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Sterling 882.00278.00 Marine Sanitation System User Manual

1. TIME 4 28 2003 10 28 08 AM Start 5 edit_device_popup b A A3 System Managem AW 10 28 AM Warning given when device is not detected Page 75 A3 System Management Software You should click No unless you know that the device is not hooked up your setting up the system before the network is in place If the device is communicating the icon will be added on the main page Ss A3 A3 System Management Software Plant View File Edit View Tools Help Se eS I I TIME 4 28 2003 10 25 46 AM start 5 new_sheet_added b As A3 System Managem AW 10 25 AM Device Type Icons Each device type has a unique graphic icon associated with it Blender 1 Blender 1 Blender 1 OS OA OL Page 76 A3 System Management Software Device States Each icon has different states to indicate the conditions of the device Blender 1 2 Blender 1 Device is communicating and is not in the Run mode ad Device is in the Run mode Elender 1 This state flashes Device has an alarm active at the unit Elender 1 Device is not communicating with A3 Editing an existing device Right click on the device and select Edit If you make changes hit OK when done Deleting a device Right click on the device and select Delete Device You can also chose to delete all devices using the Edit Delete all ACS Devices from the dropdown menu Page 77 A3 System Management So
2. Chapter 6 Working with the Report Manager Instruction Instruction Instruction Instruction Instruction Instruction Instruction Instruction Instruction Instruction Chapter 7 Working with the configuration file Startup Startup Startup Startup Startup Startup 6 1001 Sin ae EEE NENNEN DRIN ee ee ee eee 86 What is the Report Manager ccccscecessseeeeseeeeeeeeeeeneneeneeeeeees 87 Accessing the Report Managet cccccssecesseeeeeeeeseeneeseeeensaees 87 Automatic vs Manual Reports cccceseeeeeeeesseeeeeeeeeeeeenenees 88 Configuring what to include in the reports ccccseeeeeeeees 89 Saving the reports nina 90 Using Manually generated reports Job Report Manager 91 Sample folder using Automatic Generation 2222222220 92 Sample folder using Manual Generation Job Reports 93 Sample RED OWS un 94 OVVIE W Seen ee eee ere ee ee ne ee ee eT 97 What is the configuration file ccccessseeseeeeeeeeeeeeeeeeeeeseaenees 97 Setting the system back to the defaults zuu20220000220000 98 Saving the configuration cceecceeeeseeeeeeeneeeeeeeeeeeeeeeeseaeneesenens 98 Opening a previously saved configuration file 98 The location of the configuration file ccccssesseeeeeeeeeeeeees 98 Chapter 8 Working with the A3 System Log file Startup Startup Startup Startup
3. Enough information is given in these tips to train most operators on the software This feature can be turned off by deselecting the Show this at startup box If you desire to turn it back on just select Tip of the Day under the Help menu What s new in version 2 0 Sterling SGB Communications Driver Now you can communicate with any SGB blender The limitations are the same as the with the AEC OS OA blenders Up to 1000 units can be networked over an Ethernet network The system can also communicate with both the AEC units and the Sterling units at the same time over the same network cable Page 9 A3 System Management Software Chapter 1 Installing A3 This chapter explains how to install A3 from your CD to your hard drive e System requirements e Step by step installation instructions e Starting and exiting A3 software Overview AS software installs directly from the CDROM to your hard drive The CD also contains the Windows XP Service Pack 1 drivers for the USB RS422 485 Legacy module required when integrating older proprietary equipment Internet Explorer 6 0 upgrade and this manual System requirements PII 750MHZ minimum processor speed P4 1 8GHZ recommended Windows XP operating system service pack 1 must be installed Internet Explorer 6 0 30GB minimum hard drive space 60GB recommended 128MB minimum RAM 512 MB DDR Ram recommended CDROM drive CD RW recommended Video card capa
4. PC IP gt 192 168 0 1 Blender 1 IP gt 192 168 0 10 Blender 2 IP gt 192 168 0 11 Blender 3 IP gt 192 168 0 12 Page 24 A3 System Management Software Running the Cables and Hardware to interconnect the system Depending on your expertise and preference you can either purchase CAT5 cables to length with the connectors already attached to both ends This makes it somewhat difficult to get the connector into the blender panel because of the head on the cable but not impossible Either way you will need to have some sort of Hub Switch or Router to interconnect all of the blenders with the PC If you already have a plant LAN then you should just run drops to each blender and one to the PC from your main network If this will be a stand alone system then you can purchase a hub or switch to accomplish the same thing A 5 port hub will cost around 40 and is shown below Uplink Port to Existig LAN optional 192 168 0 1 192 169 0 10 192 169 0 12 192168011 Sample network Be sure not to connect the blenders or PC to the uplink port on the hub or switch and to also use straight through cables Page 25 A3 System Management Software Networking instructions for the older proprietary equipment Installing the required USB RS422 485 adapter on the PC DO NOT USE THE CD THAT COMES WITH THE ADAPTER BUT INSTEAD USE THE A3 CD WHEN PROMPTED FORA CD The installation is very easy 1 Insert the A3 CD and click ca
5. lt gt A3 System Management Software Software Manual Bulletin No BF 4 600 Part No 882 00278 00 Sterling 2900 S 160 Street New Berlin WI 53151 Tel 262 641 8610 Please note that our address and phone information has changed Please reference this page for updated contact information These manuals are obsolete and are provided only for their technical information data and capacities Portions of these manuals detailing procedures or precautions in the operation inspection maintenance and repair of the products may be inadequate inaccurate and or incomplete and shouldn t be relied upon Please contact the ACS Group for more current information about these manuals and their warnings and precautions Parts and Service Department The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications which will maximize your equipment s performance and efficiency To assist in expediting your phone or fax order please have the model and serial number of your unit when you contact us A customer replacement parts list is included in this manual for your convenience ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service For immediate assistance please contact e North Central and South America 8am 5pm CST 1 800 483 3919 for drying conveying heating and cooling and automation For size reducti
6. lt Device not listed gt To continue click Next ser cn eo Isto cova Double click on the unit you wish to program Internet Shortcut to Explorer mohradiant My Computer icrosoft Visual Ba uun w Flight WinMx Simulator 2002 DIGI SP COM4 test ht ERMEFIEID its at Recycle Bin Battlefield 1942 TheR Financial 14 B AutoCAD R14 afl Micro Cap Evaluation 7 0 Z Medal of Honor Alli tl Medal of Honor Alli i Shortcut to Projecti exe COM 1 Test ht ag Start e Setup Wizard Dig Welcome Discover Device Configure Device Save Settings Finished Version 1 2 20 0 Configure Network Settings Enter the following settings to configure the Digi One SP for your network The network settings can be assigned automatically if your network supports this capability Otherwise you need to ask your network administrator for the appropriate network settings Obtain IP settings automatically using DHCP Use the following IP settings Pace 192 168 0 11 Subnet Mask 255 255 255 0 Default Gateway DNS Server Domain Host Name To continue click Next o Digi Device Setup Wiz 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 11 Be sure that no other blender is using 11
7. COM 1 Test ht 44 start Dia From this screen click Next to save the configuration to the Ethernet module Welcome Discover Device Configure Device Save Settings Finished Version 1 2 20 0 Configure Serial Settings Configure the port settings of the Digi One SP to match the port settings of your serial device Baud Rate Data Bits Parity Stop Bits Flow Control Software 7 Reference the documentation that came with your serial device if you don t 1 know the port settings To continue click Next m ers in 50 Cone ow Digi Device Setup Wiz Configure as de Digi Device Setup Wizard Digi shown above then click next Verify Configuration Verify the configuration before it is uploaded to your device s All previous settings will be erased before the new settings are applied Welcome Discover Device Configure Device Save Settings Finished Version 1 2 20 0 Configuration Report The Digi One SP with MAC address 00 40 9D 23 34 B4 will be configured with the following settings Network Settings IP Address 192 168 0 11 Subnet Mask 255 255 255 0 Default Gateway 0 0 0 0 DNS Server 0 0 0 0 Domain lt none gt Host Name lt none gt Serial Port 1 Incoming TCP Socket Connection Other systems devices connect over the network to the device attached to this serial port Data can be sent and received Used for Device Management Also known a
8. Control the status of all blenders start and stop Read and Write the recipes to all blenders Built in recipe book with unlimited number of stored recipes Built in Alarm log that will log up to 1000 alarms for each blender Built in Batch Data log that keeps track of actual weight for every batch up to 5000 batches Monitor the inventory of all materials in all blenders Built in Uptime Percentage monitor that keeps track of the percentage of uptime for each blender Built in Report Manager that allows the system to automatically generate a report for each unit blender The report can be configured to generate from every 1 to 8 60 hours once a year Built in Job Report Manager that allows the operator to generate reports based on jobs rather than time The Job Report Manager keeps track of job numbers material reference numbers material lot numbers and material silo numbers for each hopper on every configured device The operator can select to start or stop the job at any time Reports contain inventory information uptime percentage reporting alarm logs actual batch data and the recipe info log that keeps track of all recipe changes throughout the reporting period up to 1000 recipe changes Built in Security system that allows the A3 system to be password protected with an operator and a supervisor level password Printer Routines that will work with any standard ink jet printer Can be used with the AEC AB batch blender the St
9. Hard Drive Options This option allows the user to configure the minimum allowed hard drive space to allow saving The minimum value that can be entered here is 2000 MB 2 GB Security Options These options enable or disable password protection on certain operations Once password protection is enabled the operator must enter in the user password in order to perform the operation You will be asked to enter in the master password in order to access this tab The default Master Password is 3145348 and the default User Password is 5413 These can be modified to whatever you desire If you change either password you will be asked to verify the change before the change will be allowed Options Operator must enter USER PASSWORD for the following actions Closing the 33 program Master Password Weriky Changing 43 setup User Password Starting or Stopping 4 device see Changing the recipe of a device Deleting or Saving a stored recipe Cancel Cleaning Inventory Clearing any Log Page 51 A3 System Management Software Chapter 3 Application Screens AS software has many screens that can be accessed e Virtual Control Panel for each unit This is used to start or stop the unit and to monitor the current recipe and inventories e Alarm Log for each unit This is used to view the alarm history of each device e Change Recipe Page This is used to change the running recipe of a device e Recipe Book This is
10. Save Config Save Config file as New Sheet Ctrl D Delete Sheet Ctrl X Edit Sheet Name Customer Name Exit NEXT REPORT WILL GENERATE AT 4 30 2003 8 00 00 AM TIME 4 29 2003 1 23 17 PM DAYS 0 18 36 43 UNTIL REPORT ss Start Microsoft Word A3 ff read me txt Notepad fe Z PUBLIC Projects g new_project_select As 43 System Managem 4 AB 1 23PM A A3 System Management Software Plant View a File aig View Tools Help Add ACS Device Ctrl N Delete Selected ACS Device Delete ALL ACS Devices Edit Selected ACS Device Ctri E TIME 4 28 2003 3 35 51 PM Start Microsoft Word 43 g add_acs_device_sele As 43 System Managem 9 AB 3 35 PM Page 41 A3 System Management Software Plant View View j 4 er Uptime Data SCADA ScanTimes Memory Status Blender 3 Data Parameters add_aec_device_des 43 System Managem m 10 44 AM A3 System Management Software Plant View ecipe Book Report Manager Options stem Managem 10 59 AM Page 42 A3 System Management Software Plant View Help Tip of the Day Technical Support Blender 1 About 43 ystem Managem lt 11 16 AM Page 43 A3 System Management Software Right click menus AS also uses right click menus These right click menus are all accessible from the dropdown menus listed above but right clicking is sometimes qu
11. amp 888 008 duties TOTAL 3996 036 ACCEPT RECIPE CLEAR INVENTORY Inventory Current Alarmz Inventory Push to change recipe HOPPER 5 50 00 HOPPER E 60 00 Recipe Book Current Recipe Values Current Push to go to HOFFER 4 40 00 Push to Accept New Recipe Alarm Log Push to clear the inventory Push to go to Ea the Alarm Batch Log Log Blender Push to go to the Batch Log stopped Push to Indicates running or Start or stopped Stop C t Push to start Abort V ee or stop Done Alarms blender The Virtual Control Panel Push to go Push to back to the immediately stop blender main display Page 54 A3 System Management Software Blender Name and time of log Blender 1 PLC Version 3 1 ALARM LOG 4 28 2003 11 27 25 AM 22 Hop3 333 Hopd 444 77 Hop 888 A HOPPER 1 Out of Materia M HOPPER 1 Out of Material CLEARED Alarm History up to 1000 alarms per blender Push to clear Click to send log to the printer PRINT SAVE Click to go back to Virtual Control Panel Click to save the log to a specific location The Alarm Log EZ Mode Recipe Batch Size 5 HOFFER 1 HOFFER amp 2 20 00 HOPPER 3 30 00 HOPPER 4 40 00 HOPPER 5 50 00 HOPPER amp 60 00 HOPPER 7 0o00 HOPPER amp 0o00 Change Recipe Page Enter new values and hit Load or cancel to qu
