Favorites Tools Advanced Help Q Back Q wi P Search ig Folders fsi LAN or High Speed Internet Network Tasks 1394 Connection ocal 4rea Connection Disable 4 d new Enabled nabl
63. n menu This data shows the percentage of time that each blender has been in the Run mode and is useful in seeing the overall proficiency of each machine Page Number 65 Scan Times for Data Acquisition Blender 3 1 SCADA Scan Times Page The SCADA Scan Times Page is accessed by selecting View SCADA scan Times from the dropdown menu The display is in seconds and is rounded to the nearest whole second These numbers represent how long it takes for each device to poll all of the configured parameters This time can be dramatically increased or decreased by enable or disabling features for each device see Working with A3 Device Objects for more details Page Number 66 A Memory Status Percent of Menon Used 44 amp used Physical Memory Used 523 808 Kbpte Free Memory 283 328 Kbyte Paging File Size 1 279 300 Kbyte Free Paging Size 1 122 204 Kbyte User Address Space Size 2 037 024 Kbyte Free User Space 2 035 266 Kbyte Memory Status Page The Memory Status Page is accessed by selecting View Memory Status from the dropdown menu This page is useful in determining the amount of memory you have consumed with the current configuration and is also useful when configuring systems with up to 1000 devices The most important item to look at is the first one Percent of Memory Used This should be under 60 for Windows to remain stable Page Number 67 052001 AB DATA ITEMS Blender 1 AVAILABLE
64. nager Generate System Inventory Report Manually Generate Device Reports on a time interval Generate System Inventor Reports on a time interval Interval ini hours Interval in hours Starting Time in Hours Starting Time in Hours Lancel 0 23 0 for midnight 0 23 0 for midnight OF Frequency of Reports Automatic reports are usually used when the user runs the same product on their lines or are not concerned with documenting each product run The data generated is easier to manage because of the frequency of the report Manually generated reports Job Reports are usually used when the user wants to document every product run and what went into that run This is very powertul for the health and food industry but can be overwhelming for normal users The reports can pile up quicker than someone can process the data depending on how many job changes the machine performs However there are some unique advantages when using Job Reports The operator accesses the Job Report Manager from by double clicking on the icon of the device from the main page and then clicking Job Report Manager From here they can start or stop the job and enter in the following data that is not available when using automatically generated reports e Job Number e Material Reference Number Lot number and Silo Number Page Number 94 Configuring what is included in the Reports The user can select what
65. net Module Digi p n 70001862 anda 3 foot DB9 Null Modem Cable that is female on both ends BlackBox com p n EYN257H 0006 FF per blender The Ethernet module snaps in to the DIN rail just to the right of the Mixer Motor contact and the cable snaps into the module and 232 board on the PLC follow the 232 boards instructions for mounting You will also need to make sure that you are running at least SGB 1 2 blender software this can be found on the blender under Setup F940 config Follow the instructions on page 30 to setup and configure the Digi One IA Ethernet Module Page Number 28 Networking instructions for the Maguire WSB Blender Installing the PLC hardware The first step is that you must install the Ethernet module and cable for every blender Ethernet Module ACS Part 724 00872 00 Digi One SP Ethernet Module Wall Mount ACS Part 724 00873 00 Module Cable ACS Part A0565856 10 DB9F DBO9F straight cable This module should be mounted to either the blender frame or a nearby structure using the purchased Wall Mount The module comes with a wall transformer that you must plug into a 115 VAC grounded 3 prong receptacle The module will connect to the blender via the purchased 10 cable and will connect to your network via its RJ45 Ethernet port You will also need to make sure that you are running at least 80609A 4 14 1998 or newer blender software this is displayed after powering on the Maguire b
