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Sterling 882.00722.00 - page 1
GH-M Rate Monitor Allen-Bradley Controller Part Number: 882.00722.0 0 Bulletin Number: BF2-610 Effective: 2/08/2007 ...
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Sterling 882.00722.00 - page 2
ii Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing program of product improvem ent. Specifications, appearance, and dimensions described in this manual ...
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Sterling 882.00722.00 - page 3
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. In the Event of Shipping Damage According to the contract terms and ...
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Sterling 882.00722.00 - page 4
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. Reason for requesting the return must be given. ALL returned mate ...
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Sterling 882.00722.00 - page 5
v Table of Contents CHAPTER 1: SAFETY ................................................................ 7 1-1 How to Use This Manual ............................................................................................. 7 Safety Symbols Used in this Manual ..................................................................... 7 1-2 Warnings an ...
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Sterling 882.00722.00 - page 6
vi GH Calibration ..................................................................................................... 31 WTP/RPM Calibration Page ................................................................................ 33 This page is used to monitor the lbs/hr per RPM analyzer and is used as a tool for tuning the WTP Algorithm Options me ...
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Sterling 882.00722.00 - page 7
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. This manual covers only light corrective main tenance. No other mai ...
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Sterling 882.00722.00 - page 8
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 ...
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Sterling 882.00722.00 - page 9
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. To avo ...
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Sterling 882.00722.00 - page 10
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. All personnel engaged in the use of the machin e should become familiar with its operation as describe ...
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Sterling 882.00722.00 - page 11
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. • NEVER operate, service, or adjust the rat ...
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Sterling 882.00722.00 - page 12
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 electric supplies and all accessory equipment at the m a ...
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Sterling 882.00722.00 - page 13
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 . See below for a list of available models. • GH-M Rate Monitor Units • GH Full Control Units w ...
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Sterling 882.00722.00 - page 14
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. If you have any questions regarding installation, service, repair, custom equipment, or applications, please ...
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Sterling 882.00722.00 - page 15
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) 37.0 (940) 40.0 (1016) Mo d e l Ma x i mum Ex tru ...
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Sterling 882.00722.00 - page 16
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. To accomplish this, an inductive proxi m ...
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Sterling 882.00722.00 - page 17
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. If the rate monitor is being refilled from a mezzanine-mounted GH Hopper, the surge ...
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Sterling 882.00722.00 - page 18
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 Display Figure 9: Controller Pushbuttons & Touch ...
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Sterling 882.00722.00 - page 19
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 ...
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Sterling 882.00722.00 - page 20
Chapter 2: Functional Description 20 of 60 Figure 10d: Operator Screens Common to all GH Systems ...
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Sterling 882.00722.00 - page 21
Chapter 2: Functional Description 21 of 60 Figure 11: Typical Setup Screens ...
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Sterling 882.00722.00 - page 22
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 Ethern et module and connecting cable (to PLC) is off ...
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Sterling 882.00722.00 - page 23
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. WARNING! Slide gates create a pinch-point haz ...
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Sterling 882.00722.00 - page 24
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. Caution! Use approved safety straps or ch ains to lift the rate monitor ...
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Sterling 882.00722.00 - page 25
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. Verify that the machine throat is physically capable of supporting the rate monitor ...
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Sterling 882.00722.00 - page 26
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 (1.6 m) above the floor. Make sure your ...
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Sterling 882.00722.00 - page 27
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 Weigh Hopper Installation It is necessary to inst ...
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Sterling 882.00722.00 - page 28
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. The controller will be factory set to use the Ethernet module if i ...
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Sterling 882.00722.00 - page 29
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 . For security reasons, the menu that is used to acces ...
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Sterling 882.00722.00 - page 30
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 “Inventory ” Page “Setup” Page ¾ Touch the AC S icon and e nter in the “user pas sword” Hopper Setup ¾ Hopper size ¾ Reload Per centage ...
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Sterling 882.00722.00 - page 31
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. Since the load cell is weighing the ...
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Sterling 882.00722.00 - page 32
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”. 5. After touching OK, the controller will display “PLEASE WAIT...” 6. Next ...