12. 30 3 11 enabled 12 hop amp _invertore 30 4 12 enabled 13 hopb inventor 30 5 1 S enabled 14 hopf inventor 30 6 1 4 enabled 15 hope inventor 30 7 15 enabled 16 batch inventory 30 35 16 enabled TY hopd_ fractional inventory 30 16 17 enabled 16 hope fractional inventory 30 17 18 enabled 15 hop3_ fractional inventory 30 18 19 enabled 2U hopd fractional inventory 30 19 U enabled 21 hopS fractional inventory 30 20 1 enabled 2 hoph fractional inventory 30 21 2 enabled 2s hopy fractional inventory al enabled 24 hope_ fractional inventory 30 23 4 enabled 2o batch inventor decimal parts0 39 o enabled 26 clear inventor ba 03 b enabled 2f pyvd hop temp recipe value 20 0 2 f enabled 2o pyv hope temp recipe valuel20 1 o enabled 2o pv1 hops temp recipe value l20 2 4 enabled S0 py1_ hop temp recipe value l20 3 30 enabled 31 pyv1_hopS temp recipe value 20 4 1 enabled Spy hope temp recipe value l20 5 32 enabled S pyv1 hop temp recipe value l20 6 Ss enabled 34 pv _hops_ternp_recipe_ value 20 34 enabled S5 pv1 recipe _emor message nd 2 35 enabled The Data Parameters Page is accessed by selecting View Data Parameters from the dropdown menu This page shows all of the available data parameters for each device The status of each of these items is automatically configured when you enable or disable features for the selected device see Working with A3 Device Objects for more details This page is here strictly for
13. 5 start ig report_manager_pag As 43 System Managem lt 11 11 AM The status bar on the left shows when the next automatic report will generate the bar in the middle always shows the date and time and the bar on the right shows the countdown for the automatic report Page 46 A3 System Management Software Customizing A3 The A3 layout can be modified by the user The following are some of the customizable features e The Customer Name can be configured by selecting File Customer Name Once changed the customer s name will appear in brackets on the title bar o sea oo ee A A3 System Management Softy are Perfect Plastics Inc File Edit View Tools Help eeeacee TIME 4 28 2003 10 03 42 4M TE 4 Ai 10 03 AM 3 start customer_name_cha As A3 System Managen Page 47 A3 System Management Software The Sheet Name can be modified by selecting File Edit Sheet Name Once changed the name of the sheet Plant Name will be changed to whatever the user has selected Commonly this is the location of the plant i e Dayton OH A3 A3 System Management Software Plant View x Q Page 48 File Edit view Tools Help Y a Ge i Oe aap Dayton Hi ee es eeeesee SS un TIME 4 28 2003 10 18 43 AM 9 AW 10 18 AM A3 System Management Software e Adding multiple sheets to the system A3 is capable of having up t
14. 550 SILO Number 7 Hopas Hons Material Reference Lot Number SILO Number Hong 0 Hop Material Reference Lot Number SILO Number Gps ys Hop Material Reference Lot Number SILO Number 7 Hong me Hape Material Reference LOE Number 7 77 SILO Number 7 77 Uptime Percentage 0 Manually Generated Inventory and Uptime Report Page 94 A3 System Management Software EP 2003_04_28_13_00_00 Blender 1_alarm_log log Notepad ER File Edit Format View Help 4 14 2003 9 09 24 AM HOPPER 7 Gut of Material 4 14 2003 9 15 32 AM HOPPER 7 Gut of Material CLEARED 4 14 2003 9 33 50 AM INVENTORY CHopl 12121 Hope 2323223 Hops 343434 Hopd 4544 a 4 4 14 2003 9 33 50 AM Hops 565556 CHops 6676767 CHop 78778 CHop 898989 TOTAL 10944412 4 14 2003 9 33 50 AM INVENTORY CLEARED Alarm Log same for auto or manual just name would be different It is important to note that whenever the inventory is cleared either at the blender or the PC an entry of what the inventory was prior to clearing is added If the data in the inventory and uptime report is short of what you expect then check the alarm log for the device to see if the inventory was cleared sometime into the report 2003_04_28 13 _00_00 Blender 1_recipe_info_log log Notepad Sele 4 23 2003 11 09 26 AM Inventory 5
15. click My Computer double click on your CDROM drive where the A3 CD is inserted and the installation will then run Problem You receive a message Unable to Read Disk after attempting to run the installation from the A3 CD Solution Try the CD in another computer If it runs on another computer then there is a problem with either your PC or CDROM drive If it doesn t and you have checked that you are running Windows XP then it is possible you have a defective disk Consult the factory to receive a replacement CD Page 103 A3 System Management Software How to trouble shoot a PC problem Problem Your software installation went fine but your PC crashes intermittently Solution A3 software has been tested on multiple computers from multiple manufacturers If your PC is crashing then the problem is either that the PC doesnt meet the minimum requirements see Chapter 1 Installing A3 or your PC has a separate issue that must be addressed by your local PC company Running other applications on the PC along with A3 can also cause problems see Chapter 3 memory status ACS does not perform PC repairs or installations of A3 software Problem You receive a message Hard drive is about out of space or Hard drive is out of space Solution The hard drive mentioned is either approaching or has reached the minimum allowed free space see Chapter 2 A3 Options for the minimum allowed space You need to delete some of t
16. customers who wish to develop their own SCADA package The more enabled items on this page the slower the SCADA scan time however the system speed usually makes this irrelevant don t be concerned if all items are enabled unless you are trying to add 1000 blenders Data Parameters Page Page 65 A3 System Management Software Chapter 4 Working with A3 Device Objects This chapter explains e What is an A3 Device Object e Adding new A3 Device Objects e Editing A3 Device Objects e Deleting A3 Device Objects Overview The A3 system is used to display and control many objects up to 1000 A3 Device Objects are the heart of the system and are easy to add and edit What is an A3 Device Object An A3 Device Object is any blender or weigh hopper that you are adding to the A3 communications package This could be the older HydReclaim OS OA OL OFC units the AEC AB OS OA blender or the Sterling SGB Blender Before proceeding with adding new devices you should finalize the layout that you want You should configure the number of sheets that you are going to need and name them appropriately first Once objects are created you cannot simply drag them from page to page but instead have to delete them and add them again on the page you desire Therefore it s a lot easier to put them on the correct page to begin with Page 66 A3 System Management Software Adding new A3 Device Objects Simply right click in the blank white area o
17. pins are not shorted together check all possible combinations Step 3 At this point trouble shooting gets a bit more difficult You will need to close down A3 and open up Hyper Terminal Hyper Terminal is a standard Windows program that gets installed with Windows You can find it under Start Programs Accessories Communications HyperTerminal Enter a name for the connection call it test When asked for a phone number select Direct to COM 4 or whatever comport the USB RS422 485 adapter is set to see Chapter 4 When asked for the baud rate set it to 19200 make sure the blender is also set to 19200 With the cable connected to the PC and the first blender turn off the blender and then turn it back on You should see on the PC screen Power Up If you see this then we know that at least communications from the blender to the PC is working but from the PC to the blender still needs to be tested To test that type string exactly into HyperTerminal be sure to set the blenders ID to 1 for this test see Chapter 4 Cntrl b O1T Cntrl c 45 make sure caps lock is on don t type the commas Page 109 A3 System Management Software You should see a response on the screen from the blender that looks something like 01TOOBTest String 6C If this works than communications is working Try starting the blender and then perform the same test If when the blender is running this test fails then the problem is noise from wit
18. to Start or Stop Total not 100 error message Page 57 A3 System Management Software The following are error messages given when using the older proprietary blenders Blender 3 Inventory HOPPER 1 0 0 HOPPER 2 0 0 HOPPER 3 0 0 HOPPER 4 0 0 HOPPER 1 20 00 HOPPER 2 20 00 HOPPER 3 20 00 Recipe Not HOPPER 4 40 00 otaling 100 TOTAL 0 0 CLEAR INVENTORY Current Alarms Alarm Log Blender Stopped Push to Start or stop Recipe Not Totaling 100 Page 58 A3 System Management Software The following is the successful message given when using the older proprietary blenders Blender 3 Inventory HOPPER 1 0 0 HOPPER 2 0 0 HOPPER 3 0 0 HOPPER 4 0 0 Batch Size 3 HOPPER 1 20 00 HOPPER 2 20 00 HOPPER 3 20 00 Recipe HOPPER 4 40 00 Transterred TOTAL 0 0 CLEAR INVENTORY Current Alarms Alarm Log Blender Stopped Push to Start or stop Recipe Transferred message Page 59 A3 System Management Software Recipe Book AVAILABLE RECIPES click on one BECIPE DATA default ar NUMBER OF HOPPERS my recipe ar DEVICE TPE 103704 Blender RECIPE MODE EZ Mode Batch Size z HOPPER 0000000 HOPPER 5 HOPPER ao HOPPER 4 05 HOPPERS 10 HOPPERS 5 HOPPER 8 2 HOPPER 2 Delete Delete All Save Hem Cancel V Recipe Book The recipe book can store an infinite number of recipes only limited by your h
19. 000 HOPPER 5 0 000 HOPPER E 0 000 HOPPER 7 0 000 HOPPER amp 0 000 TOTAL 0 000 HOPPER amp 0 00 CLEAR INVENTORY Current Alarma Batch Lod Blender stopped Push to Start or Stop Click to Start a Job Inventories and logs will clear at this point Job Number Material Information Job Report Manager Job Report Manager JOB IS NOT CURRENTLY STARTED a Job Reference Number for Job that 14717723 will be saved with the Start o report Material Information Reference Number or Description Lot Silo HOPPER 1 PET A FE Beo HOPPER 2 Titanium Dioxide 8 o HOPPER 3 PCR Regina ss va HOPPER amp UV Stabilizer HN oOo HOPPER p HOPPER HOPPER HOPPER amp Click to Finish a Job be sure to enter in all of the data first The report will be saved at this point Cancel Page 91 A3 System Management Software Sample Reports using Automatic Generation All of the selected reports will be saved in the path selected under the Report Manager The name of the report will be date amp time stamped for reference Below are some sample reports 7 My Reports Directory Fie Edit View Favorites Tools Help File and Folder Tasks 2003 04 76 13 00_00 Blender 1_inwenkor_and_uptime_log log E 2003 04 26 13 00 00 Blender 1_recipe_info_log log TA Make a new Folder 2003_04 28 13_00_00 Blender 2_inventory_and_uptime_log log E Publish this Folder to the 20
20. 003 Google Searching 3 083 324 652 web pages Displays program information version number and copyright s start A 4 amp 3 System Managem fm Z PUBLIC Projects Y fm Z PUBLIC Software Google Microsoft Int Step 1 Open up Internet Explorer and click Help and then About Internet Explorer Page 14 A3 System Management Software About Internet Explorer version 6 0 2000 1106 xpspl 020820 1920 Cipher Strength 126 bit Product ID SS277 0EM 001 1903 00106 Update Versions SFL Based on MCSA Mosaic MCSA Mosaici TM was developed at the National Center for Supercomputing Applications at the University of Illinois at Urbana Champaign Copyright 21995 2001 Microsoft Corp Acknowledgements Step 2 Verify that the version is at least 6 0 Installing the Internet Explorer 6 0 Upgrade 1 a gt Insert the A3 CD into the CDROM drive When the installation automatically starts cancel the installation Click Start and Click on My Computer Right Click on the picture of the CDROM and select Explore Double Click on Internet Explorer 6 0 Double Click on ie6setup exe and follow the onscreen instructions This service pack will not run if your version of XP was a pirated version The total time to complete the installation is approximately 5 minutes Page 15 A3 System Management Software Installing A3 Insert the A3 CD into the CDROM drive The instal
21. 03_04 28 13_00_00 Blender 2_recipe_info_log log 2003 04 76 13 00_00 Blender 3 alarm _log log E 2003 04 26 13 00 00 Blender 3 inventory and uptime log log Other Places 003 04 28 13 00 00 Blender 3 recipe _info_log log Web _ File Server on SERVER Kpsoftware zi My Documents Shared Documents 4 My Computer a My Network Places Details My Reports Directory File Folder Date Modified Today April 28 2005 12 54 PM Automatically generated reports The date and time stamp is as follows and cannot be changed Year_month_day_hourfin military time minutes seconds This is followed by the name of the device and the name of the log Page 92 A3 System Management Software Sample Reports using Manual Generation Job Reports All of the selected reports will be saved in the path selected under the Report Manager The name of the report will be date time and job number stamped for reference Below are some sample reports 7 My Reports Directory Fie Edit wiew Favorites Tools Help Back gt a gt Search gt Folders ria A 2 2003 File and Folder Tasks 2 2003 _ E 2003 ing Move the selected 2003 items A Copy the selected E 2003 items 2003 E Publish the selecked items bo the Web E mail the selected items bd Delete the selected items Other Places a File Server on SERVER iEpsoftware 21 G My Documents IS Shared Documents 4 My Computer EI My Ne
22. 4 9 Mice and other pointing devices Moderns Er d Monitors Network adapters Ell Ports COM amp LPT on P Communications Pork COM E Communications Pork COMe pai Kontron USB RS422 485 Port Cord SR Processors Sound video and game controllers Step 3 Expand the Ports and observe the Kontron Port If you do not see the Kontron entry then see Networking instructions for the newer AB OS OA Blender Page 74 A3 System Management Software Checking the Device you re about to Add Once you ve configured your device you will be ready to hit OK on the Add a New Device dialog Before the device is added an automatic check is performed to see if the device is responding correctly If the unit is not communicating you will see the following message and should correct the problem before proceeding check your settings A A3 System Management Software Plant View 4 Plant Name Add a New Device m Device Name elle Device Description Available Features Blender 1 IV Start or Stop Ability MV Monitor Inventory Device Type m Communications Type Jos Blender 052001 Blender OS or ee eaten IP Address iti ing vV Monitor Running Recipe 132168015 Unit is not responding Add anyways i g z p v Change Recipe Ability v Clear Inventory Ability v Log All Alarms Monitor Targets vs Actuals Iv Include this device in Report
