Sterlingメーカー882.00722.00の使用説明書/サービス説明書
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GH-M Rate Monitor Allen-Bradley Controller Part Number: 882.00722.0 0 Bulletin Number: BF2-610 Effective: 2/08/2007.
ii Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing program of product improvem ent.
iii Shipping Info Unpacking and Inspection You should inspect your equipm ent for possible shipping damage. Thoroughly check the equipment for any dam age th at might have occurred in transit, such as broken or loose wiring and components, l oose hardware and mounting screws, etc.
iv Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping departme nt. Credit Returns Prior to the return of any material, the manufacturer must give authorization. A RMA number will be assigned for the equipment to be returned.
v Table of Contents CHAPTER 1: SAFETY ................................................................ 7 1-1 How to Use This Manual ............................................................................................. 7 Safety Symbols Used in this Manual .
vi GH Calibration ..................................................................................................... 31 WTP/RPM Calibration Page ...
Chapter 1: Safety 7 of 60 Chapter 1: Safety 1-1 How to Use This Manual Use this manual as a guide and reference for in stalling, operating, and maintaining your rate monitor. The purpose is to assist you in appl ying efficient, proven techniques that enhance equipment productivity.
Chapter 1: Safety 8 of 60 Figure 1: Safety Tags and Warning Labels Tag Description Tag Description Pinch Point Slide Gate Read Operation & Installation Manual Shear Point Rotating Mixer Earth Grou.
Chapter 1: Safety 9 of 60 1-2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national a nd local safety codes. This may include, but is not limited to OSHA, NEC, CSA, SPI, and any other local, national and international regulations.
Chapter 1: Safety 10 of 60 1-3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended inst ructions are followed in the maintenance and operation of the machine.
Chapter 1: Safety 11 of 60 Learn and always use safe operation. Cooperate with co-workers to promote safe practices. Immediately report any potentially dangerous s ituation to your supervisor or app ropriate person. REMEMBER: • NEVER place your hands or any part of your body in any dangerous location.
Chapter 1: Safety 12 of 60 Maintenance Responsibility Proper maintenance is essential to safety. If you are a maintenance worker, you must make safety a priority to effectively repair and maintain equipment.
Chapter 2: Functional Description 13 of 60 Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, and m aintenance instructions for rate monitors of various extrusion rates and specifications .
Chapter 2: Functional Description 14 of 60 Customer Service The intent of this manual is to familiarize the operator and maintenance personnel with these rate monitors and help your or ganization get the maximum service from your equipment.
Chapter 2: Functional Description 15 of 60 Figure 2: Equipment Specifications 10 20 40 600 (272) 1200 ( 680) 2500 (1134) 0.35 (10) 0.7 (20) 1.41 (40) 10 20 40 1 @ 10 kg 1 @ 20 kg 1 @ 30 kg Height (5) 34.5 (875) 51.5 (1308) 56.5 ( 1435) W idth (5) 26.0 (650) 37.
Chapter 2: Functional Description 16 of 60 • Optional Ethernet communications System Component Description This section describes the various components of the rate monitor system. Extruder Inductive Proximity Switch The extruders RPM must be reported to all GH, GH-M, and GH-F Systems for them to function.
Chapter 2: Functional Description 17 of 60 OPEN Dump cone gate open all the time CLOSE Dump cone closed all the time Each surge hopper is supplied with a lid. Standa rd lids contain a cutout to accept a vacuum receiver. A blank lid may also be provided if specified.
Chapter 2: Functional Description 18 of 60 After installation and setup, the GH-M will begin monitoring the system process once the rate monitor detects an extruder speed.
Chapter 2: Functional Description 19 of 60 Figure 10a: Typical GH-M Operator Screen Figure 10b: Typical GH Full Control Operator Screen Figure 10c: Typical GH-F Gravimetric Feeder Op erator Screen.
Chapter 2: Functional Description 20 of 60 Figure 10d: Operator Screens Common to all GH Systems.
Chapter 2: Functional Description 21 of 60 Figure 11: Typical Setup Screens.
Chapter 2: Functional Description 22 of 60 2-4 Optional Components The following is a list of options, which your rate monitor may have been equipped with: Ethernet Module In lieu of an inductive proximity switch, the extruder’s RPM may be written through communications.
Chapter 2: Functional Description 23 of 60 Pneumatic Slide Gate below surge hopper The surge hopper can be equipped with a pneumatic slide gate in lieu of the air cylinder and urethane dump cone. The knife ga te is opened and closed by the PLC. A 24 VDC solenoid is used to open and close the knife gate.