66. no other solution Page Number 119 Trouble shooting network problems with ACS Mitsubishi blenders or Maguire WSB blenders Problem You ve configured more than one Ethernet device and none of them are communicating Pictures shown may differ with Maguire Digi One SP module but the descriptions of LEDs and DIP switches are the same Solution lt is easy to trouble shoot when you have some devices communicating at least one but with none communicating you re going to have to start from the beginning otep1 Disconnect all of the blenders except for one Get this one working and then go to the next one otep2 Examine the Dipswitch settings on each of the DIGI Ethernet modules Switch 1 should be on and 2 4 off see below Step 3 Examine the Power light on the PLC s Ethernet module If it is not on then check the 24VDC power connection to the module Page Number 120 step 4 If all of the previous steps have been satisfied then examine the LINK light on the Ethernet module It should not be red If it is then first make sure that the Ethernet cable is hooked up at both ends Remember that you must use straight through standard CAT5 cables when going between the blender and a hub or switch If you are trying to go directly from the blender to a PC without using a hub or switch l d then you need to use a Crossed Ethernet cable At this point you more than likely have a cable problem and should test this To test
67. oftware after installation Page Number 106 Setting the system back to defaults The system can be set back to the original defaults by selecting File Set Config to Default from the dropdown menu This should be used with caution Saving the configuration The configuration file is automatically saved when you exit the program but in the case the power is removed from the computer the configuration file will not be saved For this reason it is a good idea to save the configuration from time to time when you are configuring large systems This is not necessary to do on smaller networks If you are done configuring A3 then you should always save the configuration as well To save the configuration select File Save Config and the file will be saved The file can also be saved for back up purposes by selecting File Save Config as and choosing a location Opening a previously saved configuration file The system can be quickly configured by opening a previously saved configuration This can be done by selecting File Open and Load Config File from the dropdown menu and then selecting a file to open The location of the configuration file The A3 configuration file is always named a3 system config cfg and is located in the installation path By default the file will be found in c program files a3 system management softwareva3 system config cfg and is approximately 256 kb in size depending on your configurati
68. on but can be much larger Page Number 107 Chapter 8 Working with the A3 System Log file This chapter explains e What is the A3 System Log file e What is logged in the file e The location of the file Overview This chapter will help you understand how to use the A3 System Log What is the A3 System Log file The A3 System Log File is history log of system level alarms and operations performed by the user It is not necessary to view this log except when trouble shooting the A3 system Page Number 108 What is logged in the file Any communications error time of alarm and time cleared Time the program was started Time the program was stopped Printer error messages Setup operations performed by the user e ime of automatic and manually generated reports 5 a3 system log txt Notepad File Edit Format View Help 4 28 2003 sa operator has chosen to edit Blender 1 4 28 2003 sa As program started 4 28 2003 Paes A3 program customer configuration loaded 4 28 2003 138 CoM ERROR on Blender 1 4 28 2003 38 COM ERROR on Blender 1 CLEARED 4 28 2003 30 As program started 4 28 2003 739 A3 program customer configuration loaded 4 28 2003 tops PM 43 program started 4 28 2003 Uu PM A3 program customer configuration loaded 4 28 2003 AER PM Operator has chosen to delete all devices 4 28 2003 ig s PM operator has chosen to edit Blender 3 4 28 2003 02 PM A3 program started 4 28 2003 Jus PM A3 pro
69. on if not you need to enable DCOMM by removing the snap cover on the PLC and holding in the COMMS button Reboot after changing LED SENSITIVE DEVICES itj DO NOT TOUCH 1 UNLESS PROPERLY GROUNDED pae tm le 3 gis ga pe do c 2 i 15 pe i af r 1 ch ri A Ii peo qe be 12 ET p dp gp d i Power light on module is on Fault light on module is off but Link light on module is off This is a problem on the Ethernet side of the module and not the PLC side Check your cables and hubs or switches to resolve the issue You can bypass your network by using a crossed cable and a laptop or computer that has Ethernet Plug the crossed cable directly from the module to the computer If the Link light comes on then the problem is within your network Page Number 73 Configuring an Older Proprietary OS OA OL or OFC that uses an embedded controller not a PLC Limitations with using the Maguire WSB Batch Blender e target vs actual batch data is not available e alarm name and logging is not available These are limitations with the Hynet protocol and blender functionality and not A3 When selecting Legacy Equipment with Hynet Driver then you will be given a few extra entries to complete Add a New Device Device Mame Device Description Ayvallable Features Blender 2 w Start ar Stop Ability m Iv Monitor Inventory Device Type Communications Type m een eee ata 105 Blender
