Page 2 - ii
ii Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing program of product improvement. Specifications, ap...
Page 3 - Shipping Info; Unpacking and Inspection; Do not; If the Shipment is Not Complete; contact parts and service department; Hold the items until you receive shipping instructions
iii Shipping Info Unpacking and Inspection You should inspect your equipment for possible shipping damage. Thoroughly check the equipment for any damage that might have occurred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc. In the Event of Shippi...
Page 4 - the manufacturer must give authorization.; Warranty Returns; the manufacturer’s
iv Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department. Credit Returns Prior to the return of any material, the manufacturer must give authorization. A RMA number will be assigned for the equipment to be returned. Reason for reque...
Page 5 - Table of Contents
v Table of Contents CHAPTER 1: SAFETY ................................................................ 7 1-1 How to Use This Manual ............................................................................................. 7 Safety Symbols Used in this Manual ........................................
Page 6 - vi
vi GH Calibration..................................................................................................... 31 WTP/RPM Calibration Page ................................................................................ 33 This page is used to monitor the lbs/hr per RPM analyzer and is used ...
Page 7 - -1 How to Use This Manual; Safety Symbols Used in this Manual
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 installing, operating, and maintaining your rate monitor. The purpose is to assist you in applying efficient, proven techniques that enhance equipment productivity. This manual covers ...
Page 8 - Pinch Point Slide Gate; PE; Protected Earth Ground
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 Ground High Voltage Inside Enclosure PE Protected Earth Ground Shear Hazard Rotating Auger Lifting Point
Page 9 - -2 Warnings and Precautions
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 and local safety codes. This may include, but is not limited to OSHA, NEC, CSA, SPI, and any other loca...
Page 12 - Maintenance Responsibility; DO NOT; start; BEFORE; Reporting a Safety Defect
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. Before removing, adjusting, or replacing parts on a machine, remember to turn off all electr...
Page 13 - Chapter 2: Functional Description; -1 Models Covered in This Manual; GH-M Rate Monitor Units; Description; Accessories
Chapter 2: Functional Description 13 of 60 Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, and maintenance instructions for rate monitors of various extrusion rates and specifications. See below for a list of available models. • GH-M ...
Page 15 - Figure 2: Equipment Specifications; Features and Components; Mechanical Features; Figure 4: Typical GH Allen-Bradley PLC Enclosure; Controller Features
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) 37.5 (952) 37.0 (940) Depth (5) 22.0 (560) 3...
Page 17 - Weigh Hopper
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. Standard lids contain a cutout to accept a vacuum receiver. A blank lid may also be provided if specified. If the rate monitor is being refil...
Page 18 - Figure 8: Typical GH Series Controller Touch Screen Display; Function
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. The following figures show some typical screens of the GH-M rate monitor. Figure 8: Typical GH Series Controller Touch Screen Di...
Page 19 - Figure 10a: Typical GH-M Operator Screen
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 Operator Screen
Page 20 - Figure 10d: Operator Screens Common to all GH Systems
Chapter 2: Functional Description 20 of 60 Figure 10d: Operator Screens Common to all GH Systems
Page 21 - Figure 11: Typical Setup Screens
Chapter 2: Functional Description 21 of 60 Figure 11: Typical Setup Screens
Page 22 - Components; Ethernet Module
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. To accomplish this, an Ether...
Page 23 - Features
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 gate is opened and closed by the PLC. A 24 VDC solenoid is used to open and close the knife ga...
Page 24 - Chapter 3: Installation; -1 Uncrating the Equipment; Use approved safety straps or chains to lift the rate monitor.; Installation; Site Requirements
Chapter 3: Installation 24 of 60 Chapter 3: Installation 3-1 Uncrating the Equipment Rate monitors are shipped mounted on a skid, enclosed in a plastic wrapper, and contained in a crate. 1. Remove crate from around the rate monitor. 2. Secure strap of proper lifting capacity. Caution! Use approved s...
Page 25 - Chapter 3: Installation; Machine Mount; before; Connections
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 system begins. First, verify the machine flange dimensions match the cast spool-mounting flange. Verify that the machine throat is p...
Page 27 - Weigh Hopper Installation
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. Mechanical Set-up...
Page 28 - Final Connections; Connect the rate monitor to the appropriate power source.; Figure 13: Display Startup Screen
Chapter 3: Installation 28 of 60 If an Ethernet module was purchased with the system, the proper setting has to be changed to measure the extruder’s RPM with communications. For details on changing the settings for measuring the extruder’s RPM, please refer to the Addendum 7-4. The controller will b...
Page 30 - GH Controller Menu Structure
Chapter 3: Installation 30 of 60 “Inventory” page ¾ Clear Inventory ¾ Manual Control ¾ “Next” returns to “Recipe” page “Manual Control” Page ¾ Reload ON/OFF ¾ Return to the “Inventory” Page “Setup” Page ¾ Touch the ACS icon and enter in the “user password” Hopper Setup ¾ Hopper size ¾ Reload Percent...
Page 31 - GH Calibration; The heart of the rate monitor system is the; load cell; and the supplied calibration weight.; proper; Touch “Calibration” and then “Scale Calibration”.