23. 43 program started 43 program customer configuration loaded CoM ERROR on Blender 1 COM ERROR on Blender 1 CLEARED 43 program started A3 program customer configuration loaded 42B r200 sgl Pr 4 28 2003 Sc Pr 4 28 2003 ale as Pr 4 282003 02 Pr 4 28 2003 2 Pr 4 28 2003 202 Pr 4 28 2003 03 Pr 42B 2003 ls Ph 4 28 2003 03 Pr 4 28 2003 bla Pr 42B e003 ag i Pr 4 28 2003 ag i Pr 4 28 2003 04 Pr 4 28 2003 204 Pr 42B 2003 Pari Pr 4 28 2003 aoe Pr 4 28 2003 Tear Pr 4 282003 ragi Pr 428r e003 regi Pr 4 28 2003 230 Pr 4 28 2003 240 Ph 4 2872 003 740 Ph 4 28 2003 ee Pr 4 28 2003 12 Pr 4 282003 i423 Pr 43 program started 43 program customer configuration loaded Operator has chosen to delete all devices Operator has chosen to edit Blender 3 43 program started 43 program customer configuration loaded Operator has chosen to add a sheet Operator has chosen to add a device operator has chosen to edit Blender 1 Operator has chosen to add a dewice Operator has chosen to delete Blender 1 43 program started 43 program customer configuration loaded Operator has chosen to edit Blender 2 43 program started 43 program customer configuration loaded Operator has chosen to delete Blender 2 Operator has chosen to delete a sheet operator has chosen to add a deyice operator has chosen to edit Blender 1 43 pragram started 43 program customer conf
24. A3 System Management Software Configuring a Newer AB OS OA Device When selecting a newer AB OS OA device you will also need to enter in the IP Address for the blender This IP is a fixed IP and must be unique for every device that resides on the same LAN Ethernet Network Some examples are 192 168 0 10 192 168 0 1 192 168 0 2 etc You will also need to program the blender with the same IP address Below is a the blender s IP address and Subnet Mask under Network Setup En Bestes Target gt tual lbs 14 ER a or Stop Panel Wiew Config Dis apts 7 using BOOTF 5 Jere of Mitsubis Ad Dis play ou must send the Send data if you make nn changes before the Moari a change will take place Step 3 set appropriately Page 68 A3 System Management Software You will also need to set the SUBNET MASK for the blender This needs to be set to 255 255 255 0 Once configured you will need to make sure you have connected the Ethernet Module and Cable see Networking instructions for the newer AB OS OA Blender for details Finally touch Send Ethernet Config to Module and monitor the Ethernet module on the blender After about 30 seconds the fault light should stay off and the LINK light should be green Page 69 A3 System Management Software Here are some quick trouble shooting answers Power light is off Check that the Cable External switch is set to Cable
25. HOPPER 7 0 00 HOPPER 0 00 Current Alarms Batch Log Blender Stopped Push to Start or stop Entry over 100 error message Page 82 A3 System Management Software Blender 1 PLC Version 3 1 Inventory HOPPER 1 111 001 HOPPER 2 222 002 HOPPER 3 333 003 HOPPER 4 444 004 HOPPER 5 555 005 HOPPER 1 0 00 HOPPER 2 20 00 HOPPER 3 111 00 HOPPER 4 40 00 Total not HOPPER 6 666 006 HOPPER 7 rrr 007 HOPPER 8 855 008 TOTAL 3996 036 CLEAR INVENTORY 100 HOPPER 5 50 00 HOPPER E 60 00 HOPPER 7 0 00 HOPPER 0 00 Current Alarms Alarm Log Batch Log Blender Stopped Push to Start or Stop Total not 100 error message Page 83 A3 System Management Software The following are error messages given when using the older proprietary blenders Blender 3 Inventory HOPPER 1 0 0 HOPPER 2 0 0 HOPPER 3 0 0 HOPPER 4 0 0 HOPPER 1 20 00 HOPPER 2 20 00 HOPPER 3 20 00 Recipe Not HOPPER 4 40 00 otaling 100 TOTAL 0 0 CLEAR INVENTORY Current Alarms Alarm Log Blender Stopped Push to Start or stop Recipe Not Totaling 100 Page 84 A3 System Management Software The following is the successful message given when using the older proprietary blenders Blender 3 Inventory HOPPER 1 0 0 HOPPER 2 0 0 HOPPER 3 0 0 HOPPER 4 0 0 Batch Size 3 HOPPER 1 20 00 HOPPER 2 20 00 HOPPER 3 20 00 Recipe HOPPER 4 40 00 Transterred TOTA
26. Hopl Hope Hops Hope Hops Hope Hopr Hope TOTAL Recipe EZ Mode Batch Size Batch size 2 2 ug Hop Frame Hope 22 21 Hops 33 33 Hop4 44 44 Hop5 55 55 Hop6 66 66 Hopr 0 00 Hops 0 00 ee ee ee oe ee a RR A Ne eee ee ee ee RR 4232003 11 19 07 am Inventory Hopi 1111 123 Hope kas Hops les Hope 233 Hops 2 Hope SLs Hopr 0 Hope TOTAL Recipe EZ Mode Batch Size Batch Size 5 u Hop aoa aa Hope Hops Hopet Hops Hope Hop Hopes ee ee ee ee a a a RR RR Recipe Info report same for auto or manual just name would be different Page 95 As System Management Software 2003_04_28_13_00_00 Blender 1_batch_data_log log Notepad Sele File Edit Format View Help 4 28 2003 10245332 aM 1 002 1 098 3 002 4 5 00 8 007 F002 8 ool 4 28 2003 16 47 1 amp 8 AM li J onl Taoa a 00 a a a a a E 4282003 1 52 5 0 AM lI 2 2 O98 4 001 4 998 8 Piles ie aaa 4 28 2003 11 25 51 am 998 2 002 2 999 4 5 002 5 998 7 001 9s 002 Batch data report same for auto or manual just name would be different Page 96 A3 System Management Software Chapter Working with the configuration file This chapter explains e What is the configuration file e Setting the system back to defaults e Saving the configuration e Opening a previously saved configuration file e The location
27. Incoming Network Connection Other systems devices connect to my serial device using networking protocols Incoming TCP Socket Connection Welcome p lt Serial device Digi Discover Device TCP Sockets Configure Device Save Settings Other systems devices on the network connect to my serial device using Finished TCP Sockets Other systems devices connect over the network to my serial device Data can be sent and received Device Management TCP Server O UDP Sockets My serial device receives data from one or multiple systems devices on the network Data Collection UDP Server O Telnet Other systems devices telnet to my serial device Console Management Reverse Telnet RFC 2217 Version 1 2 20 0 To continue click Next Ow Digi Device Setup Wiz Click TCP Sockets then next ee a Internet Shortcut to Explorer mohradiant PE My Computer rR DIGI 5P te BATTLEFIELD Kir El Battlefield 1942 The R Recycle Bin mi Financial 14 U AutoCAD R14 P Evaluation 7 0 2 Medal of Medal of Honor alli a Shortcut to Projecti exe COM 1 Test ht ag Start Internet Shortcut to Explorer mohradiant PE My Computer mw Flight WinMx Simulator 2002 DIGI SP COM4 test ht ERTMEFIELD jii Financial de AutoCAD R14 2 Micro Cap Evaluation 7 0 Z Medal of Honor Alli FIN SSS H N Medal of Honor Alli ia Shortcut to Project1 exe
28. L 0 0 CLEAR INVENTORY Current Alarms Alarm Log Blender Stopped Push to Start or stop Recipe Transferred message Page 85 A3 System Management Software Chapter 6 Working with the Report Manager This chapter explains e What is the Report Manager Accessing the Report Manager Automatic vs Manually generated reports Configuring what is included in the reports Saving the reports Auto Clear Features Using Manually generated reports Job Report Manager Sample Reports using Automatic Generation Sample Reports using Manual Generation Job Reports Overview This chapter will help you understand how to use the A3 Report Manager Page 86 A3 System Management Software What is the Report Manager The A3 Report Manager is a utility that allows the user to generate reports for each device that contain e Inventory Usage information e Uptime Percentage information the percent of time that the device has been in the Run mode e Alarm Log information stores up to 1000 of the device s alarms e Recipe Info Log stores up to 1000 recipe changes along with the recipe values and the inventory when the recipe was started e Batch Data information the actual weight of every component of every batch created up to 5000 batches These reports can be automatically printed and will be automatically saved to a location specified by the user From the Report Manager you can also clear all inventories and logs w
29. OV CIVIC W nennen een 99 What is the A3 System Log file cc eeeeceeeeeeeeeeeeeneeeeeeeeeseeenees 99 What is logged in the file ccsceceseeeeeeeeeeeeeeeeeeseeeneessnenes 100 Location Of INE Tile u neni ans 101 Chapter 9 Trouble Shooting Records Records Records Records Records Records Records Records a ald RE E 102 How to trouble shoot a software installation problem 103 How to trouble shoot a PC problem u 22202u02020n0nn2n0 104 How to trouble shoot a communication problem 105 Trouble shooting AEC OS OA Blender network problems 105 Trouble shooting HydReclaim Blender network problems 109 Trouble shooting Sterling SGB Blender network problems 111 Where to go for further hel p cccccssssseessseeeeeseeeeeeseeeeesenees 115 Page 3 A3 System Management Software Preface The information in this manual is based on current industry sources and believed by the author to be correct and as complete as possible at the time of printing It is possible that later changes have been made by the manufacturers of ACS equipment and are not included in this publication Although every effort has been made to insure total accuracy ACS cannot assume any liabilities for omission errors or changes that have occurred in the production of this manual It is not possible to anticipate all possible conditions in which this machinery may be utilized
30. VICES 5 DO NOT TOUCH UNLESS PROPERLY GROUNDED go in fe 10 pr to to le N av SI K SOURCE ELAY OUTPUTS RELAY OUTPUTS go Ip I f we ma a Page 105 A3 System Management Software Step 3 Examine the Power light on the PLC s Ethernet module If it is not on then check the cable that connects the device to the plc and ensure that it is plugged in fully and is the correct cable 1761 CBL AMOO Also make sure that the power switch for the device is set to Cable Step 4 Examine the FAULT indicator If the device is faulted then check that your subnet mask is 255 255 255 0 and that you have a valid IP programmed in not 0 0 0 0 Dis able a ue ing BOOTP Ser Mitsubishi Dis play Send You mys st send the Ethernet ch 2 beta Berl Config to Thane Will take i Module pla Page 106 A3 System Management Software Step 5 If all of the previous steps have been satisfied then examine the LINK light on the Ethernet module It should be green If it is not then first make sure that the Ethernet cable is hooked up at both ends Remember that you must use straight through standard CAT5 cables when going between the blender and a hub or switch If you are trying to go directly from the blender to a PC without using a hub or switch then you need to use a Crossed Ethernet cable At this point you more than likely have a cable problem and should test this To
31. You should also see that you have a working CDROM drive on this page If the system meets all of the requirements except the Service Pack 1 requirement then you will need to install the Windows XP Service Pack 1 from the A3 CD Follow the instructions Page 13 A3 System Management Software Installing the Windows XP Service Pack 1 1 Insert the A3 CD into the CDROM drive When the installation automatically starts cancel the installation Click Start and Click on My Computer Right Click on the picture of the CDROM and select Explore Double Click on WinXP Service Packs Double Click on xpsp1a_en_x86 exe and follow the onscreen instructions This service pack will not run if your version of XP was a pirated version The total time to complete the installation is approximately 15 minutes ot EZ Checking the Internet Explorer version E Google Microsoft Internet Explorer ER ar File Edit view Favorites Tools 36m Contents and Index j 4 A G B zj M I I x a Tip of the Day z Media amp va u wy m wW z For Netscape Users s Address http fwww google com v Go Links Google Send Feedback Images Groups Directory News About Internet Explorer Advanced Search Preferences Google Search I m Feeling Lucky Language Tools l Advertise with Us Business Solutions Services amp Tools Jobs Press amp Help 2
32. agement Software You will need to go to Network Setup found under Setup on the blender and set the appropriate IP address The SUBNET mask should be set to 255 255 255 0 Make sure the Ethernet Configurator is enabled BEGEHRT ann tuali CLEAR Kg lbs Fush to Start or Stop Dis autre ay US ing BOC ITF ers Mitsubis Ad Dis El a ou must Ethernet data it you ee change will take Step 3 set appropriately What is an IP address An IP address is a unique address for each device that is on your network The number can be any number other than 0 0 0 0 Some examples are 192 168 0 10 192 168 0 11 192 168 0 12 etc Notice how I m only changing the last digit Each digit can be as high as 255 IP addresses are either Static or Dynamic Static means that the device will always have the same IP dynamic means that the IP will be given to the device by a DHCP server another computer The blenders IP is always static and cannot be dynamic when using with A3 Have your system administrator set aside a group of static IP addresses for you to use Page 21 A3 System Management Software Configuring the PC If your PC is part of your plants LAN then you will need to have your system administrator configure the IP settings for the PC Ifthe PC is a stand alone system then you will need to configure the network properties 597 My Document ts My Pictures D My Music ct My Computer ATEJ Sh
33. al Area Connection and select Properties Local Area Connection Properties General Authentication Advanced Connect using Eg Intel A PAOSTO0O VE Network Connection 2 This connection uses the following items ei Chent for Microsoft Networks a File and Printer Sharing for Microsoft Networks al as Packet Scheduler Internet Protocol TCP IP x En m Install Uninstall Properties Description Transmission Control Protocol lnternet Protocol The default Wide area network protocol that provides communication across diverse interconnected networks Show icon in notification area when connected Step 3 Double Click on Internet Protocol TCP IP Page 23 A3 System Management Software Internet Protocol TCP IP Properties General ou can get IF settings assigned automatically if your network supports this capability Othenwise You need to ask your network administrator for the appropriate IF settings Obtain an IF address automatically Use the following IP address IF address 132 168 O 1 Subnet mask gore 255 I Use the following DNS server addresses Preferred DNS server Alternate ONS server aa Advanced Cancel Step 4 Set your screen to look like this then click OK and OK again Remember that you need to have a unique IP for all of your blenders and for the PC For example you could use the following scheme
