Page 3 - Confidential Supervisory Manual; Not to be released to floor operators; Table of Contents; Preface Page
Page 2 Confidential Supervisory Manual Not to be released to floor operators Table of Contents Preface Page Hardware Overview .......................................................................................... 4 Hardware Who should use this manual.................................................
Page 5 - Preface; Copyright; Sterling SGB Blenders (Mitsubishi Controls)
Page 4 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 publica...
Page 7 - ACS Technical Support
Page 6 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 in...
Page 8 - Frequently Asked Questions; older proprietary units.
Page 7 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 I need to have on blenders and weigh hoppers in order to communicate with A3? AEC AB OS/OA software-> 3.2 Sterling SGB OS/OA softwar...
Page 9 - Make sure that your computer meets the minimum; Software and Firmware Upgrades
Page 8 • What should I 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 I run the software after the reboot I get the same message? Make sure that your computer meets the minimum requirements. This problem...
Page 10 - What’s new in version 1.1; Job Report Manager; Job Number; New Configuration Options; What’s new in version 2.0; Sterling SGB Communications Driver
Page 9 What’s new in version 1.1 Job Report Manager Now you can generate reports on demand instead of just time. Along with this comes the new feature of Job Management that allows the operator to enter in the following data into the job: • Job Number • Material reference numbers for each hopper • M...
Page 11 - Chapter; Installing A3; Overview
Page 10 Chapter 1 Installing A3 This chapter explains how to install A3 from your CD to your hard drive. • System requirements • Step-by-step installation instructions • Starting and exiting A3 software Overview A3 software installs directly from the CDROM to your hard drive. The CD also contains th...
Page 15 - Installing the Windows XP Service Pack 1:; Checking the Internet Explorer version:
Page 14 Installing the Windows XP Service Pack 1: 1. Insert the A3 CD into the CDROM drive. When the installation automatically starts, cancel the installation. 2. Click Start and Click on “My Computer”. 3. Right Click on the picture of the CDROM and select “Explore” 4. Double Click on “WinXP Servic...
Page 16 - Step 2: Verify that the version is at least 6.0; Installing the Internet Explorer 6.0 Upgrade:
Page 15 Step 2: Verify that the version is at least 6.0 Installing the Internet Explorer 6.0 Upgrade: 1. Insert the A3 CD into the CDROM drive. When the installation automatically starts, cancel the installation. 2. Click Start and Click on “My Computer”. 3. Right Click on the picture of the CDROM a...
Page 22 - Configuring the PLC; Step 1: touch the AEC icon and enter your password; What is an IP address
Page 21 Configuring the PLC You will need to go to Network Setup found under “Setup” on the blender and set the appropriate IP address. The SUBNET mask should be set to “255.255.255.0”. Make sure the Ethernet Configurator is enabled: Step 1: touch the AEC icon and enter your password Step 2: touch “...
Page 23 - Configuring the PC
Page 22 Configuring the PC If your PC is part of your plants LAN then you will need to have your system administrator configure the IP settings for the PC. If the PC is a stand-alone system then you will need to configure the network properties: Step 1: Click Start then right-click on “My Network Pl...
Page 26 - Running the Cables and Hardware to interconnect the system; hub or switch and to also use straight through cables
Page 25 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 h...
Page 27 - Wiring the interconnection cables
Page 26 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 FOR A CD . The installation is very easy. 1. Insert the A3 CD and click “cancel setup” wh...
Page 28 - ALL CABLES MUST BE RUN THROUGH CONDUIT
Page 27 The pin outs for the cables are as follows: PC to 1st BLENDER PIN9 PIN4 PIN1 PIN5 PIN2 PIN8 PIN3 PIN9 BLENDER to BLENDER PIN4 PIN4 PIN5 PIN5 PIN8 PIN8 PIN9 PIN9 It is best to ring out every pin on every connector to ensure that it is wired correctly and that there aren’t any shorts prior to ...
Page 30 - Configuring the Digi One IA Ethernet Module; The first thing to complete is configuring the PC for Ethernet.
Page 29 Configuring the Digi One IA Ethernet 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 t...
