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Sterling Home Theater Server 882.00722.00 User's Manual

1. 1 2 Start up your extruder Wait until you see the Steady Process indication on the screen or through communications Observe the Lbs hr or Kgs hr to adjust your extruder to the desired throughput Chapter 4 Operation 37 of 60 4 2 GH Full Control Operation Procedures The system will begin monitoring the process rate once the GH System is placed into RPM Mode and a target RPM is entered into the controller If started in RPM Mode then the GH should automatically load the hopper when necessary The system can also be started in Monitor Mode by placing the GH into Monitor Mode and then running your extruder using the existing control equipment such as the original speed pot Once the extruder RPM reading from the Extruder is detected in Monitor Mode the system will begin to load the hopper when necessary Again this RPM must be communicated to the PLC through the supplied inductive proximity switch or through the optional Ethernet module The extruder icon on the recipe page will become animated indicating the extruder is running and the measured Extruder RPM will be displayed The displayed value may be far from the actual value the first time the system is ran The GH goes through a learning process with each material This is indicated by a Steady Process indicator on the main recipe page Upon starting the line you should always give the hopper time to analyze the flow and give you a Steady
2. Description ALL MODELS 1 Allen Bradley PLC MicroLogix 1500 A0565880 2 Thermocouple Input Card A0565375 3 Allen Bradley PLC Base Unit A056588 1 4 24V DC Power Supply A0563932 5 12V DC Power Supply 739 00027 00 6 Alarm Light Yellow Strobe 24V DC A0565889 7 Glass Fuse 3 0 amp 115v unit A0542207 8 Ethernet Module optional A0563939 9 Ethernet Module cable A0565898 10 120V Light power switch 715 01034 02 Figure 65 Typical Allen Bradley Display Main Parts List Description All MODELS Allen Bradley Panelview Touchscreen Display 1 PV 550 DF 1 protocol 892 001462 00 2 Enclosure Mounting Feet 40567132 3 Display 8 ft Connection Cable 40565856 Display 50 ft Connection Cable 40565899 Chapter 7 Appendix 49 of 60 7 2 Addendum Service Supervisor Information Note Untrained personnel of the rate monitor controller should not use this section of the manual and or program can be compromised Note Hidden programmable features and hidden menu pages should not be made available to floor operators These pages include the Service Supervisor Information addendum located in this section Unauthorized changes to these factory settings by inexperienced operators may prevent the unit from operating properly and may void part or all of the warranty Caution After all selections are made Keep pressing the Done key until the unit returns to the Recipe menu Note Inexperienced operators or inexper
3. GH M Rate Monitor Allen Bradley Controller Part Number 882 00722 00 Bulletin Number BF2 610 Effective 2 08 2007 Write Down Your Serial Numbers Here For Future Reference We are committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice DCN No Copyright 2008 All rights reserved il Shipping Info Unpacking and Inspection You should inspect your equipment for possible shipping damage Thoroughly check the equipment for any damage that might have occurred in transit such as broken or loose wiring and components loose hardware and mounting screws etc In the Event of Shipping Damage According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment Notify the transportation company s local agent if you discover damage Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods before the transportation company s inspection and authorization File a claim with the transportation company Substantiate the claim by referring to the agent s report A certified copy of our invoice is available upon request The original Bill of Lading is attached to our original invoice If the shipment was prepaid write us for a receipted transportation bill Advise customer service regarding
4. All personnel engaged in the use of the machine should become familiar with its operation as described in this manual Proper operation of the machine promotes safety for the operator and all workers in its vicinity Becoming familiar with materials inspection speed limitations screens and guard maintenance and total user responsibility will assist you in learning potential areas in need of observation for danger Each individual must take responsibility for observing the prescribed safety rules as outlined All caution warning and danger signs must be observed and obeyed All actual or potential danger areas must be reported to your immediate supervisor General Responsibility No matter whom you are safety is important Owners operators and maintenance personnel must realize that every day safety is a vital part of their jobs If your main concern is loss of productivity remember that production is always affected in a negative way following an accident The following are some of the ways that accidents can affect your production e Loss of a skilled operator temporarily or permanently e Breakdown of shop morale Costly damage to equipment e Downtime An effective safety program is responsible and economically sound Organize a safety committee or group and hold regular meetings Promote this group from the management level Through this group the safety program can be continually reviewed maintained and improved Keep mi
5. If the Customer locks themselves out of a GH Hopper they can contact the manufacturer for a procedure that will let them back in This password is used in several places throughout the GH Hopper but can be bypassed by entering in the Manufacturer s Service Password Units Figure 75 Typical User Password Setup Screen Select Operator 2 Enter New Password Here THHHHHHHBHHBE NEW PASSWORD VERIFY PASSWORD 3 Verify New Password to Finish This screen allows the user to change the GH Hopper s unit of measurement The entire GH Hopper can be configured in either Kgs or Lbs while the Target vs Actual data can be configured for either regardless of the GH Hopper s units Alarm Log This screen shows the last 100 stored alarms The log can be viewed printed and cleared Alarm Log Go back to Setup Directory Figure 79 Typical Alarm Log Screen Clear Alarm Log Print Alarm Log P MMM D0 Y_1H MM SS PM HOPPER 6 Low Level Scroll Through Alarm Log Chapter 7 Appendix 55 of 60 7 3 Allen Bradley Communications Manual The AB rate monitor uses a Micrologix 1500 LRP processor that communicates with the outside world using DF1 protocol with Ethernet hardware Its Ethernet speed is 10 100 Mbits second The rate monitor must be purchased from ACS with the Ethernet option If this was not done at the time of purchase it can be added afterwards by consulting the fac
6. 31 WTP RPM Calibration Page 33 This page is used to monitor the Ibs hr per RPM analyzer and is used as a tool for tuning the WTP Algorithm Options mentioned later in this book 33 Hopper Size Setup itc oH eer ie co ren e E ELCHE EE dtd 33 Extruder Setup pase eet eee 34 Hauloff Setup and Encoder Calibration Page GH Full Control ONLY 34 Alarm Setup ete t b PR iere er eee eee EP sus lee ted 35 Network Setup eee ire ee reden get 35 setting Date and Time ue eden eet Ee Let eee Dae e 36 CHAPTER 4 OPERATION ccena enne e enn nee une OL 4 1 GH M Op ration FOE ebe aere tht tae co pb tope tape beber eee tte edes 37 Operator DISD ays E Ri ndo Vor enlaces ue Pas qupd aed i Re Loads 37 4 2 GH Full Control Operation Procedures A 38 ee 38 4 3 GH F Gravimetric Feeder Operation Procedures 39 ODBSralor E 39 quA COMMON orestis E 40 Alam Flags eor toU E stetit riim eei eve is eU 41 CHAPTER 5 MAINTENANCE eese 4D 5 1 Preventative Maintenance Schedule sess 42 5 2 Preventative Maintenance ic eege ect Hep et EIE HAx RE ERE RERE PER E RR re iRES 43 5 8 Corrective Maintenance AAA 43 CHAPTER 6 TROUBLESHOOTING 45 S E cool ors rm 45 CHAPTER 7 APPENDIX cens ecu cnn eurn reed 7 1 Warranty and Spare EE geed 47 Warranty Seege rr IEEE REESEN 47 Warranty Restri
7. Only the extruder Extruder PPR Update Time HHHH Directory Use Hauloff Encoder PPR Mechanical Options Screen For a GH M and GH Full Control Systems the GH Hopper Mode should always be enabled If the system is a GH F gravimetric feeder then this should be set to GH Feeder Mode unless system is a GH F GH Hopper Mode Enabled GHF Feeder Man RPM The mechanical options screen also allows the user to set the method of obtaining the extruder s RPM This setting should also be factory set If the optional Ethernet module is purchased the unit should be set to Write Ext RPM through COM F13 1 If the extruder s RPM is being measured with the supplied proximity switch the unit should be set to Measure Ext RPM with Prox If the mechanical device to measure the extruder s speed presents more than one pulse per revolution this value may be changed on the Mechanical Options page also Simply input the number of pulses per revolution in the Extruder PPR field The hauloff encoder setting is only used on GH Full Control Systems The GHF feeder max RPM setting should only be set if the system is a GH F gravimetric feeder Set this value to the maximum RPM of the feeder itself The AC drives double the maximum speed of the motor Each motor can then run 3600 RPM To calculate this setting divide by the gearbox setting i e 10 1 would be 36
8. and contained in a crate 1 Remove crate from around the rate monitor 2 Secure strap of proper lifting capacity Q Caution Use approved safety straps or chains to lift the rate monitor 3 Liftthe rate monitor until strap is taut 4 Remove bolts attaching bottom of the rate monitor to shipping skid 3 2 Mechanical Installation It is the intent of this section to familiarize the reader with the proper site requirements and installation procedures of the GH M rate monitoring system The information in this section is NOT meant to replace or supersede an established local or company implemented procedures It is meant to enhance them The installation procedure should be used as a general guideline for the proper installation steps required to install a rate monitoring system 1 Lift the rate monitor and position over machine throat 2 Setin position and secure by tightening four bolts 3 Remove lifting strap 4 Mount the material conveying system receivers on the top of the rate monitor s surge hopper If a mezzanine mounted GH Hopper is being used to supply material to the rate monitor attach the flex hose to the top of the surge hopper 5 Install the weigh hopper onto the load cell bracket Tighten the two supplied thumb screws to the flange on the weigh hopper Note Use extreme care when tightening bolts on top of the load cells so you do not spring the load cells The load cells are extremely delicate and should be trea
9. feeder s target LBS HR calculation Figure 17 Extruder RPM Setup Maximum Extruder RPM dHHHBHE UNL 0 NE EE FEEDER GHF Extruder Max Throughput Hauloff Setup and Encoder Calibration Page GH Full Control ONLY Use this page to enable the hauloff option of the GH Full Control Unit The unit should be set to Do not read speed from COEX Master if a COEX AB does not exist If it does then this setting is automatically setup by the COEX Master The Hauloff max speed must be entered if you are not using an encoder see mechanical options to turn this feature on off If you are using an encoder then you must calibrate the encoder by running the line at a known speed hand measuring the line speed with a tachometer entering the speed into the ft min box and then clicking the click here box You can also manually modify this calibration by adjusting the Distance per revolution of encoder Figure 17 Hauloff Setup and Encoder Calibration Page Hauloff Enabled HRULOFF ENCODER CALIBRATION Do not read speed from COEX Master Distance rar Revolution of iHHHBHE ft Hauloff Mau Speed ft min Measured Hauloff Speed ft min Target Hauloff Speed A Measured Hauloff Speed ft min To automatically calculate Distance Per Revolution enter actual measured speed below then click here Calibrate Encoder ft min RPM or Weight Mode only Chapter 3 Installation 34 of 60 Alarm Setup This screen allows the