34. and that you are using the correct cable see Networking instructions for the newer AB OS OA Blender The module gets power from the PLC Fault light is on Check to ensure that the DCOMM light on the PLC is on if not you need to enable DCOMM by removing the snap cover on the PLC and holding in the COMMS khutton Reboot after changing SAS 2 e e ESD SENSITIVE DEVICES 23 3 I DONOTTOLUCH 2 UNLESS PROPERLY GROUNDED oni 19 uv 24V SINK SOURCE RELAY OUTPUTS 10 11 a ae gt wT Power light is on Fault light is off but Link light is off This is a problem on the Ethernet side of the module and not the PLC side Check your cables and hubs or switches to resolve the issue You can bypass your network by using a crossed cable and a laptop or computer that has Ethernet Plug the crossed cable directly from the module to the computer If the Link light comes on then the problem is within your network Page 70 A3 System Management Software Configuring an Older Proprietary OS OA OL or OFC When selecting Legacy Equipment with Hynet Driver you will be given a few extra entries to complete Add a New Device Device Hame Device Description Blender 2 oe 0S Blender Blender ontentvantinet Diet Legacy equipment with Hynet Driver equipment with Hynet Driver Lee line Available Features Start or Stop Ability Monitor Inve
35. ard drive size see Working with the Recipe Book Page 60 A3 System Management Software Batch Data Log STATISTICAL DATA MIN MAX AVERAGE STANDARD DEVIATION 9 8 Fi 6 5 4 3 2 1 0 Batch Data Page The Batch Data Page shows the actual weight of every component of every batch made up to 5000 batches Clicking on the Show these Hoppers boxes only effects what is displayed and does not effect the data in the log The graph is automatically scaled for the hoppers you have chosen to be displayed To reload the graph click Refresh If the recipe hasn t been changed then the STATISTICAL DATA section can be very useful in determining the performance of your blender and for trouble shooting Page 61 A3 System Management Software Unit Uptime Percentage Blender 1 50 Blender amp 0 al Blender 3 0 alculation Uptime Data Page The Uptime Data page is accessed by selecting View Uptime Data from the drop down menu This data shows the percentage of time that each blender has been in the Run mode and is useful in seeing the overall proficiency of each machine Page 62 A3 System Management Software Scan Times for Data Acquisition Blender 3 1 SCADA Scan Times Page The SCADA Scan Times Page is accessed by selecting View SCADA Scan Times from the dropdown menu The display is in seconds and is rounded to the nearest whole second These numbers
36. at you see Microsoft Windows XP Service Pack 1 at least 75OMHZ and at least 128MB or RAM Next you will need to check the hard drive Pr y Internet Explorer My Computer Owner jes Command Prompt LI My Documents My Pictures E Calculator 2 My Music Release Notes bes My Computer Ss Microsoft Visual Basic 6 0 a My Network Places Shortcut to 43 exe B Control Panel Package amp Deployment Help and Support wizard z gt Search AutoCAD R14 777 Run IM Microsoft Money 2002 All Programs D Keep in touch with HP A Log Off Turn Off Computer S winxp_system_check A 43 System Managem Step 1 Click start and left click on My computer Page 12 A3 System Management Software E My Computer File Edit View Favorites Tools Help a BEL gt wi P Search Key Folders ia Files Stored on This Computer System Tasks View system information CI Shared Documents Owner s Documents T Add or remove programs G Change a setting Hard Disk Drives Other Places My Network Places My Documents DO Shared Documents G Control Panel N 43 Software D Details g HP_PAYILION C Local Dis File System NTFS Free Space 81 6 GB Total Size 107 GB Network Drives a File Server on SERVER Kpsoftware Z Step 2 Click on C and examine Free Space in the lower left corner under Details It should be at least 30 GB
37. ation part number FA149A cost around 22 each and can be ordered from www blackbox com Page 26 A3 System Management Software The pin outs for the cables are as follows PC to 1st BLENDER PINO PIN4 PIN1 PINS PIN2 PIN8 PIN3 PINY BLENDER to BLENDER PINA PIN4 PINS PINS PIN8 PIN8 PINO PINO It is best to ring out every pin on every connector to ensure that it is wired correctly and that there arent any shorts prior to connecting the cables to each blender Damage to your blenders can occur if you ve wired this incorrectly ALL CABLES MUST BE RUN THROUGH CONDUIT Page 27 Networking instructions for the Sterling SGB Blender Installing the PLC hardware The first step is that you must install the Ethernet module and cable into every PLC You will need the Mitsubishi FX2N 232 BD board added to each blender an Digi One IA Ethernet Module Digi p n 70001862 and a 3 foot DB9 Null Modem Cable that is female on both ends BlackBox com p n EYN257H 0006 FF per blender The Ethernet module snaps in to the DIN rail just to the right of the Mixer Motor contact and the cable snaps into the module and 232 board on the PLC follow the 232 boards instructions for mounting E h a la a ggg aaa a a ae LE You will also need to make sure that you are running at least SGB 1 2 blender software this can be found on the blender under Setup F940 config Page 28 A3 System Management Software Configuring the Digi One IA E
38. ayer MM AutoCAD R14 gt WY Microsoft Word MM AutoCAD R14 0 Uninstall oe Bd Windows Install Clean Up M Codemasters MM ExpresspcB gt M McAfee gt Micro Cap Evaluation 7 gt MM Microsoft Hardware gt MM QuickTime gt Rockwell Software M winrar an Winzip fm ACS Software As 43 System Management Software E Read Me 43 System Management Software an Automated Solutions Activex an Axialis Programs gt Cimquest gt 7 GMS gt MM INGEAR Activex Controls gt Microsoft Developer Network gt Microsoft Reference gt R 2 13 PM Click Exit from the File Menu Page 19 Networking instructions for the AEC AB OS OA Blender Installing the PLC hardware The first step is that you must install the Ethernet module and cable into every PLC You will need an Ethernet Module A0563939 1761 NET ENI and a Cable for the Module A0565898 1761 CBL AMOO per blender The module snaps in to the DIN rail just to the right of the Mixer Motor contact and the cable snaps into the module and PLC You will also need to make sure that you are running at least 3 2 blender software this can be found on the blender under Setup PV config The final thing to do on the PLC is to make sure that the DCOMM light is enabled If it is not then remove the snap cover from the PLC and hold in on the COMMS recessed switch until the DCOMM light is on Page 20 Configuring the PLC A3 System Man
39. before proceeding Internet Shortcut to Explorer mohradiant Mon My Computer Microsoft Visual Ba DUA m 4 Flight WinMx Simulator 2002 SideWinder Game Voice Recycle Bin Battlefield 1942 The R Financial a AutoCAD R14 of Micro Cap Evaluation 7 0 u Medal of Honor Alli IN N HS Medal of Honor Alli Am Shortcut to Project1 exe COM 1 Test ht ag Start dr Digi Device Setup Wizard D g Welcome Discover Device Configure Device Save Settings Finished Version 1 2 20 0 Select Scenario Click through the list to find the scenario that best describes how you will use your Digi One SP Incoming Connection lt Connect Serial device Digi Incoming Connection My serial device accepts incoming connections from other systems devices RealPort COM Port Redirection TCP UDP Server Reverse Telnet RFC 2217 Outgoing Connection My serial device establishes connections to one or multiple systems devices on the network Automatic Connection Data Distribution TCP Client UDP Client Bridging Serial Devices My serial devices connect to each other using Digi devices to bridge serial data over the network Serial Bridge Serial Tunneling Custom Configuration would like to manually configure the Digi One SP using the web interface on the device To continue click Next Oe Digi Device Setup Wiz Click Incoming Connectio
40. ble of 1024x768x16bit color 32bit color recommended 10Mbps Ethernet 100Mbps recommended 1 USB slot Standard Ink Jet Printer if you are going to print the reports Page 10 A3 System Management Software Installing A3 Before you start the installation you will need to be logged in as the administrator and you will need to close all programs that are running Checking your PC You should first check that your PC meets the requirements To check the operating system requirement processor and RAM A y Internet Explorer ae My Computer Owner ga Command Prompt 7 My Documents je My Pictures E Calculator 2 My Music a Release Notes 7 Explore Microsoft Visual Basic 6 0 Search Manage Shortcut to A3 exe Map Network Drive Disconnect Network Drive Package amp Deployment u Wizard Show on Desktop Rename AH autocan R14 n TI Run EEE IM Microsoft Money 2002 All Programs D Keep in touch with HP A Log Off Turn Off Computer untitled Paint A A3 System Managem Step 1 Click start then RIGHT CLICK on My Computer and select Properties Page 11 Remote Advanced System Microsoft Windows F Horne Edition Version 2002 Service Pack 1 Registered to Manufactured and supported by Hewlett Packard Pavilion Intel F Pentium R 4 CPU 1 80GHz2 1 79 GHz S12 MB of RAM a Step 2 Examine the above and ensure th
41. e Click to Delete all the stored recipes Delete Delete Al Click to save a an entered ave New Races stored recipe Ir Click to print the entire The A3 Recipe Book Recipe Book Page 79 A3 System Management Software Creating a stored recipe 1 Edit the RECIPE DATA fields to appropriate values 2 Click Save New and enter in a name in the File Name box and click Save Viewing a stored recipe Click on an AVAILABLE RECIPE and the RECIPE DATA fields will show the values for the recipe you ve selected Recipe Book AVAILABLE RECIPES click on one EEE RECIFE DATA eau 3 37 ez trecine adr NUMBER OF HOPPERS a my recipel ar DEVICE TYPE 05 04 Blender RECIFE MODE E Mode g Batch Size 5 HOPPER1 ts HOPPER 5 HOPPER 300 HOPPER 5 HOPPERS 10 HOPPER 2 5 HOPPER 22 HOPPER 2 2 2 Delete Delete All Save New Page 80 A3 System Management Software Editing Existing stored recipes 1 Click on an AVAILABLE RECIPE and the RECIPE DATA fields will show the values for the recipe you ve selected 2 Edit the RECIPE DATA fields 3 Click Save New and select the stored recipe and click Save Deleting stored recipes To delete a single recipe 1 Click on an AVAILABLE RECIPE 2 Click Delete and the recipe will be removed To delete all of the recipes 1 Click Delete All and all stored recipes will be removed Printing the recip
42. e book Click PRINT BOOK and the entire recipe book will be sent to the printer You cannot print a single recipe by itself The location of the recipe book The A3 Recipe Book is a collection of files with the extension of a3r and are located in the installation directory Using Windows you can copy all of these files to a back up location if desired By default the installation directory for A3 is c program files a3 system management software Page 81 A3 System Management Software Loading a stored recipe into a device e Access the Virtual Control Panel by double clicking on the device from the main page Click on Recipe Book Click on the AVAILABLE RECIPE that you want to load Click Load Click Accept Recipe and the recipe will be loaded only on the Newer AB OS OA blenders the recipe is already loaded at this point for the Older Proprietary blenders If the recipe is not correct an error message will be given that will prevent it from loading The following are error messages given when using the newer AB OS OA blenders Blender 1 PLC Version 3 1 Inventory HOPPER 1 111 001 HOPPER 2 222 002 HOPPER 3 333 003 HOPPER 4 444 004 HOPPER 5 555 005 Batch Size 3 HOPPER 1 fee HOPPER 2 20 00 HOPPER 111 00 HOPPER 4 40 00 Entry over HOPPER 6 666 006 HOPPER 7 F77 007 HOPPER 8 898 008 TOTAL 3996 036 CLEAR INVENTORY 100 HOPPER 5 50 00 HOPPER E 60 00
43. erling SGB Blender or any of the following older HydReclaim systems OS Blender OA Blender OL Blender OFC Weight Hopper Multiple plants can be linked together through the World Wide Web system will handle up to 1000 blenders up to 255 older units can make up the 1000 units system can be custom configured with the customers name plant locations and blender line names Page 5 A3 System Management Software Who should use this manual Use this manual if you are responsible for system integration of machinery in your facility You should have a basic understanding of Allen Bradley or Mitsubishi PLC Ethernet networking and Windows XP If you do know contact the appropriate personnel to obtain information before proceeding Your IT personnel or outside networking consultants should be involved in the installation of this software package Purpose of this manual This manual provides information on the installation operation and trouble shooting of the A3 System Management Software Technical support If you have questions or problems using the A3 software or need help with installation questions please refer to this manual first If you can t find the answer your looking for contact ACS Technical Support ACS Technical Support 800 229 2919 Please have your purchase date software version blender models and software versions and controller info AB Mitsuibishi or Proprietary and the person that networked the de
44. f the sheet you wish to add a device to and select Add ACS Device You will then see the following dialog A gt A3 System Management Software Plant View 4 Plant Name Available Features IV Start or Stop Ability ee V Monitor Inventory IV Clear Inventory Ability ications Type OS Blender _v IV Log All Alarms noes 10 V Monitor Running Recipe Y Sass IV Change Recipe Ability Monitor Targets vs Actuals V Include this device in Report TIME 4 28 2003 10 21 57 AM start W add_aec_device_sele A 4 amp 3 System Managem Sy 10 21 AM Add New Device Dialog 1 Edit the Device Name Use whatever is appropriate for your blender 2 Edit Device Description if desired Any text that is entered here will pop up when the operator holds the mouse over the icon for the device This is commonly known as Tool Tips and can be used to give the operator location information of the device 3 Select the Device Type OS OA OL and OFC A picture is given for help 4 Select the Communications Type AEC AB OS OA blenders use the OS2001 Blender OS or OA with AB Driver Older HydReclaim blenders and weigh hoppers use the Legacy Equipment with Hynet Driver and Sterling SGB blenders use the SGB Blender with Mitsubishi Driver 5 Select which features you wish to enable for this device These features are shown in the Available Features box and are self explanatory Page 67
45. ftware Chapter 5 Working with the A3 Recipe Book This chapter explains What is the A3 Recipe Book Accessing the Recipe Book Creating Stored Recipes Viewing a stored recipe Editing existing Stored Recipes Deleting Stored Recipes Printing the Recipe Book The location of the Recipe Book Loading a stored recipe into a device Overview This chapter will help you understand how to use the A3 Recipe Book What is the A3 Recipe Book The A3 Recipe Book is a book that is stored on your PC that allows the user to create delete edit print and recall stored recipes This book has nothing to do with the local recipe book that each machine might have and it is suggested that you use one or the other not both to store your recipes These recipes are used to load recipes to each device from a central location that can be managed by one person easily Page 78 A3 System Management Software Accessing the Recipe Book The recipe book can be accessed by selecting Tools Recipe Book using the dropdown menu or can be accessed by double clicking on a device and from the Virtual Control Panel clicking Recipe Book Recipe Book AVAILABLE RECIPES click on one RECIPE DATA default adr ez fecipe ar NUMBER OF HOPPERS 0 DEVICE TYPE 05 04 Blender r RECIFE MODE Percentage Mode r The stored List of Batch Size recipe s data available stored recipes my recipe adr Click to Delete a recip