70. operating system service pack 1 installed Internet Explorer 6 0 30GB minimum hard drive space 60GB recommended 128MB minimum RAM 512 MB DDR Ham recommended CDROM drive CD RW recommended Video card capable of 1024x768x16bit color 32bit color recommended 10Mbps Ethernet 100Mbps recommended 1 USB slot Standard Ink Jet Printer if you are going to print the reports What kind of cable do need to purchase for connecting all of my machinery together For ACS Allen Bradley batch ACS Mitsubishi batch and Maguire WSB batch blenders you will need CAT5 cable and Page Number 7 if you don t already have a LAN in your facility you will need to add one by purchasing an Ethernet Hub or Switch from any store that sells Ethernet equipment For older HydReclaim OS OA OL OFC equipment you will need a 2 twisted pair shielded cable such as Belden 8103 or similar You will also need a DB9Male solder type for each device and a DB9 Female solder type for the PC as well as hoods for each connection e What should do if during installation that the software keeps telling me that some of the files on my PC need to be updated and asks me to reboot but when run the software after the reboot get the same message Make sure that your computer meets the minimum requirements This problem is being caused because your operating system on the PC that you have purchased is not up to date This is common even on brand new PCs See the instructions in
71. ow the values for the redipe vou ve selected Recipe Book AVAILABLE RECIRES click on one RECIPE DATA NUMBER OF HOPPERS 8 my recipel ar DEVICE TYPE 057 04 Blender RECIFE MODE EZ Made Batch Size 5 HOPPER1 is HOPPER 5 HOPPER 30 HOPPER 5 HOPPERS 10 HOPPER 5 HOPPER 2 HOPPERS 2 Delete Delete All Save Mew Page Number 86 Editing Existing stored recipes 1 Click on an AVAILABLE RECIPE and the RECIPE DATA fields will show the values for the recipe you ve selected 2 Edit the RECIPE DATA fields 3 Click Save New and select the stored recipe and click Save Deleting stored recipes To delete a single recipe 1 Click on an AVAILABLE RECIPE 2 Click Delete and the recipe will be removed To delete all of the recipes 1 Click Delete All and all stored recipes will be removed Printing the recipe book Click PRINT BOOK and the entire recipe book will be sent to the printer You cannot print a single recipe by itself The location of the recipe book The A3 Recipe Book is a collection of files with the extension or a3r and are located in the installation directory Using Windows you can copy all of these files to a back up location if desired By default the installation directory for A3 is c program files a3 system management software Page Number 87 Loading a stored recipe into a device e
72. password you will be asked to verify the change before the change will be allowed Options Operator must enter USER PASSWORD for the following actions Closing the 43 program Master Password Verify Changing amp 3 setup User Password Starting or Stopping 4 device sx Changing the recipe of a device Deleting or Saving a stored recipe Cancel Cleaning Inventory Clearing any Log Page Number 53 Chapter 3 Application Screens A3 software has many screens that can be accessed Virtual Control Panel for each unit This is used to start or stop the unit and to monitor the current recipe and inventories Alarm Log for each unit This is used to view the alarm history of each device Change Recipe Page This is used to change the running recipe of a device Recipe Book This is used to store recipes for later recall by an operator Batch Data Page for each unit This is used to view the actual weight of each batch using a visual graph Uptime Data Page This shows the percentage of time each device has been in the Run mode SCADA Scan Times Page This page is used to determine the refresh rate of each device Memory Status Page This page shows the amount of memory that the program is consuming as well as the amount of free memory left on the PC Data Parameters Page This page show the current enabled data parameters for each device and is useful for customers wishing to develop their own SCADA front
73. r assistance with your problem Instruct your IT department that the blenders must have a fixed IP but the PC can have a dynamic IP All subnet mask for the PC and the blenders needs to be 255 255 255 0 They might not have the startup script correct for your PC If the blenders and PC all reside on a separate network that has nothing to do with your plants LAN then we need to check the PC s network properties see Chapter1 Networking instructions for the newer AB OS OA Blender for step by step Page Number 116 Problem You ve configured more than one Ethernet device and some are communicating but others aren t Solution It is easy to trouble shoot when you have some devices communicating at least one The quickest way to resolve the problem is first examine the lights on the PLC and Ethernet module for a device that is working Compare this with one that isn t working and then read the section on the prior page You can also simply swap cables and modules until you figure out what is causing the problem and then focus on the problem Page Number 117 Trouble shooting network problems with older HydReclaim units Problem You ve configured more serial devices and are having problems establishing communications Solution step 1 Disconnect the cable from all of the blenders except for the first one Check communications Be sure to read Chapter 4 before continuing Step 2 If you still don t have communications then ring out