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Sterling 882.00722.00 - page 33
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 0.003 pounds of the weight stam ped on the calibration weight, then you are withi ...
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Sterling 882.00722.00 - page 34
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. This value is automatically calculated with GH Full Control units. Also for GHF Feeder units you will need to program in the maxim u m LBS/HR of the extruder for the feeder’s target LBS/HR c ...
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Sterling 882.00722.00 - page 35
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 18: Alarm Setup Screen 8. Press the “Do ...
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Sterling 882.00722.00 - page 36
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. The date must be entered ...
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Sterling 882.00722.00 - page 37
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. The extruder icon on the ...
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Sterling 882.00722.00 - page 38
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. The system can also be started in ? ...
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Sterling 882.00722.00 - page 39
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 “Steady Pro cess” in “Monitor Mode” yo ...
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Sterling 882.00722.00 - page 40
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 default display shown when the ra te monitor is in ...
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Sterling 882.00722.00 - page 41
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. The operator can press “OK” on this pop-up to hide the screen temporarily, but if the alarm condition is still unr esolved, then the message will reappear after a sho ...
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Sterling 882.00722.00 - page 42
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. The checklist below contains a lis t of items which should be inspec ...
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Sterling 882.00722.00 - page 43
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. WARNING! Always remo ve plug and ...
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Sterling 882.00722.00 - page 44
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 extruder speed reference is generated from th e supp ...
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Sterling 882.00722.00 - page 45
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. All normal trouble-shooting m ust be accomplished with the power off, line fuses rem oved, and with the machine tagged as out of servic ...
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Sterling 882.00722.00 - page 46
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. Lower the ho pper size under “Hopper Setup” Problem Corrective action Recorded Inventory Totals don’t match what I’ve actually used Check the hopper’s scale ca ...
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Sterling 882.00722.00 - page 47
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. Warranty Specifications The manufacturer hereby expressly warrants all equipment manufactured by it to be free fro m defects in workmanship and material when used under recommended cond ...
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Sterling 882.00722.00 - page 48
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. No modifications are allowed to this equi pment that could alter the CE complianc ...
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Sterling 882.00722.00 - page 49
Chapter 7: Appendix 49 of 60 Figure 57: Typical Surge Hopper Assembly Parts List # DESCRIPTION 010 020 040 Lid (Smaller vacuum receiv ers) 08223-1 872.00769.00 872.00830.00 Lid (Larger vacuum receivers) NA 872.00783.00 - 1 Lid (Tube Stub for Mezz. Mounted GH Hopper) 08223-2 - - 2 1/8” NPT fitting 35085K, 35086K 3 1/4” NPT fitting 35154, 35155 4 ...
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Sterling 882.00722.00 - page 50
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. Passwords • User Password “5413” • Maintenance Password “3145348” Caution! Maintenance password should only be supplied to qualified personnel! Th ...
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Sterling 882.00722.00 - page 51
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: Typical Engineering Only Setup Screen Select ...
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Sterling 882.00722.00 - page 52
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. If you are using an unus ually large extruder and running it in pr oduction at a very low s ...
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Sterling 882.00722.00 - page 53
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. This will not cause any error due to the measurement algorithm that was previously mention ...
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Sterling 882.00722.00 - page 54
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. Typically make an adjust ...
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Sterling 882.00722.00 - page 55
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. Set the Selected Operator to “USER” by t ouching the box locate ...
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Sterling 882.00722.00 - page 56
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 with the Ethernet option. If this was not done at the ...
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Sterling 882.00722.00 - page 57
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. plc_battery_low,s:5/11 13. plc_memory_module_loaded,s:5/8 (this alarm only happ ...
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Sterling 882.00722.00 - page 58
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. extruder_rpm_target,f13:4 3. extruder_rpm_i ...
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Sterling 882.00722.00 - page 59
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. While in RPM mode the target recipe value will be overwrote by what the current ac ...
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Sterling 882.00722.00 - page 60
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. Please have the model and serial number of your e quipment when you call. Consult the Cus ...
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