46. grades will be provided free upon request during your warranty period after that they must be purchased labor and other hardware for these upgrades not provided by ACS Necessary Firmware upgrades for the machinery communicating with A3 can be obtained by contacting your local ACS sales office as well These will need to be purchased and are not given freely because of the cost involved Page 8 A3 System Management Software What s new in version 1 1 Job Report Manager Now you can generate reports on demand instead of just time Along with this comes the new feature of Job Management that allows the operator to enter in the following data into the job e Job Number e Material reference numbers for each hopper e Material lot numbers for each hopper e Material silo numbers for each hopper The operator can start or stop a job at any time The reports that generate are date time and job number stamped for easy recording New Configuration Options Now you can save the configuration to a specified location for either backup purposes or for distribution to others who have A3 and would like to look at the same data that you are Another new feature is the ability to load a configuration file from a specified location for restore purposes or to quickly program a new computer Tip of the Day Tip of the Day is a small window that is displayed when the program boots The operator can scroll through the tips by selecting Next Tip
47. he log files from these drives before other files will be saved A warning is given when you only have 25 space left When you reach the limit all saving including the configuration file will be prevented until the problem is resolved Problem Your receive printer error messages when the printer is hooked up Solution A3 works with all printers that work with Windows XP Using the control panel right click on the printer and select properties and then click Print Test Page If the printer doesnt print from here then the problem is with the printer or printer installation Page 104 A3 System Management Software How to trouble shoot a communication problem The approach to trouble shooting varies with the type of communications the device uses so this section is divided up into multiple sections Trouble shooting network problems with AEC AB OS OA blenders Problem You ve configured more than one Ethernet device and none of them are communicating Solution It is easy to trouble shoot when you have some devices communicating at least one but with none communicating you re going to have to start from the beginning Step1 Disconnect all of the blenders except for one Get this one working and then go to the next one Step2 Examine the DCOMM light on the PLC and ensure that it is on If it is off then remove the snap cover on the PLC and hold in the COMMS button until the DCOMM light turns on i ESD SENSITIVE DE
48. hin the blender consult service If this test fails and you see scrolling junk on the screen then the problem is that you have noise on the com cable The cable s shield should only be connected at the PC end and not at the blender end When the cables are unhooked there shouldn t be continuity between the hoods on any of the cables If there is fix the problem If you ve fixed the shields and are still seeing noise then start unhooking blenders If when you unhook a blender the noise goes away then check the blender consult service If the blenders aren t causing the noise and you ve run the cables through conduit if not then you must then some external device is creating the noise Begin shutting electrical devices off one at a time until you find the problem Sometimes this issue can be caused by weak ground circuits To resolve a weak grounding grid in the plant you have to drive a copper spike through your floor into earth ground near the source of noise no other solution Page 110 A3 System Management Software Trouble shooting network problems with Sterling SGB blenders Problem You ve configured more than one Ethernet device and none of them are communicating Solution It is easy to trouble shoot when you have some devices communicating at least one but with none communicating you re going to have to start from the beginning Step1 Disconnect all of the blenders except for one Get this one working and then go t
49. ice Configure Device Save Settings Finished Digi One SP Saving device settings a Version 1 2 20 0 Please wait while the configuration is saved to the device lt lt Stat lt Back Finish J Skip gt gt Cancel He gt Digi Device Setup Wizar Congratulations You have successfully completed the Digi Device Setup Wizard Dig Welcome 1 Saved configuration successfully Discover Device You can use the web interface to manage and monitor the Digi One SP To access the web interface check the Log on to web interface Configure Device checkbox below and click Finish or go to http 192 168 0 11 Save Settings The username and default password are oe Username root Finished Password dbps Additional information such as cabling and configuration information as well as troubleshooting tips may be found in the User s Guide De 0 C Log on to web interface Version 1 2 20 0 To close this wizard click Finish es J cr ma son Deselect Register and click Finish to complete A3 System Management Software Chapter 2 Using A3 AS software uses menus windows status bars and right click menus as do most Windows applications This chapter covers e The application window Status bar info Drop down menus Right click menus Tip of the Day Setting up the A3 options Customizing A3 Overview When A3 starts you will see an introduction screen A A3 System Ma
50. icker and easier A3 A3 System Management Software Plant View E x File Edit wiew Tools Help Blender 1 Add ACS Device Ctrl N Delete Selected ACS Device Delete ALL ACS Devices Edit Selected ACS Device Ctri E TIME 4 28 2003 3 39 19 PM 2 start Microsoft Word 43 5 right_click_blank_are As 43 System Managem Sy mM 3 39 PM Right clicking in the blank white area will bring up these Page 44 A3 System Management Software A A3 System Management Software Plant View File Edit View Tools Help Edit Device Delete Device TIME 4 28 2003 3 39 40 PM eles Microsoft Word 43 right_click_device bm As 43 System Managem 4 Ai 3 39 PM Right clicking on a device will bring up these A A3 System Management Software Plant View File Edit View Tools Help esesesesecoeeocesssosoeesseeseoes Add Sheet Blender 1 Change Sheet Name ee nl TIME 4 28 2003 10 28 50 AM Start 5 add_aec_device_war As 43 System Managem Right clicking on the sheet name will bring up these Page 45 As System Management Software Status Bar on A3 The status bar is located near the bottom of the A3 main page A A3 System Management Software Plant View File Edit view Tools Help Blender 1 Blender 2 Blender 3 YYY NEXT REPORT WILL GENERATE AT 4 29 2003 8 00 00 AM TIME 4 28 2003 11 11 50 AM DAYS 0 20 48 10 UNTIL REPORT
51. iguration loaded 43 program started 43 program customer configuration loaded Operator has chosen to edit Blender 1 4 28 2003 44 FM Operator has chosen to add a deyice 4 28 2003 44 FM Operator has chosen to add a device 4 28 2003 1 00 00 FM Automatic Report Generated The A3 System Log It is normal that when the program is started you will see communication alarms for several devices This is normal while the devices are initializing and as long as the alarms clear quickly you should not be concerned This log will automatically log up to 5MB of data before starting over Page 100 A3 System Management Software The location of the file The A3 system log file is always named a3_system_log txt and is located in the installation path By default the file will be found in c program files a3 system management software a3_system_log txt and can be as large as 5 MB in size depending on the number of entries amp C Program Files A3 System Management Software File Edit View Favorites Tools Help Back gt gt Search ey Folders Eta 3_system_config cf a3_system_config cfg File and Folder Tasks 2 A ae CFE File 1 244 KB mij Rename this File in Move this file ee P Driverx vxd T Virtual device driver Copy this File BE Bi 39 KB es Publish this File to the Web Igpktx inf read me txk E mail this File Setup Information Text Document 1 KE 5 KB E Print this Fi
52. ingpu Road SIP Mhalunge Chakan Tal Khed Suite 588 Suzhou China 215126 Dist Pune 410501 India Schaumburg IL 60173 Phone 86 8717 1919 Phone 91 21 35329112 Phone 1 847 273 7700 Fax 86 512 8717 1916 Fax 91 20 40147576 Fax 1 847 273 7804 l l Europe Middle East Africa ACS New Berlin Manufacturing Facility 2900 S 160 Street ACS Warsaw New Berlin WI 53151 UI Dzia kowa 115 Phone 1 262 641 8600 02 234 Warszawa Fax 1 262 641 8653 Phone 48 22 390 9720 Fax 48 22 390 9724 A3 System Management Software Confidential Supervisory Manual Not to be released to floor operators Preface Hardware Hardware Hardware Hardware Hardware Hardware Hardware Hardware Chapter 1 Installing A3 Hardware Hardware Hardware Hardware Hardware Hardware Hardware Chapter 2 Using A3 Screens Screens Screens Screens Screens Screens Screens Screens Screens Screens Screens Screens Screens Screens Screens Screens Screens Table of Contents Chapter 3 Application Screens Chapter 4 Working with A3 Device Objects Instruction Instruction Instruction Instruction Page DVELVIEW ee ee ee ee eee eee ee 4 Who should use this Manual ccccseeeeeeeeeeeseeeeeeneeseeneseeneeseenens 6 Purpose of this manual uuuu202000000n00nannnonnnnnnnnnnnnnnnnnn nenn 6 Technical Support ies zes east een ren sreieeaenie 6 Frequently Asked Questions uu22u0000n2nnn0nonnnnnnnnnnnnn
53. it If a box shows then this is the automatically calculated entry and does not need to be entered On newer AB OS OA blenders you then need to hit Accept from the Virtual Control Panel to finish loading the recipe Page 55 A3 System Management Software If the recipe is not correct an error message will be given that will prevent it from loading The following are error messages given when using the newer AB OS OA blenders Blender 1 PLC Version 3 1 Inventory HOPPER 1 111 001 HOPPER 2 222 002 HOPPER 3 333 003 HOPPER 4 444 004 HOPPER 5 555 005 Batch Size 3 HOPPER 1 jee HOPPER 2 20 00 HOPPER 111 00 HOPPER 4 40 00 Entry over HOPPER 6 666 006 HOPPER 7 F77 007 HOPPER 38 898 008 TOTAL 3996 036 CLEAR INVENTORY 100 HOPPER 5 50 00 HOPPER E 60 00 HOPPER 7 0 00 HOPPER 0 00 Current Alarms Alarm Log Batch Log Blender Stopped Push to Start or stop Entry over 100 error message Page 56 A3 System Management Software Blender 1 PLC Version 3 1 Inventory HOPPER 1 111 001 HOPPER 2 222 002 HOPPER 3 333 003 HOPPER 4 444 004 HOPPER 5 555 005 HOPPER 1 0 00 HOPPER 2 20 00 HOPPER 3 111 00 HOPPER 4 40 00 Total not HOPPER 6 666 006 HOPPER 7 rrr 007 HOPPER 8 855 008 TOTAL 3996 036 CLEAR INVENTORY 100 HOPPER 5 50 00 HOPPER E 60 00 HOPPER 7 0 00 HOPPER 0 00 Current Alarms Alarm Log Batch Log Blender Stopped Push
54. ith one click using Clear All Logs and Inventories Accessing the Report Manager The Report Manager can be accessed by selecting Tools Report Manager using the dropdown menus Page 87 A3 System Management Software Automatic vs Manually generated reports The report manager can be configured to either automatically generate reports based on a time interval from 1 8760 hours or manually generate reports based on Jobs This option is up to the user and can be configured using the following Report Manager F gm B Report Options Frequency i Automatically Print Report Enable Reports Clear all Logs and Generate Report every Inventories C Manually Generate Job Reports Interval in hours 24 Cancel Starting Time in Hours g Frequency of Reports Automatic reports are usually used when the user runs the same product on their lines or are not concerned with documenting each product run The data generated is easier to manage because of the frequency of the report Manually generated reports Job Reports are usually used when the user wants to document every product run and what went into that run This is very powerful for the health and food industry but can be overwhelming for normal users The reports can pile up quicker than someone can process the data depending on how many job changes the machine performs However there are some unique advantages when using Job Reports The operator accesses
55. lation software will automatically start If it doesn t then run Setup exe from the A3 CD A3 System Management Software Setup A3 System Management Software Setup es Welcome to the 43 System Management Software installation program Setup cannot install system files or update shared files if they are in use Before proceeding we recommend that you close any applications you may be running Exit Setup Step 1 Click OK Page 16 A 95 ri A L cr Ci A gt System Management Software TAY amp Yolo Th i vanage 1 ISTE 00 Wale As System Management SoftWare Setup A AJ System Management Software setup Begin the installation by clicking the button below Click this button to install 43 System Management Software software to the specified destination directory r Directory C Program Files 43 System Management Software Change Directory Exit Setup Step 2 Click the picture of the computer As System Management Sollware Setup F A3 System Management Software Choose Progr Setup will add items to the group shown in the Program Group box You can enter a new group name or select one from the Existing Groups list Program Group Existing Groups Accessories Axialis Programs Codemasters GameSpy Arcade Startup WinMx WinRAR em Step 3 Click Continue Page 17 A3 System Management Software A3 System Management Software Setup A3 Sy