Chapter 3: Installation 24 of 60 Chapter 3: Inst allation 3-1 Uncrating the Equipment Rate monitors are shipped mounted on a skid, encl osed in a plastic wrapper, and contained in a crate. 1. Remove crate from around the rate monitor. 2. Secure strap of proper lifting capacity.
Chapter 3: Installation 25 of 60 Machine Mount The GH Hopper must be machine mounted. There are a few items to review before placement and mounting of the rate monitor s ystem begins. First, verify the machine flange dimens ions match the cast spool-mounting flange.
Chapter 3: Installation 26 of 60 supply wiring to the control panel. Care must be taken to ensure that the suppl y wiring does not interfere with the low voltage DC wiring. The GH is supplied with a plug that functions as the disconnect device. The mating receptacle must be installed no higher than 5’ feet (1.
Chapter 3: Installation 27 of 60 3-5 Initial Set-up This section will discuss the mechanical setup and control system setup of the rate monitor system. After reading this section, you should be familiar with the mechanical setup and the electronic control setup of the rate monitor.
Chapter 3: Installation 28 of 60 If an Ethernet module was purchased with the sy stem, the proper setting has to be changed to measure the extruder’s RPM with communications. For details on changing the settings for measuring the extruder’s RPM, please refer to the Addendum 7-4.
Chapter 3: Installation 29 of 60 Controller Set-up This section describes the proper setup of the GH system control parameters. These parameters are operator changeable; however, these items should only require setup during the initial installation. Only authorized personne l should change them .
Chapter 3: Installation 30 of 60 “Invento ry” page ¾ Clear Invent ory ¾ Manual Control ¾ “Next” returns to “ R ecip e” page “Manual Control” Page ¾ Reload ON/OFF ¾ Return to the .
Chapter 3: Installation 31 of 60 GH Calibration The load cell on a GH Hopper is FACTORY CALIBRATED. Since the load cell can be subject to shock loading during shipping , moving, etc., we recommend that they be recalibrated. The heart of the rate monitor system is the load cell and the supplied calibration weight.
Chapter 3: Installation 32 of 60 Figure 15: Display Calibration Menu Screen 3. Once in “Scale Calibration”, enter in the scale calibration weight value stamped on the side of the weight. 4. The controller will prompt you to em pty the weigh hopper and press “OK”.
Chapter 3: Installation 33 of 60 5. Add the calibration weight to the weigh hopper and write down the value displayed in “weight”, as in step 4. 6. Subtract the values recorded in step 4 from st ep 5. This is the measured weight. If the measured weight is within a 0.
Chapter 3: Installation 34 of 60 Extruder Setup Use this page to setup the Maximum Extrude r RPM. This is critical for GH Monitor units and GHF feeder units.
Chapter 3: Installation 35 of 60 Alarm Setup This screen allows the operator to configure the alarm settings for the rate monitor. To configure the alarms do the following: 6. Enter the Setup Menu. 7. Once in the Setup menu, press “Alarm Setup.” This will take you to the “Alarm Setup” screen.
Chapter 3: Installation 36 of 60 Setting Date and Time The Set Date & Time feature is located in the “Panel View Config” menu of the Setup Screen. This feature allows the operator to set the rate monitor’s internal time clock and date. The clock data must be entered in the traditi onal Hours, Minutes, and seconds.
Chapter 4: Operation 37 of 60 Chapter 4: Operation 4-1 GH-M Operation Procedures The system will begin monitoring the process ra te once an RPM reading from the Extruder is detected. Again, this RPM must be communi cated to the PLC through t he supplied inductive proximity switch, or through the optiona l Ethe rnet module.
Chapter 4: Operation 38 of 60 4-2 GH Full Control Operation Procedures The system will begin monitoring the process rate once the GH System is placed into “RPM Mode” and a target RPM is entered into the c ontroller. If started in “RPM Mode” then the GH should automatically load the hopper when necessary.
Chapter 4: Operation 39 of 60 is that the extruder speed will be slowly adjusted as the output of the extruder drops over time due to the screen pack becoming clogged. NOTE: The GH System can be started using your older speed pots by first placing the system into “Monitor Mode”.
Chapter 4: Operation 40 of 60 4-4 Common Screens Figure 34: Typical Manual Control Operator Screen While the rate monitor system is in operation, there are a couple of displays available to the operator. These displays are selected simply by pressing the “NEXT” key when the unit is running.
Chapter 4: Operation 41 of 60 Alarm Flags An alarm message will be shown if any alar m condition occurs. A message will pop up on the screen until the alarm condition is resolved.
Chapter 5: Maintenance 42 of 60 Chapter 5: Maintenance 5-1 Preventative Maintenance Schedule The mechanical design of the GH Hopper is ve ry simple and very little maintenance is required. The only moving parts are the me tering gates, weigh hopper dum p valve, and mixer agitator.