10. on a GH M rate monitor This parameter is automatically configured if a COEXPERT AB system exist Otherwise it should always remain disabled Disable for GH M GH F or GH without Figure 31 Ethernet Setup Screen Coexpert AB Enable or Disable Se CDEXPERT COM Change monitor s IP the Ethernet BOUT Serverz 7 DISABLED Address and Subnet Module Mask Configurator Ethernet data if make Go back to Setup cha s befor e Confis ES change Will Directory Modul Place Chapter 3 Installation 35 of 60 Setting Date and Time The Set Date amp Time feature is located in the Panel View Config menu of the Setup Screen This feature allows the operator to set the rate monitor s internal time clock and date The clock data must be entered in the traditional Hours Minutes and seconds The date must be entered in Years Months and Days All values in this screen can be entered by pressing on the related button and choosing the correct number Figure 32 PanelView Configuration Screen Panel View GH Version Main 1 5 PLC GH Version PLC Operating System Series PLC Operating System Firmware Chapter 3 Installation 36 of 60 Chapter 4 Operation 4 1 GH M Operation Procedures The system will begin monitoring the process rate once an RPM reading from the Extruder is detected Again this RPM must be communicated to the PLC through the supplied inductive proximity switch or through the optional E
11. operator to configure the alarm settings for the rate monitor To configure the alarms do the following 6 Enter the Setup Menu 7 Once in the Setup menu press Alarm Setup This will take you to the Alarm Setup screen Figure 18 Alarm Setup Screen ELE EET Min System Speeds Man System Speeds Hopper 5X for low level alarm Hopper X for no material alarm Out of Material Al Sil e H Done Changes weigh hopper weight for no material alarm Change the Alarm Silence Display 8 Press the Done key at the bottom to exit this screen Min Max Speed Limits restrict the usable gravimetric range that the GH will permit in order to continue gravimetric measurement If the system becomes unstable for more than the System unstable alarm time then an alarm will notify the operator The Hopper for low level should always be set below the reload percentage hopper setup page and the Hopper for no material alarm should always be set below the low level 96 Network Setup The rate monitor s IP is the address of this rate monitor on a network The rate monitor is factory set up with an IP of 192 168 0 150 with a default subnet mask of 255 255 255 0 In order to change the values enter the Setup menu press the Network Setup button and change the values accordingly Then the send Ethernet config to module button must be pressed when changes are complete The COEXPERT COM DISABLED button is not used
12. or disable coexpert com 30 of 60 GH Calibration The load cell on a GH Hopper is FACTORY CALIBRATED Since the load cell can be subject to shock loading during shipping moving etc we recommend that they be recalibrated The heart of the rate monitor system is the load cell and the supplied calibration weight Since the load cell is weighing the amount of material entering the process proper calibration of the load cell is essential for the correct and accurate operation of the rate monitor This calibration must be performed upon initial installation and startup The calibration should also be checked once a month with a calibration weight and if necessary recalibrated to ensure that it has not been damaged in the normal routine of removing and replacing the weigh hopper for cleaning The calibration of the load cell is accomplished by using two reference points on the output of the load cell scale The first of these points is known as the Tare Weight This is the weight of the empty weigh hopper assembly on the load cell This is also known as the zero weight point starting point of the scale This zero or starting point must be initialized with an empty weigh hopper There must be no binding or leverage put on the load cell The second weight point used in the load cell calibration procedure is a known amount of weight for the weigh hopper A calibration weight is provided with all rate monitors The calibration weight is stamp
13. securely and read the actual RPM of the extruder Supplementary documentation on this proximity switch is provided from its manufacturer To wire the supplied inductive proximity switch the PLC enclosure please refer to the supplied wiring schematics Chapter 3 Installation 27 of 60 If an Ethernet module was purchased with the system the proper setting has to be changed to measure the extruder s RPM with communications For details on changing the settings for measuring the extruder s RPM please refer to the Addendum 7 4 The controller will be factory set to use the Ethernet module if it has been supplied Final Connections Connect the rate monitor to the appropriate power source Connect the compressed air piping ensuring that a 5 micron air filter is installed along with the proper water trap Verify that 60 psi of clean dry compressed air is supplied to the GH Hopper After powering up the rate monitor the following screen will be shown Figure 13 Display Startup Screen Touch here to skip quickly to the Recipe Screen Next Screen in sequence version Main 1 5 Extrusion Monitoring a gt PLC Version Copyright HHHH 8 3004 Note It may take 45 50 seconds for the screen to appear This screen displays the software version of both the PLC and the Panel View The Controller will stay on this screen for about 10 seconds or you can touch the ACS icon to quickly skip to the Recipe Screen Next Screen in s
14. the above limitation may not apply to you The Company s obligation for parts not furnished as components of its manufactured equipment is limited to the warranty of the manufacturers of said parts The company neither assumes nor authorizes any other persons to assume for it any liability in connection with the sale of its equipment not expressed in this warranty No person agent manufacturer distributor dealer installer or company is authorized to change modify or extend the terms of this warranty in any manner whatsoever The time within which an action must be commenced to enforce any obligation of the Company s arising under this warranty or under any statute or law of the United States or any state thereof is hereby limited to the duration of this warranty Some states do not permit this limitation so the above may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state For transactions involving the potential applicability of international law or that of a foreign country this warranty policy and the procedures hereunder shall be governed by applicable federal and state law but not by the United Nations Convention on Contracts for the Sale of Goods Chapter 7 Appendix 47 of 60 Customer Responsibilities Any sales use or other tax incident to the replacement of parts under this warranty is the responsibility of the purchaser Annex B Information The
15. your wish for assistance and to obtain an RMA return material authorization number If the Shipment is Not Complete Check the packing list as back ordered items are noted on the packing list You should have M GH Frame Display Enclosure w connecting cable cable in PLC enclosure on frame Calibration Weight Weigh Hopper May be mounted on the frame Bill of lading Packing list Operating and Installation packet H HR RR Electrical schematic and panel layout drawings Kl Component instruction manuals if applicable Re inspect the container and packing material to see if you missed any smaller items during unpacking If the Shipment is Not Correct If the shipment is not what you ordered contact parts and service department immediately at 810 720 7300 Have the order number and item number available Hold the items until you receive shipping instructions iii Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department Credit Returns Prior to the return of any material the manufacturer must give authorization A RMA number will be assigned for the equipment to be returned Reason for requesting the return must be given ALL returned material purchased from the manufacturer returned is subject to 1596 75 00 minimum restocking charge ALL returns are to be shipped prepaid The invoice number and date or purchase order number and date must be s
16. 0 Chapter 7 Appendix 53 of 60 Figure 72 Typical Analog Options Htruder HHHH Done Analog options screen This screen is not used with the GH M Rate Monitor Adjust appropriately for GH Full Control units and GH F units Figure 73 Typical Diagnostics Screen RFM HEHH H HHHH H HHHH E HEHH H HHHH H HHHH H HEHH 8 HHHH H HHHH E PLE Error Reset High Lows Go back to Code HHHHH Target Extruder RPM HHH 8 Engineering Measured Extruder RPM 3HBBE Steady Frac H5 HUMBER OF WTP ERT RPM Stable eed ie EXT WIP 5Stable THHHHE Hauloff Stable Only Directory Diagnostics Screen Use this screen for trouble shooting and making tuning adjustments Typically make an adjustment reset high lows and then weight for some time to observe this page Chapter 7 Appendix 54 of 60 Customer Setup Menu Password Protection The Setup screen allows you to change the default User Password that the GH Hopper uses to lock out certain screens The password by default is 5413 To change the password follow the steps listed below 1 Set the Selected Operator to USER by touching the box located next to Select Operator 2 Touch New Password and enter in a new password 3 Touch Verify Password and enter in the same password 4 A message telling you that the password has been changed will appear 1 Select USER 4 Back to Setup Directory
17. ARM 4 NO EXTRUDER RPM DETECTED 5s NO EXTRUDER FLOW DETECTED 6 HAULOFF DRIVE FAILURE 7 LOADCELL OVER MAX 8 PLC BATTER LOW Check PLC and Configure the GH Hopper 9 PLC MODULE LOADED Turn Off Unit Remove Module then Configure the GH Hopper 10 RELOAD TOO LONG 1l GRAVIMETRIC PERCENTAGE TOO LOW Decrease Extrusion Rate Chapter 7 Appendix 58 of 60 WRITING SETPOINTS EXPLANATION Extruder RPM set points recipe set points and haul off set points can be wrote to while the unit is in stop mode After engaging either RPM mode or Weight mode then the appropriate values will be applied While in RPM mode the target recipe value will be overwrote by what the current actual running value is This ensures that when you transfer to Weight Mode that the line set points do not change This acts as a virtual cruise control for your line Bring the extruder and haul off up to the desired outputs and then place the unit in Weight Mode to maintain the ratio even as the screen pack builds up material over time The Extruder RPM set points and haul off set points can be modified while in RPM mode and the unit will respond immediately The Recipe set point can be modified while in Weight mode Some recipe set points may include the extruder RPM or the haul off speed depending on the recipe mode selection If the recipe mode selection is Ibs ft and the second entry is set to extruder rpm input then the target Ibs ft and the extruder rpm is set by th
