Sterlco A3 Blender Control and Data Acquisition Software Uživatelský manuál

Page Number 1 A3 System Management Software Software Manual Bulletin number: BF4-600.2 Part number: 882.00278.00 Date: 11.14.2008 S

Page Number 10 What’s new in version 2.0 Sterling SGB Communications Driver Now you can communicate with any SGB blender. The limitations are the

Page Number 100 Automatically generated reports The date and time stamp is as follows and cannot be changed: Year_month_day_hour(in military time)

Page Number 101 Sample Reports using Manual Generation (Job Reports) All of the selected reports will be saved in the path selected under the Repor

Page Number 102 Sample Reports Here are some sample reports. All number are only shown as an example: Automatically Generated Inventory and Uptim

Page Number 103 Alarm Log (same for auto or manual, just name would be different) It is important to note that whenever the inventory is cleared e

Page Number 104 Recipe Info report (same for auto or manual, just name would be different). This log is generated every time the operator changes

Page Number 105 Batch data report (same for auto or manual, just name would be different)

Page Number 106 Chapter 7 Working with the configuration file This chapter explains: • What is the configuration file • Setting the system

Page Number 107 Setting the system back to defaults The system can be set back to the original defaults by selecting “File/Set Config to Default” f

Page Number 108 Chapter 8 Working with the A3 System Log file This chapter explains: • What is the A3 System Log file • What is logged in

Page Number 109 What is logged in the file • Any communications error (time of alarm and time cleared). • Time the program was started • Time th

Page Number 11 Chapter 1 Installing A3 This chapter explains how to install A3 from your CD to your hard drive. • System requirements • Step

Page Number 110 The location of the file The A3 system log file is always named “a3_system_log.txt” and is located in the installation path. By de

Page Number 111 Chapter 9 Troubleshooting This chapter explains: • How to trouble shoot a software installation problem • How to trouble sh

Page Number 112 How to trouble shoot a software installation problem Problem During the installation of the A3 software you receive a message sayin

Page Number 113 How to trouble shoot a PC problem Problem Your software installation went fine, but your PC crashes intermittently. Solution A3 s

Page Number 114 How to trouble shoot a communication problem The approach to trouble shooting varies with the type of communications the device use

Page Number 115 Step 3: Examine the “Power” light on the PLC’s Ethernet module. If it is not on then check the cable that connects the device to th

Page Number 116 Step 5: If all of the previous steps have been satisfied then examine the “LINK” light on the Ethernet module. It should be green.

Page Number 117 Problem You’ve configured more than one Ethernet device and some are communicating, but others aren’t. Solution It is easy to trou

Page Number 118 Trouble shooting network problems with older HydReclaim units Problem You’ve configured more serial devices and are having proble

Page Number 119 You should see a response on the screen from the blender that looks something like: 01T00BTest String6C If this works than communi

Page Number 12 Installing A3 Before you start the installation you will need to be logged in as the administrator and you will need to close all pr

Page Number 120 Trouble shooting network problems with ACS Mitsubishi blenders or Maguire WSB blenders Problem You’ve configured more than one Ethe

Page Number 121 Step 4: If all of the previous steps have been satisfied then examine the “LINK” light on the Ethernet module. It should not be re

Page Number 122 properties (see “Chapter1 Networking instructions for the ACS Mitsubishi Batch Blender” for step-by-step). Problem You’ve configur

Page Number 123 - Notes -

Page Number 124 Other service problems or questions can be answered by contacting the ACS Service Department. Service Notes

Page Number 125 Service Notes

Page Number 126 Parts Department Call [262] 641-8600 Parts shipped from the New Berlin, WI facility available for Next Day Air shipment only up

Page Number 13 Step 2: Examine the above and ensure that you see Microsoft Windows XP, Service Pack 1, at least 750MHZ, and at least 128MB or RAM.

Page Number 14 Step 2: Click on “(C:) and examine “Free Space” in the lower left corner under “Details”. It should be at least 30 GB. You shoul

Page Number 15 Installing A3: Insert the A3 CD into the CDROM drive. The installation software will automatically start. If it doesn’t, then run

Page Number 16 Step 2: Click the picture of the computer Step 3: Click Continue

Page Number 17 Step 4: Success, Click “OK” to complete.

Page Number 18 Starting and exiting A3 To start A3: 1. From the Start menu, click Programs. 2. Select ACS Software and click A3 System Management

Page Number 19 Configuring the PC If your PC is part of your plants LAN then you will need to have your system administrator configure the IP settin

Page Number 2 Confidential Supervisory Manual Not to be released to floor operators Table of Contents Overview...