Chapter 5: Maintenance 43 of 60 5-2 Preventative Maintenance Our GH Hoppers need periodic maintenance to provide long dependable service. Check these elements regularly: • Check functionality of safety circuit daily. • Maintain proper air pressure and drain water from trap assembly on regulator – as required.
Chapter 5: Maintenance 44 of 60 Input Signals to Programmable Controller The rate monitor system has two main input signals that it uses from the extrusion process: the weigh hopper load cell, and the extruder speed reference. This, of course, does not include the operator touch-screen input.
Chapter 6: Troubleshooting 45 of 60 Chapter 6: T roubleshooting 6-1 Introduction The utmost in safety precautions should be observed at all times when working on or around the machine and the electrical components.
Chapter 6: Troubleshooting 46 of 60 Problem Corrective action PLC Module Loaded Normal after a software upgrade. Follow on-screen instructions. Weigh hopper occasionally overfills.
Chapter 7: Appendix 47 of 60 Chapter 7: Appendix 7-1 Warranty and Spare Parts Unless otherwise specified, this produc t includes a Standard ONE YEAR PARTS WARRANTY.
Chapter 7: Appendix 48 of 60 Customer Responsibilities Any sales, use, or other tax incident to the replacement of parts under this warranty is the responsibility of the purchaser. Annex B Information The following design information is provided for your reference: 1.
Chapter 7: Appendix 49 of 60 Figure 57: Typical Surge Hopper Assembly Parts List # DESCRIPTION 010 020 040 Lid (Smaller vacuum receiv ers) 08223-1 872.
Chapter 7: Appendix 50 of 60 7-2 Addendum (Service Supervisor Information) Caution! After all selections are made: Keep p ressing the “Done” key until the unit returns to the Recipe menu.
Chapter 7: Appendix 51 of 60 Enter the long password “3145348” and press “Enter”. The factory setup section displays the “Engineering Only” screen. The screen similar to that shown below should be displayed and use the keystrokes described herein to change or toggle the parameters.
Chapter 7: Appendix 52 of 60 Extruder Pulse Count Method This method updates the weight every “Number of Pulses for Calculation” detected by the extruder proximity switch. This is not the most automated method of the 3 choices, but has it’s advantages.
Chapter 7: Appendix 53 of 60 recommended) and it will not cause any error in the displayed measurement. Another more common procedure would be if an operator in termittently adds a processing agent to the extruder by dumping it directly into the weigh hopper.
Chapter 7: Appendix 54 of 60 Figure 72: Typical Analog Options Analog options screen This screen is not used with the GH-M Rate Monitor. Adjust appropriately for GH Full Control units and GH-F units. Figure 73: Typical Diagnostics Screen Diagnostics Screen Use this screen for trouble shooting and making tunin g adjustments.
Chapter 7: Appendix 55 of 60 Customer Setup Menu Password Protection The Setup screen allows you to change the default User Password that the GH Hopper uses to lock out certain screens. The password by default is “5413”. To change the password, follow the steps listed below: 1.
Chapter 7: Appendix 56 of 60 7-3 Allen-Bradley Communications Manual The AB rate monitor uses a Micrologix 1500 LRP processor that communicates with the outside world using DF1 protocol with Ethernet hardware. Its Ethernet speed is 10/100 Mbits/second.
Chapter 7: Appendix 57 of 60 6. extruder_no_rpm_detected_alarm,b28:0/ 5 7. extruder_no_flow_detected_alarm,b28: 0/6 8. hauloff_drive_failure_alarm,b28:0/7 9. loadcell_over_max_alarm,b28:0/8 10. reload_too_long_alarm ,b28:0/9 11. gravimetrics_%_too_low_alarm,b28:0/10 12.
Chapter 7: Appendix 58 of 60 INVENTORY INFO 1. clear_inventory,b3:0/3 (toggle this to clear all invent ory, you must also reset this bit after completion) 2. hopper_inventory,f25:0 3. hauloff_accumalated_length,f31:4 EXTRUDER SETPOINT INFO 1. entered_extruder_rpm_target,f13: 12 (write desired rpm here) 2.
Chapter 7: Appendix 59 of 60 WRITING SETPOINTS EXPLANATION Extruder RPM set points, recipe set points, and haul-off set points can be wrote to while the u nit is in stop mode. After engaging either RPM mode or Weight m ode then the appropriate values will be applied.
Chapter 7: Appendix 60 of 60 Technical Assistance Parts Department Call Spare Parts Express toll-free 8am-8pm EST (800) 423-3183 or P hone: (810) 720-7300; Fax: (810) 720-2598. OEM quality replacement and spare parts ensu re operation at design specifications.
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