56. le 4 Delete this File ST6UNST LOG tipofday txt Text Document Text Document b EB 6 EB Other Places IS Program Files G My Documents Page 101 A3 System Management Software Chapter 9 Troubleshooting This chapter explains e How to trouble shoot a software installation problem e How to trouble shoot a PC problem e How to trouble shoot a communications problem e Where to go for further help Overview This chapter will help you understand how to properly trouble shoot the A3 System Management Software Page 102 A3 System Management Software How to trouble shoot a software installation problem Problem During the installation of the A3 software you receive a message saying that some of the files on your PC need to be updated and then asks you to reboot After rebooting and running the installation again you will receive the same message Solution The problem is that your PC does not have Windows XP Service Pack 1 installed This is an update from Microsoft and must be installed first See Chapter 1 Installing A3 for a detailed solution At this point you should thoroughly read Chapter 1 and follow every step Remember to always check that your PC meets the requirements or you could be wasting time Problem After inserting the A3 CD into your PC the installation program does not automatically start Solution Auto Play is not turned on for your PC To run the installation just click Start then
57. maintained or serviced It is not possible to provide cautions for all possible hazards Operators and maintenance personnel should use standard and accepted operating procedures and precautions ACS accepts no responsibility for the damages resulting from the utilization of the information in this manual Please note that this is a service manual it is not appropriate for use by system operators Copyright The material in this publication was compiled for the use at ACS No part of this manual may be reproduced stored transmitted or distributed without the prior written consent of ACS 2003 Revised October 21 2003 Overview The A3 System Management Software program is a Windows based program that allows you to control and monitor up to 1000 ACS devices Currently you can use A3 with the following devices e OS Blender AEC AB controls OA Blender AEC AB controls Sterling SGB Blenders Mitsubishi Controls Older OS Blender HydReclaim Proprietary Controls Older OA Blender HydReclaim Proprietary Controls Older OL Blender HydReclaim Proprietary Controls Older OFC Weigh Hopper HydReclaim Proprietary Controls Page 4 A3 System Management Software When using the system to integrate older proprietary units you will need the optional USB RS422 485 module and must limit the number of devices to 255 this is a limitation of RS422 and not the A3 package Monitor the status of all blenders started stopped alarming etc
58. mputer as U a EIN Flight Winx Simulator 2002 temp ERTMEFIELD itis Battlefield 1942 TheR Financial 14 za AutoCAD R14 all Micro Cap Evaluation 7 0 Medal of Honor Alli Shortcut to Project1 exe COM 1 Test ht a Start Shortcut to mohradiant DIGI SP test ht ERMEFIELD jin Battlefield 1942 The R Financial 14 AutoCAD R14 7 0 Medal of Honor Alli Medal of Honor Alli p Wizard Discover Device Locate your Digi device on the network Welcome Discover Device Configure Device Save Settings Finished sion 1 2 20 0 From the list below select the device you would like to configure Identify your device based on the MAC Address If your device is not in the list select lt Device not listed gt and click Next Found Devices IP Address MAC Address Host Name Product Name Refresh To continue click Next cre ee Oe Digi Devi Device Setup Wizard Dig Discover Device Locate your Digi device on the network Welcome Discover Device Configure Device Save Settings Finished Version 1 2 20 0 From the list below select the device you would like to configure Identify your device based on the MAC Address If your device is not in the list select lt Device not listed gt and click Next Found Devices IP Address MAC Address Host Name Product Name 192 168 0 10 00 40 9D 23 0B 47 Digi One SP
59. nagement Software version 1 0 Copyright 2003 Group PROCESSING SOLUTIONS WORLDWIDE WARNING This software is protected under copyright laws and international treaties Any unauthorized reproduction or distribution or this program or portions of it may result in criminal penalties and will be prosecuted to the maximum extent allowed under law Page 39 A3 System Management Software Tip ofthe day The application window will appear and will show you a Tip ofthe Day A A3 System Management Software Plant View File Edit Vie le Help 4 Plant Name As Tip of the Day amp Did you know 43 can monitor and control up to 1000 devices It will work with both AB OS 04 blenders as well as all of the older equipment Older 05 04 and OL blenders as well as single OFC weight hoppers V Show Tips at Startup TIME 4 28 2003 9 59 06 AM R sa Start W untitled Paint A gt 43 System Managem y A 9 59 AM Deselecting Show Tips at Startup will prevent the Tip of the Day from appearing the next time the program starts Also you can scroll through many random tips by hitting Next Tip Hitting OK will close the Tip dialog Page 40 A3 System Management Software Drop down menus AS has many drop down menus that can be selected A A3 System Management Software Plant View aG Edit view Tools Help Set Config to Default Open and Load Config file
60. ncel setup when setup starts 2 Remove the USB adapter from the box and plug it into a free USB port on the PC 3 Windows will find the hardware automatically keep clicking next until you see finish Windows will find 2 separate items when you plug the adapter in so you will have to repeat this step a few times until it says that your new hardware is ready to use Wiring the interconnection cables You will need to wire a Belden 8103 type cable 2 twisted pair shielded between the PC and the first blender then from the first to the third and so on until you reach the end This network cannot be a Star type network A Start type network is where you have several branches coming out of a junction box The distance between the Tap and each blender cannot exceed 1 foot The Tap is the location at which the cable passes by the blender before proceeding to the next blender To connect the cable to each blender you will need 1 DB9 Male solder type connector To connect the cable to the PC you will need 1 DB9 Female solder type connector The Tap can be made in several different ways Some solder 2 wires into each solder cup this is difficult and can easily be done incorrectly while others solder 1 set of wires to the DB9 Male and connect these wires to 2 other sets using a standard terminal block 4 connections that is inside of a j box The third method is to purchase pre made Taps from Black Box Corpor
61. nnnnnnnn nenn 7 Software and Firmware Upgrades u222020 2000nns0nnnnnnnnnnnnn nen 8 What s new in version 1 1 uu22u2 20002n00 n0nnnnnn nun nun nnnn nn 9 What s new in version 2 0 uuusuusunnnnunnnnnnnunnnnnnnnnnnnnnnnnnnen 9 VS WU rsa sere secs ee E 10 System REQUIFEMeENts cccceceeeeeeeeeeseeeeseeeeeseeeneeeeaeeeeseaeneesenens 10 Installing A3 System Management Software cscceeeee 11 Starting and exiting A3 uuzuu020n20n0nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn anne 19 Networking instructions for AEC AB OS OA Blenders 20 Networking instructions for older HydReclaim equipment 26 Networking instructions for Sterling SGB Blenders 28 OM ON ea ee ee ee ee ne eeatl eier 39 TIP OLINe Day ea nn Ainaa 40 Drop down menus 22u0220202n00nnn0nnnnnnnnnunnnnnnnnnnnnnnnnnnnnnunnnnnn anne 41 Right click MenuS iia coscdecsedcnnternetneidesccsatearetanidadcseawtdanccasteawatawedsse 44 STALUS Bai esnan E OE 46 EUStOMIZING AB nun auanei naaa 47 AS OPLONS iin rennen 50 OV 012 arses ce E A neue eres eves eres eee E A A E E 52 Virtual Control Panel een 53 PVA YN E oe gsc E E E E E 55 Change Recipe Page cccccssccsssesseesssseeeeseeneeeeeeseeeeseeesseeneesenens 55 ROCIO BOOK Are E EAEE 60 BACH D ta AOS irain AE 61 Uptime Data Page cccscccsesseeeseneeeeeseeeeeeeneeseeeeseeseeneeseeneesoenens 62 SCADA Scan Times Page uuuuusnnannnnnnnn
62. nnnnnnnnnnnnannnnn nn nun 63 Memory StatuS essen anne 64 Data Parameters Page uussnenennnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnen nennen 65 OVERVIEW ee re ee 66 What is an A3 Device Object uuuuss0s00000nnnnnnonnnnnnnnnnnnnnn nen 66 Adding new A3 Device ObjectsS uuu00002n000nnnnnnnnn anne nn 67 Editing an existing A3 Device Object uuru2222202n00nunnnnnnnen 67 Instruction A3 System Management Software Chapter 5 Working with the A3 Recipe Book Instruction Instruction Instruction Instruction Instruction Instruction Instruction Instruction Instruction Instruction Deleting an A3 device object u zuu 2u00 n00nanunannonnnnnn nennen 67 Overview of the Recipe Book uus 22020 20000 nn00nnnnnnunnnnnnnn0nn 78 What is the A3 Recipe Book u u2 2000 n00nan0nnnnun nun nnnnn anne 78 Accessing the Recipe Book u4us22n00nn0n0nnnnnnnnnnnnn ann nn nn nenn 79 Creating new stored recipes uuunuunnnnunonnnnnnnnnnnnnnnnnnnnnnn nun 80 Viewing a stored recipe uusuuuunnnn0nnnnnnnnnnnnnnnnnnnnnnnnn nun nennen 80 Editing stored recipes from the book uurzueuuu2u nnunnnnnnnnnen 81 Deleting stored recipe from the book uuuzuuuusuennnnunnnnnnnen 81 Printing th DOOK issidas aaan aaa 81 Location of the book ii neu nein nee 81 Loading a stored recipe into a device uuuuu uunannnnannnnnnnnn nennen 82
63. ns then Next Page 35 Page 36 es Internet Shortcut to Explorer mohradiant Microsoft Visual Ba td WinMx temp Programs a 7 Sidewinder DIGI SP COM4 Game Voice test ht ERMEFIELD jii Financial 14 za AutoCAD R14 Medal of Honor Alli Medal of Honor Alli Shortcut to Project1 exe COM 1 Test ht ag Start 7 Shortcut to mohradiant Flight WinMx Simulator 2002 Sidewinder DIGI SP COM4 Game Voice test ht ERMEFIELD jas Battlefield 1942 The R Financial 1a AutoCAD R14 PL Micro Cap Evaluation 7 0 fl Medal of Honor Alli HA Medal of Honor Alli Au Shortcut to Projecti exe COM 1 Test ht ag Start Incoming Connection My serial device accepts incoming connections from other systems devices Incoming Network Connection Welcome Serial device Digi Discover Device 5 Configure Device RealPort COM Port Redirection Save Settings My application requires a COM port to communicate with my serial device Finished Incoming Network Connection Other systems devices connect to my serial device using networking protocols Console Management Device Management Data Collection TCP UDP Server Reverse Telnet RFC 2217 To continue click Next lt lt Start Skip gt gt Cancel Version 1 2 20 0 Oe Digi Device Setup Wiz Click Incoming Network Connection then next
64. ntory SERIAL SETUP for all units Monitor Running Recipe T Bel gelelnse Change Recipe Ability seral ID 1 255 19200 g Monitor Targets vs Actuals fi Polling Time in milliseconds Number of Hopper fi ai Include this device in Report 4 Maximum Resend Attemps fo Cancel OK Adding a Legacy Device As you can see you will need to enter a unique Serial ID for each device on your network You will also need to configure the numberof hoppers for the device this is only necessary on the older proprietary blenders Leave the Polling Time at 100ms and Maximum Resend Attempts at 10 To configure the Serial ID on the actual blender Step 1 From the main menu press 5 and enter in your password Page 71 Page 72 A3 System Management Software Step 2 press 6 Step 4 press 4 or sg to increase or decrease Serial ID then Backup POWER u A3 System Management Software ALARM 1 4 ee aneae caeaoon Step 5 press 1 or 2 to change Baud Rate then Backup The SERIAL SETUP section is the same for all proprietary devices on the network changing the settings here means changing it for all devices The COM Port should be set to whatever the USB RS422 485 is set to To check the USB RS422 485 port setting 2 Ed My Computer jes Command Prompt E Calculator Pah Release Notes Microsoft Yisual Basic 6 0 Shortcut to A3 exe Package amp Depl
65. o 20 different sheets with up to 50 devices on each sheet To add a sheet select File New Sheet To delete a sheet click on the sheet and then select File Delete Sheet A3 AJ System Management Software Plant View A X File Edit View Tools Help o oP Plant Name 4 Plant Name e 6 gt o Ssasasascoe eooo TIME 4 28 2003 10 25 13 AM Page 49 A3 System Management Software A3 options The A3 software also has many preference options that can be changed by the user To access the options menu select Tools Options Options __HedDive Securiy Operator must werte the following actions Closing the 43 program Deleting any 43 Data Object Starting or Stopping a device Changing the recipe of a device Deleting 4 stored recipe Cancel Clearing Inventory Clear L earing any Log nk Options Vertingaston Sec Stop saving data when Hard Drive Space ts less than the following 000 MB Cancel OF Options VeitingAcion HadDive Operator must enter USER PASSWORD for the following actors Closing the 33 program Master Password Changing 43 setup User Password Starting or Stopping a device aa Changing the recipe of a device Deleting or Saving a stored recipe Cancel Cleaning Inventory Cleari L eang any Log nk Page 50 A3 System Management Software Verify Action Options These options enable or disable the Are you sure prompts after certain operations
66. o the next one Step2 Examine the Dipswitch settings on each of the DIGI Ethernet modules Switch 1 should be on and 2 4 off see below Step 3 Examine the Power light on the PLC s Ethernet module If it is not on then check the 24VDC power connection to the module Page 111 A3 System Management Software Step 4 If all of the previous steps have been satisfied then examine the LINK light on the Ethernet module It should not be red If it is then first make sure that the Ethernet cable is hooked up at both ends Remember that you must use straight through standard CAT5 cables when going between the blender and a hub or switch If you are trying to go directly from the blender to a PC without using a hub or switch then you need to use a Crossed Ethernet cable At this point you more than likely have a cable problem and should test this To test purchase a standard CATS cable that already has the ends connected and a standard hub or switch this can be purchased from Best Buy Circuit City CompUSA or Radio Shack At the blender power up the hub and connect the blender using the new cable to one of the middle ports on the hub say port 3 on a 4 port hub Examine the LINK light and if it is now clear then the problem is definitely in your original cabling This same test can be performed on the PC and PC cable All PC Ethernet cards have a LINK light as well Establish the LINK light on all devices before proceeding Ste