Page Number 20 Step 2: Right click on your Local Area Connection and select “Properties” Step 3: Double Click on “Internet Protocol (TCP/IP)”

Page Number 21 Step 4: Set your screen to look like this, then click OK, and OK again. Remember that you need to have a unique IP for all of your

Page Number 22 Running the Cables and Hardware to interconnect they system Depending on your expertise and preference you can either purchase CAT5 c

Page Number 23 Sample network. Be sure not to connect the blenders or PC to the uplink port on the hub or switch and to also use straight through

Page Number 24 Networking instructions for the ACS Allen Bradley batch blender Installing the PLC hardware The first step is that you must install t

Page Number 25 Configuring the PLC You will need to go to Network Setup found under “Setup” on the blender and set the appropriate IP address. The

Page Number 26 Networking instructions for the older proprietary Hydreclaim embedded equipment Installing the required USB RS422/485 adapter on th

Page Number 27 The pin outs for the cables are as follows: PC to 1st BLENDER PIN9 PIN4 PIN1 PIN5 PIN2 PIN8 PIN3 PIN9 BLENDER to BLEND

Page Number 28 Networking instructions for the ACS Mitsubishi batch blender Installing the PLC hardware The first step is that you must install the

Page Number 29 Networking instructions for the Maguire WSB Blender Installing the PLC hardware The first step is that you must install the Ethernet

Page Number 3 Preface The information in this manual is based on current industry sources and believed by the author to be correct and as complete

Page Number 30 Configuring the Digi One IA or Digi One SP Ethernet Modules The first thing to complete is configuring the PC for Ethernet. Configur

Page Number 31 Step 2: Right click on your Local Area Connection and select “Properties” Step 3: Double Click on “Internet Protocol (TCP/IP)”

Page Number 32 Step 4: Set your screen to look like this, then click OK, and OK again. Remember that you need to have a unique IP for all of your

Page Number 33 Running the Cables and Hardware to interconnect the system Depending on your expertise and preference you can either purchase CAT5 ca

Page Number 34 Before the modules can be used they each need to be programmed with the IP Address. You will need to have the module wired to 24VDC

Page Number 35 This will be shown until the software finds the attached module. Double click on the unit you wish to program.

Page Number 36 Configure the IP as shown above (remember that the last digit in the IP must be unique for each blender, here that digit is shown as

Page Number 37 Click Incoming Network Connection then next Click TCP Sockets then next

Page Number 38 Configure the baud rate to 19,200 for ACS Mitsubishi blenders. Configure the baud rate to 1200 or 2400 for Maguire WSB blenders *y

Page Number 39 From this screen click Next to save the configuration to the Ethernet module The configuration will begin to be saved and then the s

Page Number 4 Overview The A3 System Management Software program is a Windows based program that allows you to control and monitor up to 1000 ACS d

Page Number 40 Chapter 2 Using A3 A3 software uses menus, windows, status bars, and right click menus as do most Windows applications. This

Page Number 41 Tip of the day The application window will appear and will show you a “Tip of the Day”: Deselecting “Show Tips at Startup” will

Page Number 42 many random tips by hitting “Next Tip”. Hitting “OK” will close the Tip dialog.

Page Number 43 Drop down menus A3 has many drop down menus that can be selected:

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Page Number 46 Right click menus A3 also uses right-click menus. These right-click menus are all accessible from the dropdown menus listed above,

Page Number 47 Right-clicking on a device will bring up these. Right-clicking on the sheet name will bring up these.

Page Number 48 Status Bar on A3 The status bar is located near the bottom of the A3 main page: The status bar on the left shows when the next au

Page Number 49 Customizing A3 The A3 layout can be modified by the user. The following are some of the customizable features: • The Customer Name

Page Number 5 • Built in Job Report Manager that allows the operator to generate reports based on jobs rather than time. The Job Report Manager ke

Page Number 50 • The Sheet Name can be modified by selecting “File/Edit Sheet Name”. Once changed the name of the sheet (“Plant Name”) will be cha

Page Number 51 • Adding multiple sheets to the system. A3 is capable of having up to 20 different sheets with up to 50 devices on each sheet. To

Page Number 52 A3 options The A3 software also has many preference options that can be changed by the user. To access the options menu select “To

Page Number 53 Verify Action Options These options enable or disable the “Are you sure…” prompts after certain operations. Hard Drive Options Thi

Page Number 54 Chapter 3 Application Screens A3 software has many screens that can be accessed: • Virtual Control Panel for each unit. This

Page Number 55 Virtual Control Panel The virtual control panel is accessed by double clicking on the icon of the blender from the main page.

Page Number 56 The Virtual Control Panel. Push to immediately stop blender Push to start or stop blender Indicates running or stopped Push

Page Number 57 The Virtual Control Panel for Maguire Blenders. Blender Name and Software Version Push to clear the inventory Current Inventor

Page Number 58 The Alarm Log Change Recipe Page. Enter new values and hit “Load” or cancel to quit. If a box shows “******” then this is the

Page Number 59 If the recipe is not correct an error message will be given that will prevent it from loading. The following are error messages give

Page Number 6 Who should use this manual Use this manual if you are responsible for system integration of machinery in your facility. You should h

Page Number 60 Total not 100% error message

Page Number 61 The following are error messages given when using the older proprietary blenders: Recipe Not Totaling 100%

Page Number 62 The following is the successful message given when using the older proprietary blenders: Recipe Transferred message

Page Number 63 Recipe Book. The recipe book can store an infinite number of recipes (only limited by your hard drive size, see “Working with the R