18. Full control diagnostics Serial printer Output Chapter 2 Functional Description 15 of 60 e Optional Ethernet communications System Component Description This section describes the various components of the rate monitor system Extruder Inductive Proximity Switch The extruders RPM must be reported to all GH GH M and GH F Systems for them to function To accomplish this an inductive proximity switch is provided to let the controller know the RPM of the extruder This switch should be field mounted in an appropriate way to read the extruder s true RPM It is important this switch is reading the actual RPM of the Extruder and not an RPM before a gearbox for example Chapter 3 will detail the installation and wiring of this component Because it is field mounted wiring of the proximity switch will NOT be done at the factory and we do not provide any custom mounting brackets for your application as these vary depending on the equipment This measurement can also be achieved by writing the extruder s rpm through communications see document at the end of this manual for details NOT AVAILABLE FOR GH F FEEER UNITS If this is done through communications then it eliminates the need to install the extruder proximity switch Surge Hopper The surge hopper is located on top of the GH frame These hoppers store a supply of material to fill the weigh hopper The surge hopper is sized based on the total throughput of the extrusion rate monitori
19. Functional Description 14 of 60 Figure 2 Equipment Specifications Modell 10 20 40 Maximum Extrusion Rate Ibs hr kg hr 600 272 1200 680 2500 1134 Weigh Hopper Capacity cu ft Liters 0 35 10 0 7 20 1 41 40 Load Cell Capacity kgs 1 10kg 1 20kg 1 30 kg Typical Weigh Hopper Size bs Approximate Dimensions in mm Height 5 34 5 875 51 5 1308 56 5 1435 Width 5 26 0 650 37 5 952 37 0 940 560 5 952 Depth 5 22 0 560 37 0 940 40 0 1016 2 3 Typical Features and Components Mechanical Features Removable stainless steel weigh hoppers Stainless steel surge supper supply hopper with integral air cylinder and urethane dump cone Precision 1 1046 span accurate cantilever load cell weighing system Inductive extruder tracking proximity switch not necessary if writing extruder speed through communications Rugged industrial mild steel painted frame Cast aluminum spool with drain and purge ports Figure 4 Typical GH Allen Bradley PLC Enclosure Controller Features LCD touch screen interface display operator control panel with 8 cable optional on GH M units system requires 1 per facility for setup and maintenance Allen Bradley Micrologix 1500 PLC Thermocouple Input card for loadcell Analog Output module for GH Full Control units and GH F Gravimetric Feeder Systems Manual key switch control function for reload Visual Alarm Alarm log
20. INT INFO 1 entered extruder rpm target f13 12 write desired rpm here 2 extruder rpm target f13 4 3 extruder rpm instant f13 1 write rpm value here if you are not using the extruder prox signal for the calculation NOT FOR GH F GRAVIMETRIC FEEDER UNITS HAULOFF SETPOINT INFO 1 entered hauloff speed target f18 13 write desired line speed here 2 hauloff speed target f18 3 3 current measured hauloff speed TI RECIPE SETPOINT INFO entered recipe target f19 1 write desired recipe entry here such as Ibs hr Ibs ft Ibs ft recipe running target f19 0 running target based on hopper mode recipe actual value f19 4 compare this to target for accuracy ext wm target f11 16 Ibs hr or kgs hr depending if the system is in imperial or metric ext wtp average f11 3 Ibs hr or kgs hr depending if the system is in imperial or metric layflat f19 3 Er Se le STEADY FLAGS 1 system stable b50 2 5 2 extruder rpm stable b50 1 14 3 extruder wtp stable b50 2 0 4 hauloff stable b50 2 1 Alarm Number Explanation The alarms are given in individual bits and are reflected in the alarm number The alarm number is only used to drive a pop up message and will probably not be very useful to you If you decide to use the alarm number instead of reading the individual alarm bits then the related values are shown below N26 0 Value Alarm Description 0 NO ALARM l HOPPER LOW LEVEL 2 HOPPER OUT OF MATERIAL 3 HOPPER OVER FILLING AL
21. K the controller will display PLEASE WAIT Next the controller will ask you to hang the calibration weight on the weight hopper and press OK Finally the controller will ask you to remove the calibration weight and press OK to complete the calibration The controller will verify that the calibration was done correctly by showing Calibration Successful Press Done until you have reached the Recipe screen Figure 16 Display Calibration Screen Enter in the Calibration Weight Press here to perform the calibration Go Back to the Done Calibration Directory Calibration Weight for Meu Calibration Load Cell Bits 4HHHHHHt ENTER CALIBRATION WEIGHT BOVE then Remove Weigh Hopper and press OK Verifying Calibration Recommended on a periodic basis to ensure accuracy 1 From the Recipe Page touch the Manufacturer s icon and enter 5413 then press the Enter key Touch Calibration and then Direct Scale Readout Ensure the weigh hopper is empty Locate the weight display for the load cell directly below Current Bits Write down the displayed value Chapter 3 Installation 32 of 60 Add the calibration weight to the weigh hopper and write down the value displayed in weight as in step 4 Subtract the values recorded in step 4 from step 5 This is the measured weight If the measured weight is within a 0 003 pounds of the wei
22. Process before making adjustments based on the displayed throughput The initial learning process will be complete when the Steady Process indicator is displayed on the recipe screen You are now ready to run the unit as normal The Steady flag indicates that the measured throughput in reliable and can be used for control The system will automatically stop loading the hopper once the GH is put into Stop Mode Operator Displays Figure 33b Typical Operator Screen for GH Full Control system ACS EXT RPM Stable Group EXT WTP Stable Hauloff Stable Mode 3 Follow these steps to run the line 1 Place the GH in RPM Mode by touching the RPM Mode button from the recipe page 2 Enter a target extruder RPM and hauloff speed 3 Wait until you see the Steady Process indication before using Ibs hr data 4 If you stay in RPM Mode then the extruder RPM and hauloff speed will remain constant However the function of the system is weight control By placing the system in Weight Mode you can then adjust the system to a target Lbs hr and Feet Min There are 2 other modes that can be used Weight Per Length and Weight Per Area In each of these modes the system can be custom configured for your recipe format see setup The benefit of placing the system in Weight Mode Chapter 4 Operation 38 of 60 is that the extruder speed will be slowly adjusted as the output of the extruder drops over t
23. RANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES GUARANTEES AGREEMENTS AND SIMILAR OBLIGATIONS OF THE COMPANY AND OR MANUFACTURER UNLESS OTHERWISE SPECIFIED IN THE SPECIFIC PRICE PAGE OR LIMITED BY THE MANUFACTURERS WARRANTY FOR PARTS The Company s obligation is limited to repair or replace FOB the factory any parts that are returned prepaid within one year of equipment shipment to the original purchaser and which in the Company s opinion are defective Any replacement part assumes the unused portion of this warranty Warranty Restrictions This parts warranty does not cover any labor charges for replacement of parts adjustment repairs or any other work This warranty does not apply to any equipment which in the Company s opinion has been subjected to misuse negligence or operation in excess of recommended limits including freezing or which has been repaired or altered without the Company s express authorization If the serial number has been defaced or removed from the component the warranty on that component is void Defective parts become the property of the warrantor and are to be returned immediately without any further use or handling Warranty Liabilities THE COMPANY EXPRESSLY DISCLAIMS ANY AND ALL LIABILITY FOR ANY SPECIAL CONSEQUENTIAL OR INCIDENTAL DAMAGES OR EXPENSES THAT RESULT FROM THE USE OF THIS PRODUCT Some states do not allow the exclusion or limitation of special consequential or incidental damages so
24. back to Analog Options Setup Directory Select the desired menu to advance to the screens listed below The exit to the Setup screen select Done Figure 69 Typical Advanced Weight Options Screen Weight Filter Time to settle hopper after as sec reload valve has shut EZA Hopper Height San Lbs No Flow Timer E No Flow Bits Advanced Weight Options Screen Only adjust the weight filter upon request by service Increase the Time to settle hopper after reload valve has shut if the hopper needs more time to settle after reloading Increase No flow timer and decrease No flow bits to reduce nuisance no flow alarms Set to 0 will disable this alarm Figure 70 Typical WTP Alogorithm Options Higorithm Uptions Percent of Hopper for Calculation ES Number of Pulses for Calculation Ea WTP RPM Filter Steady WTP RPM Window Max Allowed WTP RPM WTP Algorithm Options Screen The method that is used to calculate the measured Ibs hr is entirely adjustable to fit any application The three methods that can be used is Extruder Pulse Count Method Percent of Hopper Method or Full hopper Method You cannot use the Extruder Pulse Count Method if you are writing the extruder speed through communications instead of using our inductive proximity switch Chapter 7 Appendix 51 of 60 Extruder Pulse Count Method This method updates
25. ce changes in the loadcell and cause an erratic response in your control system When set properly the weigh hopper can be hit with a hammer not Chapter 7 Appendix 52 of 60 recommended and it will not cause any error in the displayed measurement Another more common procedure would be if an operator intermittently adds a processing agent to the extruder by dumping it directly into the weigh hopper This will not cause any error due to the measurement algorithm that was previously mentioned Max Allowed WTP RPM If a Ibs hr per RPM value is every calculated above this setting then the GH will ignore the sample This is to prevent an operator from draining a hopper while running and causing an erroneous but consistent measurement The flow through an open drain tube is very consistent and would cause the extruder to respond by speeding up unless this value is setup By default this is disabled and must be configured by a knowledgeable service person After running for some time you can go to the WTP RPM Calibration page and observe the average WTP RPM factor You can then set this value above that by 200 300 to eliminate the error caused by draining the hopper while running Figure 71 Typical Mechanical Options Screen Max speed of Should be factory set to GH Hopper Mode GH F Gravimetric Feeder GH F Only Used to change Mrite Ext RPM through COM F13 1 the pulses per Go back to revolution of Removeable Hopper Engineering
26. charge This section includes instructions checks and adjustments that should be followed before commencing with operation of the GH Hopper These instructions are intended to supplement standard shop procedures performed at shift daily and weekly intervals The Operation chapter includes a description of electrical and mechanical controls in addition to information for operating the GH Hopper safely and efficiently The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service Preventive maintenance sections are included to ensure that your GH hopper provides excellent long service The Troubleshooting chapter serves as a guide for identification of most common problems Potential problems are listed along with possible causes and related solutions The Appendix contains technical specifications drawings schematics parts lists and available options Refer to this section for a listing of spare parts for purchase Have your serial number and model number ready when ordering Safety Symbols Used in this Manual The following safety alert symbols are used to alert you to potential personal injury hazards Obey all safety messages that follow these symbols to avoid possible injury or death DANGER DANGER indicates an imminently hazardous situation that if not avoided will result in death or serious injury WARNING WARNING indicates a po