67. of the configuration file Overview This chapter will help you understand how to manage the A3 configuration file What is the configuration file The configuration file is a file that is used by A3 to remember your preferences and settings This is what makes your system different from the next This file can be backed up so that if you purchase a new computer you can quickly configure your A3 software after installation Page 97 A3 System Management Software Setting the system back to defaults The system can be set back to the original defaults by selecting File Set Config to Default from the dropdown menu This should be used with caution Saving the configuration The configuration file is automatically saved when you exit the program but in case the power is removed from the computer the configuration file will not be saved For this reason it is a good idea to save the configuration from time to time when you are configuring large systems This is not necessary to do on smaller networks If you are done configuring A3 then you should always save the configuration as well To save the configuration select File Save Config and the file will be saved The file can also be saved for back up purposes by selecting File Save Config as and choosing a location Opening a previously saved configuration file The system can be quickly configured by opening a previously saved configuration This can be done by selec
68. of this connection Other Places G Control Panel My Network Places My Documents ig My Computer Details Local Area Connection LAN or High Speed Internet Enabled Intel R PRO 100 VE Step 2 Right click on your Local Area Connection and select Properties Local Area Connection Properties General Authentication Advanced Connect using Eg Intel A PAOSTO0 VE Network Connection 2 This connection uses the following items el Chent for Microsoft Networks ja File and Printer Sharing for Microsoft Networks ml as Packet Scheduler Internet Protocol TCP IP g Install Uninstall Description Transmission Control Protocol lnternet Protocol The default Wide area network protocol that provides communication across diverse interconnected networks C Show icon in notification area when connected Step 3 Double Click on Internet Protocol TCP IP Page 30 A3 System Management Software Internet Protocol TCP IP Properties General ou can get IF settings assigned automatically if your network supports this capability therwise you need to ask your network administrator for the appropriate IP settings Obtain an IP address automatically Use the following IP address IF address 192 168 O 1 Subnet mask ona ee oil Use the following DNS server addresses Preferred ONS server Alternate DNS server ee Step 4 Set y
69. ogrammed with the IP Address You will need to have the module wired to 24VDC and plugged into your Ethernet network If you have a separate 24VDC power supply you can program these modules without installing them into the blender and they will retain the programmed address Locate your A3 CD and run Setup exe that is found under the Digi Software folder this can be found by double clicking on my computer then the icon for the CD then the Digi Software folder and finally the Setup exe icon After setup starts you will see the following screen gt Digi Device Setup Wizard Welcome to the Digi Device Setup Wizard This wizard will quide you ifs ugh ie initial device installation He wizard will dis scover your r device on the network hel ED set it up for your ication scenario and save the configuration to the devi Ele in Battlefield 1942 The R Before you continue make sur The device is connected ana poneredu een BODEN SELBER If you have a wireless dev recommended to connect it to tl two using the Ethemet port for ini rial de levice configuration You have the MAC address of the device available Tre MAC address is located on the white label on the bottom or back of the devic ersion 1 2 20 0 ba Digi One IA Digi One untitled Paint Oe Digi Device Setup Wiz k JA 10 43 AM Click Next Page 33 Page 34 g Internet Shortcut to Explorer mohradiant PI did My Co
70. ollowing Up to 99 999 999 Lbs or Kgs of total inventory for each device Up to 1000 alarms per device Up to 1000 stored recipe changes per device Up to 5000 batches of actual weight data per device These limitations are limitations to each report If these logs are set to Auto Clear after each report doesnt effect the generated report then these limits should never be reached Page 89 A3 System Management Software Saving the reports The user can specify the location where all reports will be saved using the following Report Manager a gm Report Options W Automatically Print Repot i Enable Reports l Clear all Logs and Save Report to the following Inventories Select a director by clicking select directo go to the directory then click save Z termp y To select the lacation click Select Directory go to the desired directory and then click Save The path will automatically be calculated for you Page 90 A3 System Management Software Using Manually generated Reports Job Report Manager To access double click on the icon of the device from the main page then click on Job Report Manager Blender 1 PLC Version 3 1 EY Moge Recipe Recipe Book Change Recipe Batch Size 3 HOPPER 1 HERE HOPPER 2 20 00 HOPPER 3 30 00 HOPPER 4 40 00 HOPPER 5 50 00 HOPPER 6 60 00 HOPPER 7 0 00 Inventory HOPPER 1 0 000 HOPPER 2 0 000 HOPPER 3 0 000 HOPPER 4 0
71. on 1 800 229 2919 North America emergencies after 50m CST 847 439 5855 North America email acsuscanadacustserv corpemail com e Mexico Central amp South America Email acslatinamericacustserv corpemail com e Europe Middle East amp Africa 48 22 390 9720 Email acseuropecustserv corpemail com e India 91 21 35329112 Email acsindiacustserv corpemail com e Asia Australia 86 512 8717 1919 Email acsasiacustserv corpemail com Sales and Contracting Department 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 Let us install your system The Contract Department offers any or all of these services project planning system packages including drawings equipment labor and construction materials and union or non union installations For assistance with your sales or system contracting needs please Call North Central and South America 1 262 641 8600 or 1 847 273 7700 Monday Friday 8am 5pm CST Europe Middle East Africa 48 22 390 9720 India 91 21 35329112 Asia Australia 86 512 8717 1919 Facilities ACS offers facilities around the world to service you no matter where you are located For more information please visit us at www acscorporate com United States Asia Australia India ACS India ACS Schaumburg Corporate Offices ACS Suzhou Gat No 191 1 Sandbhor Complex 1100 E Woodfield Road 109 X
72. ortcut to A3 exe amp My Network Places Open Expl xplore B Control Panel Search for Computers m Map Network Drive 1 Microsoft Word Help and Support Disconnect Network Drive pP Search Show on Desktop PhotoStudio 2000 5E R 777 Run Release Notes All Programs gt Keep in touch with HP A Log Off Turn Off Computer Microsol ft Word A3 P read me txt Notepad P 33_system_log txt A A3 System Managem fm 2 PUBLIC Projects V untitled Paint amp 12 23 PM Step 1 Click Start then right click on My Network Places and click on Properties Page 22 s Network Connections mS ar File Edit View Favorites Tools Advanced Help Q Bact gt wi P Search Er Folders fsi LAN or High Speed Internet Network Tasks E creat S 1394 Connection J Disable reate a new Enabled z connection A status 394 Net Adapter Onn La 1394 Net Adapter uit ntel R PRO 100 VE Net nec Set up a home or small office network Disable this network device Create Shortcut xX Repair this connection Delete Bridge Connections mij Rename this connection Rename view status of this nein Properties Change settings of this connection Other Places G Control Panel a My Network Places E My Documents ig My Computer Details Local Area Connection LAN or High Speed Internet Enabled Intel R PRO 100 VE Step 2 Right click on your Loc
73. ou ve configured more than one Ethernet device and some are communicating but others aren t Solution It is easy to trouble shoot when you have some devices communicating at least one The quickest way to resolve the problem is to first examine the lights on the PLC and Ethernet module for a device that is working Compare this with one that isn t working and then read the section on the prior page You can also simply swap cables and modules until you figure out what is causing the problem and then focus on the problem Page 108 A3 System Management Software Trouble shooting network problems with older HydReclaim units Problem You ve configured more serial devices and are having problems establishing communications Solution Step 1 Disconnect the cable from all of the blenders except for the first one Check communications Be sure to read Chapter 4 before continuing Step 2 If you still don t have communications then ring out the cables PIN 9 on the PC should go to PIN 4 on the first blender PIN 1 on the PC should go to PIN 5 on the first blender PIN 2 on the PC should go to PIN 8 on the first blender and PIN 3 on the PC should go to PIN 9 on the first blender From there PIN 4 on blender 1 goes to PIN 4 on all of the other blenders PIN 5 on blender 1 goes to PIN 5 on all other blenders PIN8 on blender 1 goes to PIN 8 on all other blenders and PIN 9 on blender 1 goes to PIN 9 on all other blenders Also check that these
74. our screen to look like this then click OK and OK again Remember that you need to have a unique IP for all of your blenders and for the PC For example you could use the following scheme PC IP gt 192 168 0 1 Blender 1 IP gt 192 168 0 10 Blender 2 IP gt 192 168 0 11 Blender 3 IP gt 192 168 0 12 Page 31 A3 System Management Software Running the Cables and Hardware to interconnect the system Depending on your expertise and preference you can either purchase CAT5 cables to length with the connectors already attached to both ends This makes it somewhat difficult to get the connector into the blender panel because of the head on the cable but not impossible Either way you will need to have some sort of Hub Switch or Router to interconnect all of the blenders with the PC If you already have a plant LAN then you should just run drops to each blender and one to the PC from your main network If this will be a stand alone system then you can purchase a hub or switch to accomplish the same thing A 5 port hub cost around 40 and is shown below Uplink Port to Existig LAN optional 192 168 0 1 192 169 0 10 192 169 0 12 192 168 0 11 Sample network Be sure not to connect the blenders or PC to the uplink port on the hub or switch and to also use straight through cables Page 32 A3 System Management Software Configuring the Digi One IA Ethernet modules Before the modules can be used they each need to be pr
75. oyment Wizard IH Autocan R14 di 4 Microsoft Money 2002 All Programs gt 7 start Yy CJ My Documents 2 My Pictures pe Wr ty C B Contr wy Help po Searc a roperties 777 Run Keep in touch with HP g 2 My Music Open Explore Search Manage Map Network Drive Disconnect Network Drive Show on Desktop Rename na spate Ja Step 1 click start right click on My Computer then click Properties Page 73 A3 System Management Software System Properties System Restore Automatic Updates Remote General Computer Name Hardware Advanced Add Hardware Wizard The Add Hardware Wizard helps you install hardware Add Hardware Wizard Device Manager The Device Manager lists all the hardware devices installed on your computer Use the Device Manager to change the properties of any device Driver Signing Hardware Profiles 2 Hardware profiles provide a way for you to set up and store zy different hardware configurations Hardware Profiles Step 2 Click the Hardware tab and then click Device Manager Device Manager File Action View Help STATION F 9 Computer See Disk drives a Display adapters HA DVD CD ROM drives E l Floppy disk controllers Floppy disk drives Ba Human Interface Devices H IDE ATAJATAPI controllers IEEE 1394 Bus host controllers e Keyboards
76. p 6 If you have LINK lights on all units including the PC and no fault link lights on the PLCs but you still cannot establish communications then we need to check the PC s network properties If this computer resides on your plant network and was set up by your IT department then you will need to involve them for further assistance with your problem Instruct your IT department that the blenders must have a fixed IP but the PC can have a dynamic IP All subnet masks for the PC and the blenders need to be 255 255 255 0 They might not have the startup script correct for your PC If the blenders and PC all reside on a separate network that has nothing to do with your plants LAN then we need to check the PC s network properties see Chapter1 Networking instructions for the Sterling SGB Blender for step by step Page 112 A3 System Management Software Problem You ve configured more than one Ethernet device and some are communicating but others aren t Solution It is easy to trouble shoot when you have some devices communicating at least one The quickest way to resolve the problem is first examine the lights on the PLC and Ethernet module for a device that is working Compare this with one that isn t working and then read the section on the prior page You can also simply swap cables and modules until you figure out what is causing the problem and then focus on the problem Where to go for further help Contact ACS service a
77. represent how long it takes for each device to poll all of the configured parameters This time can be dramatically increased or decreased by enabling or disabling features for each device see Working with A3 Device Objects for more details Page 63 A3 System Management Software A Memory Status Percent of Menor Used 44 amp used Physical Memor Used 523 808 Kbyte Free Memon 293 328 Kbyte Paging File Size 1 279 300 Kbyte Free Paging Size 1 122 204 Kbyte User Address Space Size 2 097 024 Kbyte Free User Space 2 035 268 Kbyte Memory Status Page The Memory Status Page is accessed by selecting View Memory Status from the dropdown menu This page is useful in determining the amount of memory you have consumed with the current configuration and is also useful when configuring systems with up to 1000 devices The most important item to look at is the first one Percent of Memory Used This should be under 60 for Windows to remain stable Page 64 A3 System Management Software 052001 AB DATA ITEMS Blender 1 AVAILABLE DATA ITEMS STATUS status status 1 enabled blender started 6 5 0 0 enabled gt alarm_number n11 74 enabled 4 plc_version na 0 4 enabled B blender stark request b3 0 11 enabled b abort_batch_reguest ba 078 b enabled number_of_hoppers n9 3 enabled Shop inventor 30 0 S enabled 9 hope inventory 30 1 4 enabled 10 hops inventor 30 2 10 enabled 11 hopd_inwentor