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 calibr...
Page 32 - Figure 15: Display Calibration Menu Screen; Press “Done” until you have reached the Recipe screen.; Figure 16: Display Calibration Screen; Touch “Calibration” and then “Direct Scale Readout”
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 empty the weigh hopper and press “OK”. 5. After touching OK, the controller ...
Page 33 - WTP/RPM Calibration Page; Enter the Setup Menu.; Figure 17: Hopper Setup
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 step 5. This is the measured weight. If the measured weight is within a 0.003 pounds of the weight stamped o...
Page 34 - Extruder Setup
Chapter 3: Installation 34 of 60 Extruder Setup Use this page to setup the Maximum Extruder RPM. This is critical for GH Monitor units and GHF feeder units. This value is automatically calculated with GH Full Control units. Also for GHF Feeder units you will need to program in the maximum LBS/HR of ...
Page 35 - Alarm Setup; Figure 18: Alarm Setup Screen
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. Figure...
Page 36 - Setting Date and Time
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 traditional Hours, Min...
Page 37 - Chapter 4: Operation; Operator Displays; Figure 33a: Typical Operator Screen for GH-M system; Start up your extruder
Chapter 4: Operation 37 of 60 Chapter 4: Operation 4-1 GH-M Operation Procedures The system will begin monitoring the process rate once an RPM reading from the Extruder is detected. Again, this RPM must be communicated to the PLC through the supplied inductive proximity switch, or through the option...
Page 38 - -2 GH Full Control Operation Procedures; Figure 33b: Typical Operator Screen for GH Full Control system; Follow these steps to run the line:
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 controller. If started in “RPM Mode” then the GH should automatically load the hopper when necess...
Page 39 - -3 GH-F Gravimetric Feeder Operation Procedures; Figure 33c: Typical Operator Screen for GH Full Control system
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”. After you receive a ...
Page 40 - Screens; Figure 34: Typical Manual Control Operator Screen
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. The defa...
Page 41 - Alarms with Descriptions
Chapter 4: Operation 41 of 60 Alarm Flags An alarm message will be shown if any alarm condition occurs. A message will pop up on the screen until the alarm condition is resolved. The operator can press “OK” on this pop-up to hide the screen temporarily, but if the alarm condition is still unresolved...
Page 42 - Chapter 5: Maintenance; -1 Preventative Maintenance Schedule; Figure 52: Sample Preventative Maintenance Schedule; Photocopy this page for your maintenance records
Chapter 5: Maintenance 42 of 60 Chapter 5: Maintenance 5-1 Preventative Maintenance Schedule The mechanical design of the GH Hopper is very simple and very little maintenance is required. The only moving parts are the metering gates, weigh hopper dump valve, and mixer agitator. The checklist below c...
Page 43 - Always remove plug and disconnect power before servicing hopper.; Maintenance; Electrical
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...
Page 44 - Input Signals to Programmable Controller; The surge hopper refill solenoid is controlled by a PLC output.
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. The ex...
Page 45 - Chapter 6: Troubleshooting; Problem; Click “Unlock” and enter in your User Password.
Chapter 6: Troubleshooting 45 of 60 Chapter 6: Troubleshooting 6-1 Introduction The utmost in safety precautions should be observed at all times when working on or around the machine and the electrical components. All normal trouble-shooting must be accomplished with the power off, line fuses remove...
Page 47 - Chapter 7: Appendix; -1 Warranty and Spare Parts; Warranty Specifications
Chapter 7: Appendix 47 of 60 Chapter 7: Appendix 7-1 Warranty and Spare Parts Unless otherwise specified, this product includes a Standard ONE YEAR PARTS WARRANTY. Warranty Specifications The manufacturer hereby expressly warrants all equipment manufactured by it to be free from defects in workmansh...
Page 49 - Figure 65: Typical Allen-Bradley Display Main Parts List
Chapter 7: Appendix 49 of 60 Figure 57: Typical Surge Hopper Assembly Parts List # DESCRIPTION 010 020 040 Lid (Smaller vacuum receivers) 08223-1 872.00769.00 872.00830.00 Lid (Larger vacuum receivers) NA 872.00783.00 - 1 Lid (Tube Stub for Mezz. Mounted GH Hopper) 08223-2 - - 2 1/8” NPT fitting 350...
Page 50 - Passwords; User Password; Figure 67: Typical Operator Setup Screen
Chapter 7: Appendix 50 of 60 7-2 Addendum (Service Supervisor Information) Caution! After all selections are made: Keep pressing the “Done” key until the unit returns to the Recipe menu. Passwords • User Password “5413” • Maintenance Password “3145348” Caution! Maintenance password should only be su...
Page 51 - *Only adjust the weight filter upon request by service; Figure 70: Typical WTP Alogorithm Options
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. Figure 68: Typica...
Page 56 - -3 Allen-Bradley Communications Manual; Below are the items that can be accessed for the GH Hopper:
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. The rate monitor must be purchased from ACS wit...
Page 59 - FIXED DECIMAL EXPLANATION
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 unit is in stop mode. After engaging either RPM mode or Weight mode then the appropriate values will be applied. While in RPM mode the target recip...