Page 34 - Configuring the Digi One IA Ethernet modules
Page 33 Configuring the Digi One IA Ethernet modules Before the modules can be used, they each need to be programmed with the IP Address. You will need to have the module wired to 24VDC and plugged into your Ethernet network. If you have a separate 24VDC power supply you can program these modules wi...
Page 36 - Click Incoming Connections then Next
Page 35 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” before proceeding.) Click Incoming Connections then Next
Page 38 - Configure as shown above then click next
Page 37 Configure as shown above then click next From this screen, click Next to save the configuration to the Ethernet module.
Page 39 - Deselect Register and click Finish to complete.
Page 38 The configuration will begin to be saved and then the system will reboot the Ethernet Module. This takes about a minute. Deselect Register and click Finish to complete.
Page 40 - Using A3
Page 39 Chapter 2 Using A3 A3 software uses menus, windows, status bars, and right click menus as do most Windows applications. This chapter covers: • The application window • Status bar info • Drop down menus • Right-click menus • Tip of the Day • Setting up the A3 options • Customizing A3 Overview...
Page 42 - Drop down menus
Page 41 Drop down menus A3 has many drop down menus that can be selected:
Page 45 - Right click menus; Right-clicking in the blank white area will bring up these.
Page 44 Right click menus A3 also uses right-click menus. These right-click menus are all accessible from the dropdown menus listed above, but right-clicking is sometimes quicker and easier. Right-clicking in the blank white area will bring up these.
Page 48 - The; Customer Name; can be configured by selecting “File/Customer Name”. Once
Page 47 Customizing A3 The A3 layout can be modified by the user. The following are some of the customizable features: • 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.
Page 49 - Sheet Name; can be modified by selecting “File/Edit Sheet Name”. Once
Page 48 • 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).
Page 50 - Adding; multiple sheets; to the system. A3 is capable of having up to 20 different
Page 49 • Adding multiple sheets to the system. A3 is capable of having up to 20 different sheets with up to 50 devices on each sheet. To add a sheet select "File/New Sheet”. To delete a sheet, click on the sheet and then select “File/Delete Sheet”.
Page 53 - Application Screens
Page 52 Chapter 3 Application Screens A3 software has many screens that can be accessed: • Virtual Control Panel for each unit. This is used to start or stop the unit and to monitor the current recipe and inventories. • Alarm Log for each unit. This is used to view the alarm history of each device. ...
Page 55 - The Virtual Control Panel.
Page 54 The Virtual Control Panel. Push to immediately stop blender Push to start or stop blender Indicates running or stopped Push to go to the Batch Log Push to go to the Alarm Log Push to Accept New Recipe Push to go to Recipe Book Push to change recipe Current Recipe Values Recipe Entry Mode Ble...
Page 57 - Entry over 100% error message
Page 56 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: Entry over 100% error message
Page 58 - Total not 100% error message
Page 59 - Recipe Not Totaling 100%
Page 58 The following are error messages given when using the older proprietary blenders: Recipe Not Totaling 100%
Page 60 - Recipe Transferred message
Page 59 The following is the successful message given when using the older proprietary blenders: Recipe Transferred message
Page 61 - size, see “Working with the Recipe Book”)
Page 60 Recipe Book. The recipe book can store an infinite number of recipes (only limited by your hard drive size, see “Working with the Recipe Book”)
Page 63 - Uptime Data Page
Page 62 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 64 - SCADA Scan Times Page
Page 63 SCADA Scan Times Page The SCADA Scan Times Page is accessed by selecting “View/SCADA Scan Times” from the dropdown menu. The display is in seconds and is rounded to the nearest whole second. These numbers represent how long it takes for each device to poll all of the configured parameters. T...
Page 66 - Data Parameters Page
Page 65 Data Parameters Page The Data Parameters Page is accessed by selecting “View/Data Parameters” from the dropdown menu. This page shows all of the available data parameters for each device. The status of each of these items is automatically configured when you enable or disable features for th...
Page 67 - Working with A3 Device Objects; This chapter explains:
Page 66 Chapter 4 Working with A3 Device Objects This chapter explains: • What is an A3 Device Object • Adding new A3 Device Objects • Editing A3 Device Objects • Deleting A3 Device Objects Overview The A3 system is used to display and control many objects (up to 1000). A3 Device Objects are the hea...