74. rop down menu on the Job Report Manager for assignment to each hopper e Built in Uptime Percentage monitor that keeps track of the percentage of uptime for each blender e Built in Report Manager that allows the system to automatically generate a report for each blender The report can be configured to generate from every 1 to 8 60 hours once a year e Built in System Inventory Report keeps track of how much of each resin type was used as well as where these materials came from Page Number 4 e Built in Job Report Manager that allows the operator to generate reports based on jobs rather than time The Job Report Manager keeps track of job numbers material reference numbers material lot numbers and material silo numbers for each hopper on every configured device The operator can select to start or stop the job at any time e Reports contain inventory information uptime percentage reporting alarm logs actual batch data and the recipe info log that keeps track of all recipe changes throughout the reporting period up to 1000 recipe changes e Built in Security system that allows the A3 system to be password protected with an operator and a supervisor level password e Printer Routines that will work with any standard ink jet printer e Can be used with the AEC AB batch blender the Sterling SGB Blender or any of the following older HydReclaim systems OS Blender OA Blender OL Blender OFC Weight Hopper e Multiple plants can b
75. s Alarm Log Batch Log Blender Stopped Push to Start or stop Total not 100 error message Page Number 89 The following are error messages given when using the older proprietary blenders Blender 3 Inventory HOPPER 1 0 0 HOPPER 2 0 0 HOPPER 3 0 0 HOPPER 4 0 0 Batch Size 2 HOPPER 1 20 00 HOPPER z 20 00 HOPPER 3 20 00 Recipe Not HOPPER 4 40 00 otaling 100 TOTAL 0 0 CLEAR INVENTORY Current Alarms Blender Stopped Push to Start or stop Recipe Not Totaling 100 Page Number 90 The following is the successful message given when using the older proprietary blenders Blender 3 Inventory HOPPER 1 0 0 HOPPER 2 0 0 HOPPER 3 0 0 HOPPER 4 0 0 HOPPER 1 20 00 HOPPER 2 20 00 HOPPER 3 20 00 HOPPER 4 40 00 Transterred TOTAL 0 0 CLEAR INVENTORY Current Alarms Blender Stopped Push to Start or stop Recipe Transferred message Page Number 91 Chapter 6 Working with the Report Manager This chapter explains e What is the Report Manager Accessing the Report Manager Automatic vs Manually generated reports Configuring what is included in the reports Saving the reports Auto Clear Features Using Manually generated reports Job Report Manager Sample Reports using Automatic Generation sample Reports using Manual Generation Job Reports Overview This chapter will help you understand how to use the A3 Report Manager Page Number 92 What is t
76. the cables PIN 9 on the PC should go to PIN 4 on the first blender PIN 1 on the PC should go to PIN 5 on the first blender PIN 2 on the PC should go to PIN 8 on the first blender and PIN 3 on the PC should go to PIN 9 on the first blender From there PIN 4 on blender 1 goes to PIN 4 on all of the other blenders PIN 5 on blender 1 goes to PIN 5 on all other blenders PIN8 on blender 1 goes to PIN 8 on all other blenders and PIN 9 on blender 1 goes to PIN 9 on all other blenders Also check that these pins are not shorted together check all possible combinations step 3 At this point trouble shooting gets a bit more difficult You will need to close down A3 and open up Hyper Terminal Hyper Terminal is a Standard Windows program that gets installed with Windows You can find it under Start Programs Accessories Communications HyperTerminal Enter a name for the connection call it test When asked for a phone number select Direct to COM 4 or whatever comport the USB RS422 485 adapter is set to see Chapter 4 When asked for the baud rate set it to 19200 make sure the blender is also set to 19200 With the cable connected to the PC and the first blender turn off the blender and then turn it back on You should see on the PC screen Power Up If you see this then we know that at least communications from the blender to the PC is working but from the PC to the blender still needs to be tested To test that type the follow