Page Number 64 Batch Data Page. The Batch Data Page shows the actual weight of every component of every batch made (up to 5000 batches). Clicking

Page Number 65 Uptime Data Page The Uptime Data page is accessed by selecting “View/Uptime Data…” from the drop down menu. This data shows the pe

Page Number 66 SCADA Scan Times Page The SCADA Scan Times Page is accessed by selecting “View/SCADA Scan Times” from the dropdown menu. The displ

Page Number 67 Memory Status Page. The Memory Status Page is accessed by selecting “View/Memory Status” from the dropdown menu. This page is usef

Page Number 68 Data Parameters Page The Data Parameters Page is accessed by selecting “View/Data Parameters” from the dropdown menu. This page sh

Page Number 69 Chapter 4 Working with A3 Device Objects This chapter explains: • What is an A3 Device Object • Adding new A3 Device Objects

Page Number 7 Frequently Asked Questions • How many units can A3 integrate? 1000 units, which 255 can be the older proprietary units. • What min

Page Number 70 Adding new A3 Device Objects Simply right click in the blank white area of the sheet you wish to add a device to and select “Add ACS

Page Number 71 Configuring a ACS Allen Bradley Batch Blender Device When selecting a newer AB OS/OA device you will also need to enter in the IP Ad

Page Number 72 You will also need to set the SUBNET MASK for the blender. This needs to be set to “255.255.255.0”. Once configured you will need

Page Number 73 Here are some quick trouble shooting answers: • Power light on module is off: Check that the “Cable/External” switch is set to “Cabl

Page Number 74 Configuring an Older Proprietary OS/OA, OL, or OFC that uses an embedded controller (not a PLC): Limitations with using the Maguire

Page Number 75 Step 1: From the main menu hit “5” and enter in your password. Step 2: hit “6” Step 3: hit “back up”

Page Number 76 Step 4: hit “1” or “2” to increase or decrease Serial ID, then Backup Step 5: hit “1” or “2” to change Baud Rate, then Backup The

Page Number 77 Step 1: click start, right-click on “My Computer”, then click “Properties” Step 2: Click the “Hardware” tab and then click “Devic

Page Number 78 Step 3: Expand the “Ports” and observe the Kontron Port # If you do not see the Kontron entry then see “Networking instructions for

Page Number 79 Configuring an ACS Mitsubishi Batch Blender Device: When selecting “SGB Blender” under Device type you will be given a few extra ent

Page Number 8 if you don’t already have a LAN in your facility you will need to add one by purchasing an Ethernet Hub or Switch from any store that

Page Number 80 Configuring a Maguire WSB Batch Blender Device: When selecting “Maguire WSB” using Device Type you will be given a few extra entries

Page Number 81 Checking the Device your about to Add Once you’ve configured your device you will be ready to hit “OK” on the “Add a New Device…” di

Page Number 82 You should click “No” unless you know that the device is not hooked up (your setting up the system before the network is in place).

Page Number 83 Device States Each icon has different states to indicate the conditions of the device: Device is communicating and is not in the “Ru

Page Number 84 Chapter 5 Working with the A3 Recipe Book This chapter explains: • What is the A3 Recipe Book • Accessing the Recipe Book •

Page Number 85 Accessing the Recipe Book The recipe book can be accessed by selecting “Tools/Recipe Book” using the dropdown menu or can be accesse

Page Number 86 Creating a stored recipe 1. Edit the RECIPE DATA fields to appropriate values. 2. Click “Save New” and enter in a name in the “Fil

Page Number 87 Editing Existing stored recipes 1. Click on an AVAILABLE RECIPE and the RECIPE DATA fields will show the values for the recipe you’

Page Number 88 Loading a stored recipe into a device • Access the Virtual Control Panel by double clicking on the device from the main page. • Cl

Page Number 89 Total not 100% error message

Page Number 9 What’s new in version 1.1 Job Report Manager Now you can generate reports on demand instead of just time. Along with this c

Page Number 90 The following are error messages given when using the older proprietary blenders: Recipe Not Totaling 100%

Page Number 91 The following is the successful message given when using the older proprietary blenders: Recipe Transferred message

Page Number 92 Chapter 6 Working with the Report Manager This chapter explains: • What is the Report Manager • Accessing the Report Manager

Page Number 93 What is the Report Manager The A3 Report Manager is a utility that allows the user to generate reports for each device that contain:

Page Number 94 Automatic vs. Manually generated reports The report manager can be configured to either automatically generate reports based on a ti

Page Number 95 Configuring what is included in the Reports The user can select what information will be included in each report by enabling or disa

Page Number 96 Saving the reports The user can specify the location where all reports will be saved using the following: Saving the Reports To se

Page Number 97 Using Manually generated Reports (Job Report Manager) First step is to create the System Inventory Resin Database. This database c

Page Number 98 To access double click on the icon of the device from the main page, then click on “Job Report Manager”: Click to Start a Job, Inv

Page Number 99 Sample Reports using Automatic Generation All of the selected reports will be saved in the path selected under the Report Manager.