27. ctions oett EI EE ONDE ali est ot dee 47 Kerg timo teles iode i i Dos oae Lo eei ets aEe aU 47 Customer di6sponpsiDIIIeS o or eio o E ae Rn e Poe tenda idee obese 48 Ann x Be LO ONION me D cr 48 7 2 Addendum Service Supervisor Information EE 50 Programmable Seflings etg e trata ed Ehe 50 Customer Setup MODs iere ds lees Seege ee 55 7 3 Allen Bradley Communications Manual 56 Parts Depantment m 60 EES e dee 60 Sales Department e e eei NE qe tor ue dada catu eagle 60 Contract Department sso Moon entire tup denen end eue puedas 60 vi Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining your rate monitor The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This manual covers only light corrective maintenance No other maintenance should be undertaken without first contacting a service engineer The Functional Description section outlines models covered standard features and safety features Additional sections within the manual provide instructions for installation pre operational procedures operation preventive maintenance and corrective maintenance The Installation chapter includes required data for receiving unpacking inspecting and setup of the GH hopper We can also provide the assistance of a factory trained technician to help train your operator s for a nominal
28. e Internal components of the control panel e Input signal to the control panel Output signals from the control panel Internal Components of the Control Panel Note See Installation Packet supplied with unit for complete electrical schematics This section describes the internal components of the GH Hopper system control panel It is not the intent of this section to completely familiarize the reader with the details on industrial control panel construction or standards but simply to familiarize the reader with the major components inside the control panel The customer must supply 120 1 50 or 60 or 220 1 50 or 60 via wires L1 amp L2 N Please insure that the earth ground connection is properly connected to an established earth ground e Power on is indicated by a lighted on off switch e Reload switch controls the vertical reload gate above the hopper e Safety Active light displays status of safety interlock circuit Audible alarm horn alerts operator to GH Hopper fault Chapter 5 Maintenance 43 of 60 Input Signals to Programmable Controller The rate monitor system has two main input signals that it uses from the extrusion process the weigh hopper load cell and the extruder speed reference This of course does not include the operator touch screen input The extruder speed reference is generated from the supplied inductive proximity switch or is wrote to the PLC through the optional Ethernet module Load cells r
29. e operator while the PLC calculates the target feet min needed to achieve the desired recipe No set points can be modified while in Monitor Mode The PLC will take constant snap shots of the extruder RPM haul off speed and recipe set points and will write these to ensure a bump less transfer when entering into either RPM Mode or Weight Mode The system can be placed in RPM Mode or Monitor Mode from stop at any time The system can go from RPM Mode Weight Mode or Monitor Mode into stop mode at any time as well However there are restrictions when transferring between other modes The system must be stable before it will allow you to transfer from RPM Mode into Weight Mode Also the system must be stable when transferring from Monitor Mode to RPM Mode If you are in Monitor Mode you must transfer into RPM Mode and then stabilize before going into Weight Mode FIXED DECIMAL EXPLANATION All weight values and recipe values use fixed decimal This must be taken into consideration when writing or reading values If you see xxx xxx above this means the data is in fixed decimal and must be scaled when reading or writing A decimal is shown next to each item to represent the format Chapter 7 Appendix 59 of 60 Technical Assistance Parts Department Call Spare Parts Express toll free 8am 8pm EST 800 423 3183 or Phone 810 720 7300 Fax 810 720 2598 OEM quality replacement and
30. e software Figure 48 Typical Manual Control Operator Screen MANUAL CONTROL CAUTION System will stop if manual reload is turned on Hop Ht G gpugn Lbs The dump valve opens as soon as you touch the Reload Off button The button then changes to show Reload On Note The system will stop if you attempt to turn the manual reload on This could be devastating if you are running the extruder Print Inventory The print inventory menu item is used to produce on demand inventory printouts Before selecting this item be sure that the printer is properly connected and ready This function will generate an inventory Chapter 4 Operation 41 of 60 Chapter 5 Maintenance 5 1 Preventative Maintenance Schedule The mechanical design of the GH Hopper is very simple and very little maintenance is required The only moving parts are the metering gates weigh hopper dump valve and mixer agitator The checklist below contains a list of items which should be inspected and or replaced to keep your GH Hopper operating at peak efficiency Perform each inspection at the regular intervals listed below Figure 52 Sample Preventative Maintenance Schedule Dail Date Date Date Date Date Date Date Date Date Date Date Date Date y By By By By By By By By By By By By By Inspect hopper for any loose parts tighten them immediately Verify quality of compressed air supply Inspect weigh hopper f
31. echanical Features eee Lx ed imt me dg du ded 15 Controller FG QUIRES ee Eege Eege 15 System Component Description sessi essen eene rn nnns nitens nnn 16 Extruder Inductive Proximity Switch 16 el eer Tei 16 Weight Hopper iiss EE 17 Operator Control Panel Display optional on GH M units 1 required per facility for setup and Maintenance nsore nn p enne enne 17 2 4 Optional Reen En CN 22 Ethernet Module sts pipe teo ido t ra Seo SD ar eget e EP or ens fost Eu 22 Pneumatic Slide Gate below surge hopper sessi 23 Low Level Proximity Sensors ets tr p e RR Ratte RERUM NE RehE 23 2b Safety EE 23 CHAPTER 3 INSTALLATION eeese ses 24 JT Urncraung the e len ET 24 3 2 Mechanical Installation t eee ria e SCENE 24 Site PAC OUI TIONG ebat aces ridet eate pet ete eR ue tee n ta E iege IE HS 24 Mounting Configurations EE 24 Machine MOUT toi eic Elite iet eae EN eo LE AER ea ESEE E EE etA 25 ou Electrical GCOHBBOlIODS iio od Eeer 25 3 4 Pneumatic Connections os en trim tag xa qe n EENS EEN 26 9 5 Tu EIER e NEE 27 Mechanical SOT UD ci eege E 27 Weigh Hopper Installation eese nennen nennen nennen 27 Extruder RPM connection cccccccccesssssecesseeeceeeescececseaeececsesaececeeaaeeecneaaeeeeneaaes 27 Final ert e EE 28 COMMONER EE 29 GH Controller Menu Structure sese eene ener enne 30 GH Calibration E 30 CA RH ie TT EE
32. ed with its actual weight on top If this is not available any object with a known weight accurate to the nearest 1 1000th of a pound in the 2 10 Ib range proportional to your size rate monitor will suffice The weight should be as close as possible to the weigh hopper s capacity The weight will be in pounds unless the rate monitor is provided for metric operation In the case of a metric display the weight to be used is calibrated in kilograms Given the two weight points on the load cell scale the controller should determine any other weight on the load cell span This is limited to the maximum capacity of the load cell The standard load cell used on rate monitors has a span accuracy of 10 The maximum capacity of each load cell is clearly marked on top of the load cell This value will be indicated in kilograms 1 kg 2 2 Ibs Weigh Hopper Load Cell Calibration 1 From the Recipe Page touch the Manufacturer s icon and enter 5413 then press the Enter key 2 Touch Calibration and then Scale Calibration Chapter 3 Installation 3 of 60 Instructions Figure 15 Display Calibration Menu Screen Go back to the Setup Directory Direct Scale Readout eight RPM Calibration Once in Scale Calibration enter in the scale calibration weight value stamped on the side of the weight The controller will prompt you to empty the weigh hopper and press OK After touching O
33. ent damage to the equipment do not exceed 60 psi 4 14 bar air Caution Always disconnect the compressed air supply when working on any part of the rate monitor Chapter 3 Installation 26 of 60 3 5 Initial Set up This section will discuss the mechanical setup and control system setup of the rate monitor system After reading this section you should be familiar with the mechanical setup and the electronic control setup of the rate monitor Mechanical Set up Weigh Hopper Installation It is necessary to install the weigh hopper Remove the weigh hopper from the shipping box and install it onto the load cell bracket Two provided thumbscrews are used to secure the weigh hopper to the load cell bracket Figure 12 Picture of Weigh Hopper Note THE WEIGH HOPPER ASSEMBLY MUST HANG FREELY AND BE FREE FROM FRICTION WITH NO MECHANICAL OBSTRUCTIONS OTHER THAN THE LOAD CELL ITSELF It is very important the tube stub of the weigh hopper does not touch the supplied dust ring It is also important the flange of the weigh hopper be completely flush with the load cell bracket Extruder RPM connection The supplied inductive proximity switch must be mounted to accurately read the Extruder s RPM If the optional Ethernet module was purchased the extruder s speed may be reported to the controller via communications see communications section at the end of this manual NOT AVAILABLE FOR GH F UNITS The proximity switch must be mounted
34. equence The software versions are also available on the Panel View Configuration Screen Figure 14 GH M Display Main Recipe Screen To access the Setup Menu to change the controller features refer to the following pages of this manual Chapter 3 Installation 28 of 60 Controller Set up This section describes the proper setup of the GH system control parameters These parameters are operator changeable however these items should only require setup during the initial installation Only authorized personnel should change them For security reasons the menu that is used to access these parameters is password protected Many of the variables and setup parameters have been preset at the factory and do not need to be changed However this section of the manual will address all of the rate monitor setup parameters that were available at the time of printing The purpose of this is to familiarize the reader with all the setup parameters and their usage A complete listing of all default values is provided at the end of this manual Chapter 3 Installation 29 of 60 Recipe Page Start Extruder RPM is displayed Extruder throughput is displayed Line Speed is displayed GH Full Control with Line speed option Only Weight Per Length Weight Per Area or simple throughput is displayed on GH Full Control versions depending on setup parameters GH F Target throughput and percent is displayed GH F Only Access Inventory Page Acc
35. equire 12 volts DC to operate This is known as the load cell s excitation voltage Output Signals from Programmable Controller The rate monitoring system uses several output control signals to control the process All of these are very similar in nature The surge hopper refill solenoid is controlled by a PLC output Chapter 5 Maintenance 44 of 60 Chapter 6 Troubleshooting 6 1 Introduction The utmost in safety precautions should be observed at all times when working on or around the machine and the electrical components All normal trouble shooting must be accomplished with the power off line fuses removed and with the machine tagged as out of service The use of good quality test equipment cannot be over emphasized when troubleshooting is indicated Use a good ammeter that can measure at least twice the AC and DC current that can be encountered for the machine Be sure that the voltmeter has at least minimum impedance of 5 000 OHMS per volt on AC and 20 000 OHMS per volt on DC scales Popular combination meters VOM and VTVM can be selected to provide the necessary functions Before making haphazard substitutions and repairs when defective electrical components are malfunctioning we recommend that you check the associated circuitry and assemblies for other defective devices It is common to replace the obviously damaged component without actually locating the real cause of the trouble Such hasty substitutions will only destr