78. s TCP Server Serial Settings Baud Rate 19200 To save the configuration report to disk for future reference click here To save these settings to the device click Next Cese Lena I er sie cava Page 37 Internet Shortcut to Explorer mohradiant fy Flight WinMX Simulator 2002 Fam Ee My Software temp Programs 7 rs SideWinder DIGI SP COM4 Game Voice test ht z ERMEFIELD she Recycle Bin Battlefield 1942 The R Financial da AutoCAD R14 afl Micro Cap Evaluation 7 0 Medal of Honor Alli FIN oS H N Medal of Honor Alli Shortcut to Projecti exe COM 1 Test ht ag Start The configuration will begin to be saved and then the system will reboot the Ethernet Module This takes about a minute e Internet Shortcut to Explorer mohradiant My Computer Mi Visual Ba w Flight WinMx Simulator 2002 Sidewinder DIGI SP COM4 Game Voice test ht ERTMEFIELD 1982 Recycle Bin Battlefield 1942 TheR Financial as AutoCAD R14 7 Micro Cap Evaluation 7 0 Medal of Honor Alli Medal of Honor Alli p Shortcut to Project1 exe Page 38 De Digi Device Setup Wizard Save Settings The configuration is being saved to your Digi One SP Dig Saving the configuration may take a while During this time your Digi One SP will be rebooted to apply the new settings Do not cancel this operation Welcome Discover Dev
79. stem Management Software Setup 43 System Management Software Setup was completed successfully Step 4 Success Click OK to complete Page 18 A3 System Management Software Starting and exiting A3 To start A3 1 From the Start menu click Programs 2 Select ACS Software and click A3 System Management Software 7 A Internet Explorer x Cr 7 2 My Computer Owner jes Command Promp Calculator ee Release Notes Microsoft Visual Basic SSSSSGSGSGSGGSGRR8 0008 UL 080689 fae Shortcut to A3 exe Package amp Deployme Wizard 4 AutoCAD R14 B D amp All Programs E MI Paint To exit A3 WeatherBug Windows Catalog Windows Update Set Program Access and Defaults WinZip New Office Document Open Office Document Accessories ATI Hydravision ATI Multimedia Center Detto IntelllMover hp center HP RecordNow hp tools Intervideo WinDYD Microsoft Works My Movies My Photo Center Quicken Financial Center Real Startup Studio Version 7 WeatherBug WordPerfect Office 2002 Acrobat Reader 5 0 EMusic Encarta Online Deluxe Internet Explorer MarketBrowser Microsoft Money 2002 Microsoft Works Move Your Stuff wg MSN Explorer A Outlook Express Microsoft Access Microsoft Binder BE Microsoft Excel B Microsoft Outlook amp Microsoft Photo Editor Microsoft PowerPoint s Remote Assistance windows Media Pl
80. t 800 229 2919 Page 113 A3 System Management Software Notes Page 114 A3 System Management Software Notes Page 115 A3 System Management Software Other service problems or questions can be answered by contacting the ACS Service Department Service Notes Page 116 A3 System Management Software Service Notes Page 117 A3 System Management Software Parts Department Call 630 595 1060 Parts shipped from the Wood Dale IL facility available for Next Day Air shipment only up to 3 pm CST The ACS Parts Department at ACS Inc is ready to provide the parts to keep your systems up and running Application Engineering replacement parts ensure operation at design specifications Please have the model and serial number of your equipment when you call Consult the Customer Parts List included in your information packet for replacement part numbers Service Department Call 8am 5pm CST 630 595 1060 Emergencies after 50m CST call 847 439 5655 ACS has a qualified service department ready to help Service contracts are available for most ACS products Sales Department Call 630 595 1060 Monday Friday 8am 5pm CST ACS products are sold by a world wide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Contract Department Call 630 350 7468 Monday Friday 8am 5pm CST Let ACS install your system The Contract Depar
81. test purchase a standard CAT5 cable that already has the ends connected and a standard hub or switch this can be purchased from Best Buy Circuit City CompUSA or Radio Shack When powering the blender up connect the hub and the blender using the new cable to one of the middle ports on the hub say port 3 on a 4 port hub Examine the LINK light and if it is on now then the problem is definitely in your original cabling This same test can be performed on the PC and PC cable All PC Ethernet cards have a LINK light as well Establish the LINK light on all devices before proceeding Step 6 If you have LINK lights on all units including the PC and no fault lights but you still cannot establish communications then we need to check the PC s network properties If this computer resides on your plant network and was set up by your IT department then you will need to involve them for further assistance with your problem Instruct your IT department that the blenders must have a fixed IP but the PC can have a dynamic IP All subnet masks for the PC and the blenders need to be 255 255 255 0 They might not have the startup script correct for your PC If the blenders and PC all reside on a separate network that has nothing to do with your plants LAN then we need to check the PC s network properties see Chapter 1 Networking instructions for the newer AB OS OA Blender for step by step Page 107 A3 System Management Software Problem Y
82. the Job Report Manager by double clicking on the icon of the device from the main page and then clicking Job Report Manager From here they can start or stop the job and enter in the following data that is not available when using automatically generated reports e Job Number e Material Reference Number Lot number and Silo Number Page 88 A3 System Management Software Configuring what is included in the Reports The user can select what information will be included in each report by enabling or disabling the following check boxes also what is cleared Report Manager eo Man Report Options i Automatically Print Report W Disable all manual log and inventor clearing on all pages other than this when using reports l i l Clear all Logs and Select what data to include in the report Automatic Report Features Inventories v Total Inventory Information W Automatically Clear the Inventory after Report W Hopper Inventory Information W Include Uptime Percentage info W Restart Uptime Downime after Report Ww Include Alarm Log in Report W Automatically Clear the Alarm Log after Report Ders v All Recipe Information i Automatically Clear the Recipe Info after Report M Include Actual Batch info i Automatically Clear the batch data after Report Report Options You should select to have all reports automatically clear and restart so that the system does not exceed the limitations of each report size The system can accumulate the f
83. thernet Module The first thing to complete is configuring the PC for Ethernet Configuring the PC If your PC is part of your plant s LAN then you will need to have your system administrator configure the IP settings for the PC If the PC is a stand alone system then you will need to configure the network properties 10 My Documen ts My Pictures ey My Music ei g My Computer y My Network Places Open Explore B Control Panel Search for Computers Map Network Drive Help and Support Disconnect Network Drive pP Search Show on Desktop R 77 Run Keep in touch with HP A Log Off Turn Off Computer Microsol ft Word AS P read me txt Notepad OE e A A3 System Managem Z PUBLIC Projects W untitled Paint amp J 12 23 PM Step 1 Click Start then right click on My Network Places and click on Properties Page 29 s Network Connections File Edit View Favorites Tools Advanced Help Q Bact gt wi P Search Er Folders AR LAN or High Speed Internet Network Tasks 1394 Connection ocal Area Connection Disable E Create a new Enabled nabled che connection 1394 Net Adapter Intel R PRO 100 VE Net Set up a home or small al i aia o Repair office network Disable this network R device Create Shortcut x Repair this connection en Bridge Connections mi Rename this connection Rename View status of this een a Change settings
84. ting File Open and Load Config File from the dropdown menu and then selecting a file to open The location of the configuration file The A3 configuration file is always named a3_system_config cfg and is located in the installation path By default the file will be found in c program files a3 system management software a3_system_config cfg and is approximately 256 kb in size depending on your configuration but can be much larger Page 98 A3 System Management Software Chapter 8 Working with the A3 System Log file This chapter explains e What is the A3 System Log file e What is logged in the file e The location of the file Overview This chapter will help you understand how to use the A3 System Log What is the A3 System Log file The A3 System Log File is a history log of system level alarms and operations performed by the user It is not necessary to view this log except when trouble shooting the A3 system Page 99 A3 System Management Software What is logged in the file Any communications error time of alarm and time cleared Time the program was started Time the program was stopped Printer error messages Setup operations performed by the user Time of automatic and manually generated reports E a3_system_log txt Notepad File Edit 4 782003 4 28 2003 4 28 2003 4 282003 4 28 2003 4 28 2003 4 28 2003 Format View Help Operator has chosen to edit Blender 1
85. tment offers any or all of these services project planning system packages including as built drawings equipment labor and construction materials union or non union installations and field supervision ACS Inc 800 Wood Dale Rd G rou p Wood Dale IL 60191 1198 USA PROCESSING 1630 595 1060 SOLUTIONS Hours 8 00 am to 5 00 pm CST WORLDWIDE Page 118
86. to print the reports What kind of cable do need to purchase for connecting all of my machinery together For AEC AB OS OA and Sterling SGB equipment you will need CATS cable and if you don t already have a LAN in your facility you will need to add one by purchasing an Ethernet Hub or Switch from any store that sells Ethernet equipment For older HydReclaim OS OA OL OFC equipment you will need a 2 twisted pair Shielded cable such as Belden 8103 or similar You will also need a DB9Male solder type for each device and a DB9 Female solder type for the PC as well as hoods for each connection Page 7 A3 System Management Software e What should do if during installation that the software keeps telling me that some of the files on my PC need to be updated and asks me to reboot but when run the software after the reboot get the same message Make sure that your computer meets the minimum requirements This problem is being caused because your operating system on the PC that you have purchased is not up to date This is common even on brand new PCs See the instructions in this manual for installing the software and install Win XP Service Pack 1 before proceeding If you still are having problems after upgrading to service pack 7 consult your IT department this is a problem with the PC you ve purchased and not the A3 software Software and Firmware Upgrades A3 software can be upgraded by contacting your local ACS sales office Up
87. twork Places Details 2 items selected Total File Size 1 14 KB Manually generated reports in blue The date time and job number stamp is as follows and cannot be changed Year_month_day_hourfin military time minutes seconds JOB_job This is followed by the name of the device and the name of the log Page 93 A3 System Management Software Sample Reports Here are some sample reports All number are only shown as an example P 2003_04_28_13_00_00 Blender 1_inventory_and_uptime_log log Notepad E BX File Edit Format View Help TOTAL INVENTORY 3996 036 Hopl 111 001 Hope 7 222 002 Hops 333 003 Hopd 7 444 004 Hops 7 555 005 Hope 666 006 HOOF 27 007 Hops 7 888 008 Uptime Percentage 7 0 Automatically Generated Inventory and Uptime report M 2003 04 28 16 19 34 JOB 14717723 Blender 1_inventory_and_uptime_log log Notepad Sle File Edit Format View Help TOTAL INVENTORY 7 0 JOB STARTED 2003 04 28 16 18 03 JOB FINISHED 2003 04 28 16 19 34 Hopl 07730 Hopl Material Reference PET Lot number 1044 SILO Number 9 Hope Hope Material Reference Titanium Dioxide Lot Number 332a SILO Number 4 Hess d Hops Material Reference PER Regrind Lot Number 205 SILO Number n a Hop 0 Hop4 Material Reference Uw stabilizer Lot Number
88. used to store recipes for later recall by an operator e Batch Data Page for each unit This is used to view the actual weight of each batch using a visual graph e Uptime Data Page This shows the percentage of time each device has been in the Run mode e SCADA Scan Times Page This page is used to determine the refresh rate of each device e Memory Status Page This page shows the amount of memory that the program is consuming as well as the amount of free memory left on the PC e Data Parameters Page This page show the current enabled data parameters for each device and is useful for customers wishing to develop their own SCADA front end to the blenders Overview This chapter will provide you with information on screen access and details Page 52 A3 System Management Software Virtual Control Panel The virtual control panel is accessed by double clicking on the icon of the blender from the main page Eje X A A3 System Management Software Plant View File Edit view Tools Help iz T TIME 4 28 2003 10 25 46 AM T start g new_sheet_added b As 43 System Managem Sy 10 25 AM Page 53 A3 System Management Software Blender Name and Blender 1 PLC Version 3 1 Ex Mode Recipe Mode En za HOPPER 1 111 001 k es 1 HOPPER 2 222 002 HOPPER 2 20 00 HOPPER 3 333 003 HOPPER 3 30 00 HOPPER 4 444 004 HOPPER amp 555 005 HOPPER amp 666 006 HOPPER 7 777 007 HOPPER
89. vices when you call Page 6 A3 System Management Software Frequently Asked Questions How many units can A3 integrate 1000 units of which 255 can be the older proprietary units What minimum software version do need to have on blenders and weigh hoppers in order to communicate with A3 AEC AB OS OA software gt 3 2 Sterling SGB OS OA software gt 1 2 Older Proprietary HydReclaim OS OA software gt 700A Older Proprietary HydReclaim OFC software gt 5 5A Older Proprietary HydReclaim OL software gt 10 5A NOTE if being used with newer AB OS OA equipment you need to purchase the Ethernet option for each blender if it wasn t purchased when you bought the blender Ethernet Module gt A0563939 1761 NET ENI Ethernet Module Cable gt A0565898 1761 CBL AMOO NOTE if being used with older proprietary equipment you need to purchase the USB RS422 485 Legacy Module for the PC which will allow you to communicate only one module required for entire system What are the system requirements for the PC PII 750MHZ minimum processor speed P4 recommended Windows XP operating system service pack 1 installed Internet Explorer 6 0 30GB minimum hard drive space 60GB recommended 128MB minimum RAM 512 MB DDR Ram recommended CDROM drive CD RW recommended Video card capable of 1024x768x16bit color 32bit color recommended 10Mbps Ethernet 100Mbps recommended 1 USB slot Standard Ink Jet Printer if you are going

Sterling 882.00278.00 Marine Sanitation System User Manual

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