Page 68 - Adding new A3 Device Objects; Add New Device Dialog; in the “Available Features” box and are self-explanatory.
Page 67 Adding new A3 Device Objects Simply right click in the blank white area of the sheet you wish to add a device to and select “Add ACS Device”. You will then see the following dialog: Add New Device Dialog 1. Edit the Device Name. Use whatever is appropriate for your blender. 2. Edit Device De...
Page 69 - Configuring a Newer AB OS/OA Device
Page 68 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...
Page 71 - Here are some quick trouble shooting answers:
Page 70 Here are some quick trouble shooting answers: • Power light is off: Check that the “Cable/External” switch is set to “Cable” and that you are using the correct cable (see “Networking instructions for the newer AB OS/OA Blender”). The module gets power from the PLC. • Fault light is on: Check...
Page 72 - Adding a Legacy Device; Step 1: From the main menu press “5” and enter in your password.
Page 71 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: 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...
Page 74 - Step 5: press “1” or “2” to change Baud Rate, then Backup
Page 73 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...
Page 76 - Checking the Device you’re about to Add; Warning given when device is not detected
Page 75 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 ...
Page 77 - Device Type Icons; OS
Page 76 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: Device Type Icons Each device type has a unique graphic icon associated with it: OS OA ...
Page 78 - Device States; Device is communicating and is not in the “Run” mode.
Page 77 Device States Each icon has different states to indicate the conditions of the device: Device is communicating and is not in the “Run” mode. Device is in the “Run” mode. This state flashes. Device has an alarm active at the unit. Device is not communicating with A3. Editing an existing devic...
Page 79 - Working with the A3 Recipe Book
Page 78 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 Bo...
Page 80 - Accessing the Recipe Book; The A3 Recipe Book
Page 79 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”. The A3 Recipe Book List of available stored recipes The stored rec...
Page 82 - Editing Existing stored recipes; for the recipe you’ve selected.; Deleting stored recipes; You cannot print a single recipe by itself
Page 81 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: ...
Page 83 - Loading a stored recipe into a device; Click on “Recipe Book”.
Page 82 Loading a stored recipe into a device • 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 N...
Page 87 - Working with the Report Manager
Page 86 Chapter 6 Working with the Report Manager This chapter explains: • 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 ...
Page 89 - Frequency of Reports; Job
Page 88 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: Frequency...
Page 90 - Report Options; Up to 99,999,999 Lbs or Kgs of total inventory for each device.
Page 89 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 Options You should select to have all reports automatically clear and restart so that the system ...
Page 91 - Saving the Reports
Page 90 Saving the reports The user can specify the location where all reports will be saved using the following: Saving the Reports To select the location click “Select Directory”, go to the desired directory, and then click “Save”. The path will automatically be calculated for you.
Page 93 - Automatically generated reports
Page 92 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 & time stamped for reference. Below are some sample reports: Automatically generated reports The date and time stamp is a...
Page 96 - Alarm Log (same for auto or manual, just name would be different)
Page 95 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 ...
Page 98 - Working with the configuration file
Page 97 Chapter 7 Working with the configuration file This chapter explains: • What is the configuration file • Setting the system back to defaults • Saving the configuration • Opening a previously saved configuration file • The location of the configuration file Overview This chapter will help you ...
Page 100 - Working with the A3 System Log file; This chapter will help you understand how to use the A3 System Log.
Page 99 Chapter 8 Working with the A3 System Log file This chapter explains: • What is the A3 System Log file • What is logged in the file • 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 ...
Page 101 - The A3 System Log
Page 100 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 The A3 System Log It is ...
Page 103 - Troubleshooting
Page 102 Chapter 9 Troubleshooting This chapter explains: • How to trouble shoot a software installation problem • How to trouble shoot a PC problem • How to trouble shoot a communications problem • Where to go for further help Overview This chapter will help you understand how to properly trouble s...
Page 104 - Problem; Problem; Solution
Page 103 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...
Page 105 - Your receive printer error messages when the printer is hooked up.
Page 104 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 doesn’t meet the minimum ...
Page 117 - Service Notes
Page 116 Other service problems or questions can be answered by contacting the ACS Service Department. Service Notes