36. ervice All gravimetric rate monitors are sized to meet the specific requirements stated by the Customer at the time of purchase 2 2 General Description GH M Rate Monitor Systems are designed to measure the extrusion rate of plastic pellets and regrind This measurement can be read at a local display or monitored through the communications using the Ethernet module GH Full Control Systems are designed to measure the extrusion rate of plastic pellets and regrind This system can then control the output of the extruder and hauloff if using the line speed option to a desired target value that is entered by the operator This system can be used for monitoring as well as full control Some of the configurable methods of operator input are Ibs hr kgs hr feet min meters min weight length and weight area GH F Gravimetric Feeders are designed to gravimetrically control the feed rate of an additive feeder using a loss in weight hopper that is mounted directly on the feeder This feeder then flows into the extruder The operator enters in a desired percent The system continuously measures the speed of the extruder through a proximity switch mounted at the back of the screw this can also be wrote through communications and then calculates the extruders throughput based on a volumetric approximation Based on the entered percent and the current calculated extruder throughput the system then calculates a target Ibs hr or kgs hr for the feeder Then ba
37. ess Setup Page Next to access Inventory page GH Controller Menu Structure Inventory page gt Clear Inventory gt Manual Control gt Next returns to Recipe page Manual Control Page gt Reload ON OFF gt Return to the Inventory Page Setup Page gt Touch the ACS icon and enter in the user password Chapter 3 Installation Recipe Format for GH Full Control Only gt System Rate amp Line Speed gt Weigh Per Length Mode gt Weight Per Area Mode Hopper Setup gt Hopper size gt Reload Percentage Extruder Setup gt Maximum Extruder RPM gt GHF Extruder Max Throughput GH F Only Hauloff Setup for GH Full Control Only Hauloff enable disable Read Do Not read speed from COEX Master Hauloff Max Speed Calibrate Encoder Calibration gt Scale Calibration gt Direct Scale Readout gt Weight RPM Calibration Panel View Config Panel view GH version gt PLC GH version Units gt Lbs vs Kgs Password gt New Password gt Verify Password Alarm Log gt View print and clear the alarm log Alarm Setup gt Min System Speed gt Max System Speed gt System Unstable Alarm Time gt Maximum allowed reload time gt Hopper for low level alarm gt Hopper for no material alarm gt Out of material alarm silence delay Network Setup IP Address Subnet Mask Send Config to ENI Module Enable Ethernet Configurator Enable
38. fer to the assembly drawing with the unit for actual height and width dimensions Note Allow at least 36 clearance around the GH System to provide adequate room for cleaning servicing etc Using proper lifting equipment lift the rate monitor Affix the rate monitor to the processing machine Note Larger rate monitors may need to be braced as part of the installation Take care to insure proper orientation with adequate access to operator controls mix chamber and metering units Note Never weld on the GH Hopper support stand machine or mezzanine without first removing the control panel and verifying that the hopper is properly grounded 3 3 Electrical Connections The standard rate monitor system is designed to operate on 120 1 60 supply voltage For exact current requirements check the GH Hopper serial number tag located on the right side of the PLC enclosure If a step down transformer was provided it should never be used to power anything other than the rate monitor Loading equipment etc must be powered by another power source As well as possibly overloading the transformer the additional equipment may induce power line noise that may affect the operation of the rate monitor The transformer will be mounted and wired by the customer or your installer If company or local codes require fusing or disconnects these items must be supplied wired and mounted by the customer Note Each GH System MUST be connected to a se
39. following design information is provided for your reference 1 2 Qo Sd V UV aea bo 11 12 13 14 15 16 17 Cable support may be required for power cord depending on final installation 19 20 Two hand control is not required or provided 22 23 21 24 25 26 No modifications are allowed to this equipment that could alter the CE compliance Ambient temperature 40 degrees Celsius Maximum 104 degrees Fahrenheit Humidity range 50 relative humidity Altitude Sea level Environment Clean dust free and non explosive Radiation None Vibration Minimal i e machine mounting Special installation requirements Clean dry compressed air 1 cfm 60 psi 1 7 m hr 4 14 bar Allowable voltage fluctuation 10 Allowable frequency fluctuation Continuous 1 Intermittent 2 Nominal supply voltage 120 1 60 or 220 1 50 60 Verify on serial number tag Earth ground type TN system has one point directly earthed through a protective conductor Power supply should include a neutral power connection Over current protection is supplied in the GH Hopper but additional protection should be supplied by the user The plug on the power cord serves as the electrical disconnect device Unit is not equipped with three phase motors Functional identification No one is required to be in the interior of the electrical enclosure during the normal operation of the unit Only skilled electr
40. ght stamped on the calibration weight then you are within spec If not follow the steps above to calibrate the rate monitor If your rate monitor is frequently out of calibration verify the operator is being cautious removing the weigh hopper Press Done until you have reached the Recipe screen Anything in the Diagnostics Menu that is not covered here is in the Detailed Controller Setup Section WTP RPM Calibration Page This page is used to monitor the Ibs hr per RPM analyzer and is used as a tool for tuning the WTP Algorithm Options mentioned later in this book AYG WTP RPM race Wt RPM FIFO 8 1 a 3 4 2 6 8 3 MTP RPM Dif HHHHH Hopper Size Setup The weigh hopper size is factory set In may be necessary however to change this value due to varying bulk densities of material 1 St 2 c9 Enter the Setup Menu Select Hopper Setup Enter the required size for the weigh hopper should be close to full Set the refill percentage to 50 Press done to return the setup menu Figure 17 Hopper Setup Hopper size HHH Lbs Reload Percentage oe O 5 Chapter 3 Installation 33 of 60 Extruder Setup Use this page to setup the Maximum Extruder RPM This is critical for GH Monitor units and GHF feeder units This value is automatically calculated with GH Full Control units Also for GHF Feeder units you will need to program in the maximum LBS HR of the extruder for the
41. hands while it is running Before you start the GH Hopper check the following e Remove all tools from the unit Be sure no objects tools nuts bolts clamps bars are laying in the feeding area Note Note Note Note If your rate monitor has been inoperative or unattended check all settings before starting the unit At the beginning of your shift and after breaks verify that the controls and other auxiliary equipment are functioning properly Keep all safety guards in place and in good repair NEVER attempt to bypass modify or remove safety guards Such alteration is not only unsafe but will void the warranty on your equipment When changing control settings to perform a different mode of operation be sure selector switches are correctly positioned Locking selector switches should only be adjusted by authorized personnel and the keys removed after setting Report the following occurrences IMMEDIATELY Unsafe operation or condition Unusual action Leakage Improper maintenance Note Note Note Note NEVER stand or sit where you could slip or stumble into the rate monitor while working on it DO NOT wear loose clothing or jewelry which can be caught while working on a rate monitor In addition cover or tie back long hair Clean the rate monitor and surrounding area DAILY and inspect the machine for loose missing or broken parts Shut off power to the GH Hopper when it is no
42. hot and time are used to calculate the overall usage since the last reload This is also the least responsive setting WTP RPM Filter When switching between the 3 methods you need to understand the sample time and configure the WTP RPM Filter appropriately A good example of this is that by default the hopper is configured to reload at 5096 keeps material in the vertical section of the hopper sample in Percent of Hopper Method at 20 and uses a filter of 9 If it is desired to switch to the Full Hopper Method then you don t need a filter of 9 A filter of 9 uses 10 points At a sample of 20 you get 2 samples per reload It would therefore take 5 reloads to fill the analyzer upon starting the line After that the measurement will be updated with each and every 20 When switching to the Full Hopper Method you only need a filter of 4 to achieve the same time frame of samples but the response will be much dampened to any oscillation or error in measurement If using the Extruder Pulse Count Method then you must do the math to determine what sample time frame you need Steady WTP RPM Window No matter which method you chose the analyzer compares the series of measurements to the Steady WTP RPM Window percent to determine if the measurements are stable If this is set too small the system might never give you a Steady Process indication If set too big then the system could respond to nuan
43. icians should be inside the enclosure for maintenance Doors can be opened with a screwdriver but no keys are required All hoppers should be moved around and set in a place with a lift truck or equivalent There are no frequent repetitive cycles that require manual control repetitive functions are automatic while the GH Hopper is operating An inspection report detailing the functional test is included with the GH Hopper The machine is not equipped with cableless controls Color coded harmonized power cord is sufficient for proper installation Chapter 7 Appendix 48 of 60 Figure 57 Typical Surge Hopper Assembly Parts List DESCRIPTION 010 020 040 Lid Smaller vacuum receivers 08223 1 872 00769 00 872 00830 00 1 Lid Larger vacuum receivers NA 872 00783 00 Lid Tube Stub for Mezz Mounted GH Hopper 08223 2 2 1 8 NPT fitting 35085K 35086K 3 1 4 NPT fitting 35154 35155 4 Bulkhead 35146 5 Brass elbow 35118 6 24V DC Solenoid 33128 7 Dump cone 15370 15237 8 Aircylinder 33126 33073 33011G Figure 60 Typical Weigh Hopper Assembly Parts List DESCRIPTION 010 020 040 1 WEIGH HOPPER 822 00382 00 822 00383 00 822 00384 00 2 LOAD CELL 61 1010E 10KG A0564528 A0564546 LOAD CELL 3 BRACKET 872 00669 00 Figure 64 Typical Allen Bradley Controller Main Parts List
44. id will have a tube stub on it The surge hopper will be mounted on the frame at the factory The 24V dc solenoid will also be factory wired In some rare cases it may be necessary to remove the surge hopper for shipping purposes Weigh Hopper The weigh hopper is located within the GH frame The hopper size is set within the controls Default for refilling to occur is 50 of the weigh hopper size The weigh hopper on the rate monitor is used to weigh the material entering the extrusion process Once the weigh hopper goes below 50 of its set weight capacity the solenoid valve on the surge hopper will open allowing material to fall from the surge hopper to the weigh hopper The surge hopper solenoid will close once the weigh hopper reaches its set weight capacity Details for installing and removing the weigh hopper are included in the next section The weigh hopper will need to be installed before operation can begin It is necessary to remove the weigh hopper for shipment so the loadcell is not damaged When the weigh hopper is installed use care not to damage the load cell Position the hopper Note Use care when replacing the weigh hopper since the load cells are delicate weighing instruments and can be easily damaged Do not use force to push in the weigh hopper Note Load cells if damaged will have to be sent back to the manufacturer for testing and evaluation Note Make sure no part of the load cell bracket is touching the p
