Sterling 882.00722.00 manual GH Full Control Operation Procedures

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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 necessary.

The system can also be started in “Monitor Mode” by placing the GH into “Monitor Mode” and then running your extruder using the existing control equipment such as the original speed pot. Once the extruder RPM reading from the Extruder is detected in “Monitor Mode’ the system will begin to load the hopper when necessary. Again, this RPM must be communicated to the PLC through the supplied inductive proximity switch, or through the optional Ethernet module. The extruder icon on the recipe page will become animated, indicating the extruder is running and the measured Extruder RPM will be displayed.

The displayed value may be far from the actual value the first time the system is ran. The GH goes through a learning process with each material. This is indicated by a “Steady Process” indicator on the main recipe page. Upon starting the line you should always give the hopper time to analyze the flow and give you a “Steady Process” before making adjustments based on the displayed throughput.

The initial learning process will be complete when the “Steady Process” indicator is displayed on the recipe screen. You are now ready to run the unit as normal. The “Steady” flag indicates that the measured throughput in reliable and can be used for control.

The system will automatically stop loading the hopper once the GH is put into “Stop Mode”.

Operator Displays

Figure 33b: Typical Operator Screen for GH Full Control system

Follow these steps to run the line:

1.Place the GH in “RPM Mode” by touching the “RPM Mode” button from the recipe page

2.Enter a target extruder RPM and hauloff speed

3.Wait until you see the “Steady Process” indication before using “lbs/hr” data

4.If you stay in RPM Mode then the extruder RPM and hauloff speed will remain constant. However, the function of the system is weight control. By placing the system in “Weight Mode” you can then adjust the system to a target “Lbs/hr” and “Feet/Min”. There are 2 other modes that can be used. “Weight Per Length” and “Weight Per Area”. In each of these modes the system can be custom configured for your recipe format (see setup). The benefit of placing the system in “Weight Mode”

Chapter 4: Operation

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Contents GH-M Rate Monitor Allen-Bradley Controller Write Down Your Serial Numbers Here For Future Reference Event of Shipping Damage Shipping InfoUnpacking and Inspection If the Shipment is Not CompleteCredit Returns Warranty ReturnsReturns Table of Contents Maintenance Safety Symbols Used in this Manual SafetyHow to Use This Manual Safety Tags and Warning Labels Description Follow all Safety Codes Wear Safety Glasses and Work GlovesOperator Responsibility ResponsibilityGeneral Responsibility Remember Maintenance Responsibility Reporting a Safety DefectModels Covered in This Manual AccessoriesFunctional Description General DescriptionCustomer Service Controller Features Typical Features and ComponentsMechanical Features Surge Hopper Extruder Inductive Proximity SwitchSystem Component Description Open Weigh HopperFunction Typical GH-M Operator Screen Operator Screens Common to all GH Systems Typical Setup Screens Optional Components Ethernet ModuleLow Level Proximity Sensors Safety FeaturesPneumatic Slide Gate below surge hopper Mounting Configurations InstallationMechanical Installation Uncrating the EquipmentElectrical Connections Machine MountPneumatic Connections Mechanical Set-up Weigh Hopper InstallationInitial Set-up Extruder RPM connectionFinal Connections Display Startup ScreenController Set-up GH Controller Menu Structure Recipe Page StartGH Calibration Weigh Hopper Load Cell CalibrationDisplay Calibration Menu Screen Hopper Size Setup WTP/RPM CalibrationExtruder Setup Hauloff Setup and Encoder CalibrationAlarm Setup Network SetupSetting Date and Time PanelView Configuration ScreenOperator Displays GH-M Operation ProceduresOperation GH Full Control Operation Procedures Typical Operator Screen for GH Full Control systemGH-F Gravimetric Feeder Operation Procedures Common Screens Typical Manual Control Operator ScreenPrint Inventory Alarm FlagsAlarms with Descriptions Maintenance Preventative Maintenance ScheduleElectrical Preventative MaintenanceCorrective Maintenance Internal Components of the Control PanelInput Signals to Programmable Controller Output Signals from Programmable ControllerTroubleshooting IntroductionProblem Corrective action ProblemWarranty Restrictions Warranty and Spare PartsWarranty Specifications Warranty LiabilitiesCustomer Responsibilities Annex B InformationTypical Surge Hopper Assembly Parts List Programmable Settings Addendum Service Supervisor InformationPasswords Typical Engineering Only Setup Screen Full Hopper Method Percent of hopper Method DefaultExtruder Pulse Count Method WTP/RPM FilterMax Allowed WTP/RPM Mechanical Options ScreenDiagnostics Screen Typical Analog Options Analog options screenAlarm Log Customer Setup MenuPassword Protection UnitsBelow are the items that can be accessed for the GH Hopper Allen-Bradley Communications ManualAppendix Reload TOO Long Fixed Decimal Explanation Contract Department Service Department Sales DepartmentParts Department
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