77. this manual for installing the software and install Win XP Service Pack 1 before proceeding If you still are having problems after upgrading to service pack 1 consult your IT department this is a problem with the PC you ve purchased and not the A3 software Software and Firmware Upgrades A3 software can be upgraded by contacting your local ACS sales office Upgrades will be provided free upon request during your warranty period after that they must be purchased labor and other hardware for these upgrades not provided by ACS Necessary Firmware upgrades for the machinery communicating with A3 can be obtained by contacting your local ACS sales office as well These will need to be purchased and are not given freely because of the cost involved Maguire WSB Firmware upgrades need to be purchased from Maguire Consult Maguire for instructions and assistance Page Number 8 What s new in version 1 1 Job Report Manager Now you can generate reports on demand instead of just time Along with this comes the new feature of Joo Management that allows the operator to enter in the following data into the job e Job Number Material reference numbers for each hopper Material lot numbers for each hopper Material silo numbers for each hopper The operator can start or stop a job at any time The reports that generate are date time and job number stamped for easy recording New Configuration Options Now you can save the configuration to
78. tor for the appropriate IF settings Obtain an IP address automatically Use the following IP address IF address 132 168 Ij en Subnet mask 256 265 455 Use the following DNS server addresses Preferred ONS server Eee Alternate DNS server Step 4 Set your screen to look like this then click OK and OK again Remember that you need to have a unique IP for all of your blenders and for the PC For example you could use the following scheme PC IP gt 192 168 0 1 Blender 1 IP gt 192 168 0 10 Blender 2 IP gt 192 168 0 11 Blender 3 IP gt 192 168 0 12 Page Number 32 Running the Cables and Hardware to interconnect the system Depending on your expertise and preference you can either purchase CAT5 cables to length with the connectors already attached to both ends This makes it somewhat difficult to get the connector into the blender panel because of the head on the cable but not impossible Either way you will need to have some sort of Hub Switch or Router to interconnect all of the blenders with the PC If you already have a plant LAN then you should just run drops to each blender and one to the PC from your main network If this will be a stand alone system then you can purchase a hub or switch to accomplish the same thing A 5 port hub cost around 40 and is shown below Uplink Port to Existig LAN optional 192 169 0 10 182 158 0 12 182 158 0 11 oample network Be sure not
79. ured when you enable or disable features for the selected device see Working with A3 Device Objects for more details This page is here strictly for customers who wish to develop there own SCADA package The more enabled items on this page the slower the SCADA scan time however the system speed usually makes this irrelevant don t be concerned if all items are enabled unless you are trying to add 1000 blenders Page Number 68 Chapter 4 Working with A3 Device Objects This chapter explains e What is an A3 Device Object e Adding new A3 Device Objects e Editing A3 Device Objects e Deleting A3 Device Objects Overview The A3 system is used to display and control many objects up to 1000 A3 Device Objects are the heart of the system and are easy to add and edit What is an A3 Device Object An A3 Device Object is any blender or weigh hopper that you are adding to the A3 communications package This could be the older HydReclaim OS OA OL OFC units the AEC AB OS OA blender or the Sterling SGB Blender Before proceeding with adding new devices you should finalize the layout that you want You should configure the number of sheets that you are going to need and name them appropriately first Once objects are created you cannot simply drag them from page to page but instead have to delete them and add them again on the page you desire Therefore it s a lot easier to put them on the correct page to begin with Page Number 69
80. w Tools Help Add ACS Device Ctrl N Delete Selected ACS Device Delete ALL ACS Devices Edit Selected ACS Device Ctrlt E TIME 4 28 2003 3 35 51 PM B E dat Microsoft Word 43 add acs device sele As A3 System Managem By 3 35 PM Page Number 43 A A3 System Management Software Plant View File Edit RYE Tools Help SCADA ScanTimes Memory Status Blender 3 Data Parameters TIME 4 28 2003 10 44 14 AM add aec device des A3 A3 System Management Software Plant View File Edit View DESS Help a z Recipe Book Report Manager Blender 1 Options m Managem 2 li 10 44 AM Eje k TIME 4 28 2003 10 59 42 AM te start data_paramaters_pa 3 System Managem Page Number 44 lt j 10 59 AM A A3 System Management Software Plant View File Edit View Tools Mis apia Show Tip of the Day Technical Support About A3 Blender 1 TIME 4 28 2003 11 16 21 AM s start options page securit tem Managem Page Number 45 lt 11 16 AM Right click menus A3 also uses right click menus These right click menus are all accessible from the dropdown menus listed above but right clicking is sometimes quicker and easier As A3 System Management Software Plant View File Edit View Tools Help Add ACS Device Ctrl N Delete Selected ACS

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