45. ienced plant personnel should not access programmable features Unauthorized changes may prevent the rate monitor from operating properly and may void part or all of the warranty Note Call the Service Department for assistance or for further explanation of these or any other programmable features which may or may not be shown in this manual Note Information included in this manual is subject to change without notice Passwords e User Password 5413 e Maintenance Password 3145348 Caution Maintenance password should only be supplied to qualified personnel The program can be compromised Programmable Settings The rate monitor software program has been designed to allow some customizing to achieve certain desired operating parameters The following is a listing of the selections that are field programmable followed by the procedure for doing so Pressing the manufacturer s icon when in the Setup Directory Screen menu accesses this menu Figure 67 Typical Operator Setup Screen Touch this icon and enter in the Service Password to access the Engineering Only Directory Chapter 7 Appendix 50 of 60 Enter the long password 3145348 and press Enter The factory setup section displays the Engineering Only screen The screen similar to that shown below should be displayed and use the keystrokes described herein to change or toggle the parameters HTF Algorithm Options Mechanical Options Go
46. ily but if the alarm condition is still unresolved then the message will reappear after a short delay During an alarm condition a visual alarm will be activated The following is a list of all alarm names and descriptions Alarms with Descriptions Hopper low level alarm Hopper is about out of material Hopper out of material Hopper is out of material Inventory cleared Operator has cleared the inventory only logged Extruder no rpm detected alarm ONLY ON GH FULL CONTROL Extruder no flow detected alarm ONLY ON GH FULL CONTROL Hauloff drive failure alarm ONLY ON GH FULL CONTROL Loadcell over max alarm check loadcell circuit Reload too long alarm First indication that you are about to run out of material System not stable alarm System has been unstable for too long hopper flow over allowed max System rate is above allowed maximum setting extruder overspeed Extruder is out of allowed linear range extruder underspeed Extruder is out of allowed linear range hauloff overspeed Hauloff is out of allowed linear range ONLY ON FULL CONTROL hauloff underspeed Hauloff is out of allowed linear range ONLY ON FULL CONTROL feeder overspeed GHF only GHF Feeder is running too fast feeder underspeed GHF only GHF Feeder is running too slow surge hopper empty alarm OPTIONAL Prox is uncovered in Surge bin plc battery low replace battery with power on as soon as possible plc memory module loaded Indicates you have upgraded th
47. ime due to the screen pack becoming clogged NOTE The GH System can be started using your older speed pots by first placing the system into Monitor Mode After you receive a Steady Process in Monitor Mode you can then transfer to Step 1 mentioned above Starting the system in Monitor Mode takes longer and requires a double stabilization step NOTE You can always go from any mode to Stop Mode NOTE You can always go from Weight Mode to RPM Mode NOTE You cannot go from RPM Mode back to Monitor Mode because the GH does not know where the speed pots are set at This is a safety and can be bypassed only by placing consulting the factory for details 4 3 GH F Gravimetric Feeder Operation Procedures The system will automatically start loading the hopper after the operator has first placed the GH F feeder in either RPM Mode and enters in a target RPM for the feeder or Weight Mode and the system observes an extruder RPM measured by the extruder tracking proximity switch that is mounted on the rear of the extruder It is important to note that you cannot write the extruder RPM measurement through communications on a GH F feeding system You must mount the extruder proximity switch that is shipped with the unit Operator Displays Figure 33c Typical Operator Screen for GH Full Control system ACS EXT RPM St Group EXT WTP Stable Hauloff Stable Feeder WTP Follow these steps to run the line 1 Place
48. itor may have been equipped with Ethernet Module In lieu of an inductive proximity switch the extruder s RPM may be written through communications To accomplish this an Ethernet module and connecting cable to PLC is offered as an option Chapter 2 Functional Description 22 of 60 Pneumatic Slide Gate below surge hopper The surge hopper can be equipped with a pneumatic slide gate in lieu of the air cylinder and urethane dump cone The knife gate is opened and closed by the PLC A 24 VDC solenoid is used to open and close the knife gate WARNING Slide gates create a pinch point hazard Low Level Proximity Sensors Detects material supply problems before rate monitor hoppers are empty A 24VDC capacitive proximity switch is utilized for this option The proximity switch is wired directly into the PLC enclosure If there is a material supply problem a visual alarm is activated 2 5 Safety Features This section includes information on safety devices and procedures that are inherent to the rate monitor system This manual is not intended to supersede or alter safety standards established by the user of this equipment Instead the material contained in this section is recommended to supplement these procedures in order to provide a safer working environment Chapter 2 Functional Description 23 of 60 Chapter 3 Installation 3 1 Uncrating the Equipment Rate monitors are shipped mounted on a skid enclosed in a plastic wrapper
49. l and local codes When you have completed the repair or maintenance procedure check your work and remove your tools rigging and handling equipment Do not restore power to the rate monitor until all persons are clear of the area DO NOT start and run the unit until you are sure all parts are functioning correctly BEFORE you turn the rate monitor over to the operator for production verify all enclosure panels guards and safety devices are in place and functioning properly Reporting a Safety Defect If you believe that your equipment has a defect that could cause injury you should immediately discontinue its use and inform the manufacturer The principle factors that can result in injury are failure to follow proper operating procedures i e lockout tagout or failure to maintain a clean and safe working environment Chapter 1 Safety 12 of 60 Chapter 2 Functional Description 2 1 Models Covered in This Manual This manual provides operation installation and maintenance instructions for rate monitors of various extrusion rates and specifications See below for a list of available models e GH M Rate Monitor Units e GH Full Control Units with or without Line Speed Control e GH F Gravimetric Feeder Units Model numbers are listed on the serial tag Make sure you know the model and serial number of your equipment before contacting the manufacturer for parts or service GH systems are as varied as the applications they s
50. lastic housing on the load cell This could result in inaccurate weight readings If necessary the plastic on the loadcell can be trimmed back tube stub as close to the center of the hole in the bottom of the frame as possible Operator Control Panel Display optional on GH M units 1 required per facility for setup and Maintenance The operator control panel includes an 8 foot 2 4 m cable and can be remote mounted not recommended adjacent to the GH Hopper The panel can be unplugged and removed if necessary The cable provides 24VDC power to the display as well as communications to the PLC A programmable logic controller PLC controls the GH operation This design provides excellent performance along with an easily replaceable control panel in the unlikely failure of any computer or electronic part Chapter 2 Functional Description 17 of 60 After installation and setup the GH M will begin monitoring the system process once the rate monitor detects an extruder speed The following figures show some typical screens of the GH M rate monitor Figure 8 Typical GH Series Controller Touch Screen Display Allen Bradley PanelView 550 PAG Ext een Stable Group EXT WTP Stable Figure 9 Controller Pushbuttons amp Touchscreen Tags Function Turns power on to the GH Hopper controller Power On Found on the back of the controller Turns power off to the GH Hopper controller Power Off Found on the back of
51. n hatches Automatic operation may start unexpectedly A PINCH HAZARD CAPABLE OF CAUSING BODILY INJURY EXISTS ANY TIME THE POWER IS ON Wear SAFETY GLASSES and WORK GLOVES Work only with approved tools and devices Disconnect and or lock out power and compressed air before servicing or maintaining the equipment Use care when LOADING UNLOADING RIGGING or MOVING this equipment Operate this equipment within design specifications OPEN TAG and LOCK ALL DISCONNECTS before working on equipment You should remove the fuses and carry them with you NEVER PUT FINGERS OR TOOLS IN AN AUGER OR SLIDE GATE AREA Make sure the equipment and components are properly GROUNDED before you switch on power Do not restore power until you remove all tools test equipment etc and the equipment and related components are fully reassembled Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration We expect you as a user to abide by the foregoing recommendations in order to make operator safety a reality Chapter 1 Safety 9 of 60 1 3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the machine
52. ng system Each surge hopper contains a 24V DC solenoid that is used to open and close the internal dump cone The internal urethane dump cone is mechanically opened and closed with a compressed air cylinder The GH s surge hopper does not include any level indication devices as standard equipment Optional surge hopper low level sensors are available The GH controller will alarm if it runs out of material while trying to fill the weigh hopper but low level sensors will alert floor personnel to the problem sooner If an optional low level sensor is purchased it will activate a visual alarm This optional proximity switch can be mounted anywhere the customer desires and is not mounted unless specifically requested The refill system is equipped with a manual key switch to open and close the surge hopper This three position key switch is located on the front of the PLC enclosure Figure 5 Typical Surge Hopper Figure 6 Refill Switch Positions Position Description The rate monitor controller automatically controls surge hopper AUTO g functions Chapter 2 Functional Description 16 of 60 OPEN Dump cone gate open all the time CLOSE Dump cone closed all the time Each surge hopper is supplied with a lid Standard lids contain a cutout to accept a vacuum receiver A blank lid may also be provided if specified If the rate monitor is being refilled from a mezzanine mounted GH Hopper the surge hopper l
53. nutes or a record of the meetings Hold daily equipment inspections in addition to regular maintenance checks You will keep your equipment safe for production and exhibit your commitment to safety Please read and use this manual as a guide to equipment safety This manual contains safety warnings throughout specific to each function and point of operation Operator Responsibility The operator s responsibility does not end with efficient production The operator usually has the most daily contact with the equipment and intimately knows its capabilities and limitations Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates or through a casual attitude toward machinery formed over a period of months or years Your employer probably has established a set of safety rules in your workplace Those rules this manual or any other safety information will not keep you from being injured while operating your equipment Chapter 1 Safety 10 of 60 Learn and always use safe operation Cooperate with co workers to promote safe practices Immediately report any potentially dangerous situation to your supervisor or appropriate person REMEMBER e NEVER place your hands or any part of your body in any dangerous location e NEVER operate service or adjust the rate monitor without appropriate training and first reading and understanding this manual e NEVER try to pull material out of the rate monitor with your
54. o toggle between 2 graphics n9 0 0 then hauloff is not used n9 0 1 then show graphic 1 n9 0 2 then show graphic 2 HOPPER MODE STATUS 1 ramp to stop engaged b50 6 0 2 monitor mode engaged b50 6 1 3 control by rpm engaged b50 6 2 4 control by weight engaged b50 6 3 HOPPER MODE CONTROL l ramp to stop pushed b50 5 0 toggle this bit to stop line 2 monitor mode pushed b50 5 1 toggle this bit to put in monitor mode 3 control by rpm mode pushed b50 5 2 toggle this bit to put unit in rpm mode 4 control by weight mode pushed b50 5 3 toggle this bit to put unit in weight mode HOPPER ALARMS 1 alarm number N26 0 see below for description 2 hopper low level alarm b28 0 1 3 hopper out of material alarm b28 0 2 4 hopper over filling alarm b28 0 3 5 inventory cleared b28 0 4 Chapter 7 Appendix 56 of 60 6 extruder no rpm detected alarm b28 0 5 7 extruder no flow detected alarm b28 0 6 8 hauloff drive failure alarm b28 0 7 9 loadcell over max alarm b28 0 8 10 reload too Jong alarm b28 0 9 11 gravimetrics Op too low alarm b28 0 10 12 plc battery low s 5 11 13 ple memory module loaded s 5 8 this alarm only happens while upgrading the GH Hopper s software Chapter 7 Appendix 57 of 60 INVENTORY INFO 1 clear inventory b3 0 3 toggle this to clear all inventory you must also reset this bit after completion 2 hopper_inventory f25 0 3 hauloff accumalated length f31 4 EXTRUDER SETPO
55. or obstructions Date Date Date Date Date Date Date Date Date Date Date Date Date Every week TES Verify the rate monitor is properly calibrated Check to make sure that all hose connections are air tight Inspect air regulator and air safety circuits if equipped Recalibrate rate monitor If necessary Photocopy this page for your maintenance records Chapter 5 Maintenance 42 of 60 5 2 Preventative Maintenance Our GH Hoppers need periodic maintenance to provide long dependable service Check these elements regularly e Check functionality of safety circuit daily e Maintain proper air pressure and drain water from trap assembly on regulator as required WARNING Always remove plug and disconnect power before servicing hopper lt WARNING Always read operating manual before operating or servicing hopper 5 3 Corrective Maintenance Electrical This section is designed to give the operator an overview of the electrical system that controls the GH Hopper system Since the hopper s control panel is a self contained pluggable item seldom will a maintenance person be required to enter the control panel For purposes of understanding the system it is advisable that the maintenance personnel be familiar with not only the internal workings of the control panel but also with the input and output signals to the GH Hopper This section includes the following
56. oy the new component Refer to wiring diagrams and schematics Locating mechanical problems should they occur is relatively straightforward When necessary refer to the parts catalog section Figure 53 Typical Troubleshooting Problems and Suggested Corrective Actions Problem Corrective action Check to make sure that air is hooked up and the regulator gauge reads at precisely 60 PSI Nothing happens when I start the extruder Look on the Recipe Screen If you don t see a displayed Extruder RPM then check the inductive proximity switch If you do see a displayed RPM then check the hopper s calibration Interface has been Locked is shown Tve toreonen ny Uer Contact the Service Department Password Change out the PLC with your spare and reprogram new unit PEC Banery Low Send old PLC back to Manufacturer for repair Click Unlock and enter in your User Password Chapter 6 Troubleshooting 45 of 60 PLC Module Loaded Weigh hopper occasionally overfills Problem Normal after a software upgrade Follow on screen instructions Lower the hopper size under Hopper Setup Corrective action Recorded Inventory Totals don t match what I ve actually used Printer did not print Problem The feeder calibration values are moving too much Problem Check the hopper s scale calibration and verify that the hopper is not overfilling If the hopper is overfilling adjust your hopper size If
57. parate source of power Do not connect other electrical equipment especially self contained hopper loaders on the same line as the rate monitor Ensure that the power entrance location on the rate monitor panel remains unchanged Make sure that the proper size wire and proper wire routing techniques are used when installing the Chapter 3 Installation 25 of 60 supply wiring to the control panel Care must be taken to ensure that the supply wiring does not interfere with the low voltage DC wiring The GH is supplied with a plug that functions as the disconnect device The mating receptacle must be installed no higher than 5 feet 1 6 m above the floor Make sure your installation conforms to your regional electrical standards Please refer to the supplied electrical schematics for detailed connection points for the supply power 3 4 Pneumatic Connections The GH system uses plant supplied compressed air to operate the surge hopper CLEAN AND DRY air must be supplied to the GH System The air supply should be filtered through a 5 micron air filter with a water separator Oil should not be used unless air dryers are installed on the compressed air supply In this situation an oiler may be required on the rate monitor to keep the air cylinder seals lubricated Usage is about 5 cu inches per refill A single 1 8 NPT standard pipe thread fitting is provide on the surge hopper solenoid to supply air pressure Caution To prev
58. sed on the measured rate of the additive the GH F continuously adjust the motor speed of the feeder to achieve accurate results Standard equipment is not designed to measure powder or any other materials Optional equipment may be purchased to measure the extrusion rate of powders Accessories The manufacturer offers a variety of standard options for GH Systems including knife gates low level proximity switches Ethernet communication modules and hoppers specifically designed to measure the extrusion rate of powders All accessories are designed and manufactured to ensure proper results for your application Chapter 2 Functional Description 13 of 60 Customer Service The intent of this manual is to familiarize the operator and maintenance personnel with these rate monitors and help your organization get the maximum service from your equipment If you have any questions regarding installation service repair custom equipment or applications please do not hesitate to contact us for the information required Prices for additional equipment accessories or repair parts will be furnished promptly upon request Note If you desire to use a rate monitor for an application other than that for which it was purchased please contact your sales representative or our factory to verify compatibility of the equipment with the new process Misapplication of the equipment could result in injury to the operator or damage to the equipment Chapter 2
59. spare 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 toll free 800 423 3183 8am 8pm EST Emergency service available 24 hours a day We have a qualified service department ready to help Service contracts are available for most of our products www acscustomerservice com Sales Department Call 810 720 7300 Monday through Friday 8am 5pm CST Our products are sold by a worldwide network of independent sales representatives Contact our sales department for the name of the sales representative nearest you Contract Department Call 810 720 7300 Monday through Friday 8am 5pm CST Let us install your system The Contract Department offers any or all of these services project planning system packages including drawings equipment labor construction materials and union or non union installations Chapter 7 Appendix 60 of 60
60. stem Rate Height F amp Line Speed Spa D Maintain Layflat in Estruder RPM centimeters Maximum Extruder RPM HHH UN FUR H GAR FEEDER GHF Extruder Max Throughput HHHH lbszhr HAULOFF ENCODER CALIBRATION Distance Per Revolution of Encoder Com amp Measured Hauloff Speed ft min To automatically calculate Distance Per Revolution enter actual measured speed below then click here ee HHHHHHH Lbs Calibration Load Cell Bits 1HHHHHHE ENTER CALIBRATION WEIGHT ABOVE then Remove Weigh Hopper and press OK 21 of 60 9 per RPM Calibration HHHHHH Cal Weight used Instant Wt RPM AUG WTP RPM DIRECT SCALE READOUT in stored HHEHHHH Lbs Kn FIFO calibration dHHHHHE Lei Tare Zero Bits tHHHHHHE Weight Cal Bits HHHHHHH current Bits HHHHH Weis HHH Lbs iU Weight iH HHH Lbs WTP RPM Dif Total wt minus tare wt Lbs HHHHHH AAAA a eem oooooooooo etetereeerereret ere DOO CTI P GIN Co Yoy must Ethernet I ch b e the Contig to sc E take LAR TT OE TUE Min System Speeds May System Speeds Hopper X for low level alarm Panel Wiew GH Wersion Main 1 5 s A PLC GH Version 444 8 Hopper for no material alarm PLC Operating System Series D Gut of Material PLO Operating System Firmware Bii Alarm Silence Delay x NOTE If NEW PRSSHORD from eithe VERIFY PASSWORD d e 2 4 Optional Components The following is a list of options which your rate mon
61. t in use Turn the switch to the OFF position or unplug it from the power source Chapter 1 Safety 11 of 60 Maintenance Responsibility Proper maintenance is essential to safety If you are a maintenance worker you must make safety a priority to effectively repair and maintain equipment Before removing adjusting or replacing parts on a machine remember to turn off all electric supplies and all accessory equipment at the machine and disconnect and lockout electrical power Attach warning tags to the disconnect switch When you need to perform maintenance or repair work on a rate monitor above floor level use a solid platform or a hydraulic elevator If there is a permanently installed catwalk around your rate monitor use it The work platform should have secure footing and a place for tools and parts DO NOT climb on unit machines or work from ladders If you need to repair a large component use appropriate handling equipment Before you use handling equipment portable A frames electric boom trucks fork trucks overhead cranes be sure the load does not exceed the capacity of the handling equipment or cause it to become unstable Carefully test the condition of lifting cables chains ropes slings and hooks before using them to lift a load Be sure that all non current carrying parts are correctly connected to earth ground with an electrical conductor that complies with current codes Install in accordance with nationa
62. ted with care 6 Check to see that the weigh hopper is completely unrestricted The load cell bracket should not touch any part of the plastic housing on the load cell The tube stub on the bottom of the weigh hopper should not touch any part of the cast spool If either of these conditions are not met inaccurate weight readings may result Site Requirements This section describes site requirements in detail These requirements are broken down into mechanical mounting electrical connections and pneumatic connections Mounting Configurations The rate monitoring system must be machine mounted Chapter 3 Installation 24 of 60 Machine Mount The GH Hopper must be machine mounted There are a few items to review before placement and mounting of the rate monitor system begins First verify the machine flange dimensions match the cast spool mounting flange Verify that the machine throat is physically capable of supporting the rate monitoring system with a full load of material and vacuum loading equipment installed Note While in operation the GH system applies horizontal and vertical pressures to the mounting flange If there is a question as to the mechanical stability of a mounting flange contact the manufacturer s engineering department Verify all clearances on the top and beside the processing machine This is to insure that all motors hoppers control panels etc have adequate room for proper operation and servicing Re
63. tentially hazardous situation or practice that if not avoided could result in death or serious injury Caution CAUTION indicates a potentially hazardous situation or practice that if not avoided may result in minor or moderate injury or in property damage Chapter 1 Safety 7 of 60 Figure 1 Safety Tags and Warning Labels Tag Description Description Read Operation amp Pinch Point Slide Gate Installation Manual e Shear Point Rotating Earth Ground Mixer High Voltage Inside Protected Earth Ground Enclosure A Shear Hazard Rotating Lifting Point v Auger Chapter 1 Safety 8 of 60 1 2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications following national and local safety codes This may include but is not limited to OSHA NEC CSA SPI and any other local national and international regulations To avoid possible personal injury or equipment damage when installing operating or maintaining this equipment use good judgment and follow these safe practices EN m Read and follow these operation and installation instructions when installing operating and maintaining this equipment If these instructions become damaged or unreadable additional copies are available from the manufacturer Follow all SAFETY CODES Keep fingers away from slide gates augers clean outs and calibratio
64. the Feeder into either RPM Mode no extruder tracking or Weight Mode extruder tracking start extruder first 2 Ifin RPM MODE enter in a target RPM for the feeder and the feeder will run at that RPM regardless of the extruder This is useful for feeder calibration the first time you run the system with a new auger size 3 Ifin WEIGHT MODE enter in a desired and let the system track the extruder RPM You should not consider you are making good product until you see the STEADY PROCESS flag 4 Ifin WEIGHT MODE the system will automatically stop once the extruder stops Chapter 4 Operation 39 of 60 4 4 Common Screens Figure 34 Typical Manual Control Operator Screen CAUTION System Mill stop if manual reload is turned on Hop Ht ipu Lbs While the rate monitor system is in operation there are a couple of displays available to the operator These displays are selected simply by pressing the NEXT key when the unit is running The default display shown when the rate monitor is in run mode is the Recipe Screen Figure 35 Typical Inventory Display Operator Screen ACS Total Lbs HHHHHHHHHHE Group Total Feet THHHHHHHHHE 8 Clear Inventory Chapter 4 Operation 40 of 60 Alarm Flags An alarm message will be shown if any alarm condition occurs A message will pop up on the screen until the alarm condition is resolved The operator can press OK on this pop up to hide the screen temporar
65. the controller Abort Stops GH Hopper amp restarts controller Press to move back one screen level in controller function Move forward one screen level in controller function Hent E E 2 5 Chapter 2 Functional Description 18 of 60 Figure 10a Typical GH M Operator Screen EXT RPM Stable EXT WIP Stable ACS Group EXT RPM Stable EXT WTP Stable Hauloff Stable EXT RPM Stable EXT WTP Stable Hauloff Stable rrr LM uuus A Next Buses A ewe iuimum m EXT RPM Stable EXT WIP Stable Hauloff Stable Lbs per Layflat FH in HHH Feet ay ft min CER y EXT RPM Stable EXT WIP Stable Hauloff Stable Chapter 2 Functional Description 19 of 60 Figure 10d Operator Screens Common to all GH Systems IHARUAL CONTROL ACS Total Lbs S nn CAUTION System will stop if manual rea Total Feet HHHHHHHHHE reload ie turned an Hop Ht HEHEHEH Lbs Clear Inventory The Operator Interface has been locked Unlock Chapter 2 Functional Description 20 of 60 Figure 11 Typical Setup Screens Hopper size HEHEHE Lbs Reload Percentage nm O Do not read speed from COEX Master Hauloff Max Speed Target Hauloff Speed A Measured Hauloff Speed femin Calibrate Encoder RPM or Weight Mode only Scale Calibration Direct Scale Readout Weight RPM Calibration Chapter 2 Functional Description Hauloff is not enabled Sy
66. the weight every Number of Pulses for Calculation detected by the extruder proximity switch This is not the most automated method of the 3 choices but has it s advantages If you are using an unusually large extruder and running it in production at a very low speed then this method works best because the snapshot is taken at the same rotational position of the extruder and eliminates errors in measurement that are caused by the pulsing of the feed throat Percent of hopper Method DEFAULT This is the most automated and responsive of the 3 choices The snapshot sample is based on the Percent of Hopper for Calculation setting The smaller you make this setting the quicker the hopper will update If this value is set too small then you will be measuring the instantaneous throughput of the feed throat instead of the average loss in weight The average consumption at the feed throat always equals what is coming out at the die However the instantaneous feed throat usage is not equal to the usage at the die This is due to the pressure barrier sections and design of your extruder The goal of the GH system is to accurately control and measure what is coming out the die and not to respond to nuance changes at the feed throat It is not recommended that you reduce this setting unless consulting engineering or service and you fully understand this feature Full Hopper Method This is the most stable of all 3 choices Upon reloading a weight snaps
67. thernet module The extruder icon on the recipe page will become animated indicating the extruder is running and the measured Extruder RPM will be displayed If the system does not automatically start loading upon starting of the extruders then check this value for trouble shooting At this point the controller will refill the weigh hopper to its set weight capacity The GH M rate monitor will start tracking the extruder as soon as it is started The displayed value may be far from the actual value the first time the system is ran The GH M goes through a learning process with each material This is indicated by a Steady Process indicator on the main recipe page Upon starting the line you should always give the hopper time to analyze the flow and give you a Steady Process before making adjustments based on the displayed throughput The initial learning process will be complete when the Steady Process indicator is displayed on the recipe screen You are now ready to run the unit as normal The Steady flag indicates that the measured throughput in reliable and can be used for control The system will automatically stop loading the hopper upon stopping the extruder There is no need to manually start stop a GH M unit Operator Displays Figure 33a Typical Operator Screen for GH M system ACS Group It is not necessary to perform any special routine in order to start up a GH M Rate Monitor System Use these easy steps
68. this is correct then you are probably not accounting for material scrap or other items in your process Check that the printer is a SERIAL printer If not then you will need to either get a SERIAL printer or purchase a SERIAL to PARALLEL converter Corrective action Check to ensure that the weigh hopper is not touching any part of the frame and that the loadcell bracket is not touching the plastic cover of the loadcell If these have been verified then check loadcell and replace if necessary Corrective action I can t calibrate the Scale without an error message Note This Is caused by the difference in bits not being large enough Using the Direct Scale Readout examine current loadcell bits with and without the calibration weight If the bits do not change significantly then check for pellets jamming the loadcells and check the loadcell circuit You might have a bad loadcell Other service problems or questions can be answered by contacting the Service Department Chapter 6 Troubleshooting 46 of 60 Chapter 7 Appendix 7 1 Warranty and Spare Parts Unless otherwise specified this product includes a Standard ONE YEAR PARTS WARRANTY Warranty Specifications The manufacturer hereby expressly warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions as set forth in the operating manuals for such equipment THE FOREGOING EXPRESS WAR
69. tory The rate monitor has a programmable IP address and subnet mask that can be programmed from the Panel View that comes with the GH Hopper refer to GH Hopper manual Ethernet is the standard that we support but AB also supports Device Net DF and DH485 protocol to these PLCs Refer to AB documentation The DF1 port is 19200 baud with no parity and a source ID of 1 This is usually not important since you will be communicating with the Ethernet module instead of directly with the DF1 port Be sure that the DCOMM light is on by depressing the COMMS switch under the PLC front panel After this light is on then you can touch the ACS icon and enter 5413 then select Ethernet Setup program in you IP address click send config to module and then wait about 45 seconds for it to program the new IP address If you cannot ping the module then reboot the rate monitor and try again 45 seconds after booting Note ITEMS MARKED R ARE READ ONLY AND ITEMS MARKED RW ARE READ WRITE Below are the items that can be accessed for the GH Hopper GENERAL HOPPER INFO 1 plc version n23 0 xx x 2 hopper weight percent n20 1 0 1150 easy to use scale to show weight 3 total weight minus tare f30 16 this is the material weight 4 reload output o 0 0 to show reloading 5 extruder running graphic cycle T4 9 dn use this to toggle between 2 graphics off show graphic 1 on show graphic 2 6 hauloff running graphic cycle n9 9 use this t
70. upplied No credit will be issued for material that is not within the manufacturer s warranty period and or in new and unused condition suitable for resale Warranty Returns Prior to the return of any material the manufacturer must give authorization A RMA number will be assigned for the equipment to be returned Reason for requesting the return must be given All returns are to be shipped prepaid The invoice number and date or purchase order number and date must be supplied After inspecting the material a replacement or credit will be given at the manufacturer s discretion If the item is found to be defective in materials or workmanship and it was manufactured by our company purchased components are covered under their specific warranty terms iv Table of Contents CHAPTER 1 SEENEN Lei Howto Use This Manual nt eene e e eoe repo Rad Fen ir EE dee 7 Safety Symbols Used in this Manual seen 7 1 2 Warnings and Giele dede de ette iei ete Cady casi de bares Dui o emm eei dix espe dag ees 9 E Ee ele EE 10 General Responsibility EE 10 Operator Hespotsibilily ad re o tete Uu Pee DENM UR R RR E HREBEE RE eneen 10 Maintenance Ee EE 12 Reporting a E 12 CHAPTER 2 FUNCTIONAL DESCRIPTION 13 2 1 Models Covered in This Manual oett tte Deer tek ee eb Rue xn 13 2 2 GOS DR TEE 13 tee 13 CUSIOIDeI SOFVICO ee tege 14 2 3 Typical Features and Combpaonoenls 5 ote tierce EE gege 15 M

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