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A3 System Management Software Software Manual Bulletin No: BF4-600 Part No: 882.00278.00 Sterling 2900 S. 160 th Street New Berlin, WI 53151 Tel [262] 641-8610.
Please note that our address and phone information has changed. Please reference this page for updat ed contact information. These manuals are obsolet e and are provided only for their technical information , data and capacities.
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 3 Instruction Deleting an A3 devi ce object ....................................................... 67 Chapter 5 Working with the A3 Recipe Book Instruction Overview of the Reci pe Book ...................................................... 78 Instruction What is the A3 Reci pe Book .
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 publication.
Page 5 When using the system to integrate ol der propri etary units you will need the optional “USB RS422/485” module and must limit the number of devices to 255 (this is a limitation of RS 422 and not the A3 package). • Monitor the status of all blenders (started, stopped, alarming, etc.
Page 6 Who should use this manual Use this manual if you are responsibl e for system integration of machinery in your facility. You should have a basic und erstanding of Allen Bradley or Mitsubishi PLC, Ethernet networking, and Windows XP. If you do know, contact the appropriate personnel to obtain inform ation before proceeding.
Page 7 Frequently Asked Questions • How many units can A3 integrate? 1000 units, of wh ich 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.
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 aft er the reboot I get the same message? Make sure that your computer meets the minimum requirements.
Page 9 What’s new in version 1.1 Job Report Manager Now you can generate repor ts on demand instead of just time. Along with this comes the new feature of Job Ma nagement that allows the operator to.
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 dr ive.
Page 11 Installing A3 Before you start the installation you will nee d to be logged in as the administ rator and you will need to close all programs that are running.
Page 12 Step 2: Examine the above and ensure that you see Microsoft Windows XP, Service Pack 1, at least 750MHZ, and at least 128MB or RAM. Next you will need to check the hard drive: Step 1: Click st.
Page 13 Step 2: Click on “(C:) and exami ne “Free Space” in the lower left corner under “Details”. It should be at least 30 GB. You should also see that you have a working CDROM drive on this page.
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.
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 driv e. When the insta llation automatically starts, cancel the installation. 2. Click Start and Click on “My Computer”.
Page 16 Installing A3: Insert the A3 CD into the CDROM drive. The installati on software will automatically start. If it doesn’t, then r un Setup.exe from the A3 CD.
Page 17 Step 2: Click the pictur e of the computer Step 3: Click Continue.
Page 18 Step 4: Success, Click “OK” to complete..
Page 19 Starting and exiting A3 To start A3: 1. From the Star t menu, click Programs . 2. Select ACS Software and click A3 System Management Software .
Page 20 Networking instructions for the AEC AB OS/OA Blender Installing the PLC hardware The first step is that you must install the Ethernet module and cable into every PLC. You will need an Ethernet Module (A0563939, 1761-NET-ENI) and a Cable for the Module (A0565898, 1761-CBL-AM00) per blender.
Page 21 Configuring the PLC You will need to go to Netw ork Setup found under “Setup” on the blender and set the appropriate IP address. The SUBNET mask should be set to “255.
Page 22 Configuring the PC If your PC is part of your plants LA N then you will need to have your system administrator configure the IP settings for the PC.
Page 23 Step 2: Right click on your Local Ar ea Connection and select “Properties” Step 3: Double Click on “Int ernet Protocol (TCP/IP)”.
Page 24 Step 4: Set your screen to look like this, then click OK, and OK again. Remember that you need to have a unique IP fo r all of your blender s and for the PC. For example you could use the following scheme: PC IP -> 192.168.0.1 Blender 1 IP -> 192.
Page 25 Running the Cables and Hardwa re 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 blend er panel because of the head on the cable, but not impossible.
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 COME S WITH THE ADAPTER, BUT INSTEAD USE THE A3 CD WHEN PROMPTED FOR A CD . The installation is very easy.
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 connecting the cables to each blender.
Page 28 Networking instructions for the Sterling SGB Blender Installing the PLC hardware The first step is that you must install the Ethernet module and cable into every PLC.
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.
Page 30 Step 2: Right click on your Local Ar ea Connection and select “Properties” Step 3: Double Click on “Int ernet Protocol (TCP/IP)”.
Page 31 Step 4: Set your screen to look like this, then click OK, and OK again. Remember that you need to have a unique IP fo r all of your blender s and for the PC. For example you could use the following scheme: PC IP -> 192.168.0.1 Blender 1 IP -> 192.
Page 32 Running the Cables and Hardwa re 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 bl ender panel because of the head on the cable, but not impossible.
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.
Page 34 This will be shown until the so ftware finds the attached module. Double click on the unit you wish to program..
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” .
Page 36 Click Incoming Network Connection then next Click TCP Sockets then next.
Page 37 Configure as shown a bove then click next From this screen, click Next to save the configuration to the Ethernet module..
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 c lick Finish to complete.
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 • .
Page 40 Tip of the day The application window will appe ar and will show you a “Tip of the Day”: Deselecting “Show Tips at Startup” will prev ent the “Tip of the Day” from appearing the next time the program starts. Also you can scroll through many random tips by hitting “Next Tip”.
Page 41 Drop down menus A3 has many drop down menus that can be selected:.
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Page 44 Right click menus A3 also uses right-click menus. These ri ght-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 brin g up these.
Page 45 Right-clicking on a device will bring up these. Right-clicking on the sheet name will bring up these..
Page 46 Status Bar on A3 The status bar is located near the bottom of the A3 main page: The status bar on the left s hows when the next automatic r eport will generate, the bar in the middle always shows the date and time , and the bar on the right shows the countdown for the automatic report.
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 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 lo cation of the plant (i.e. Dayton, OH).
Page 49 • Adding multiple sheets to the system. A3 is capabl e 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 50 A3 options The A3 software also has many preference options that can be changed by the user. To access the options menu, select “Tools/Options”:.
Page 51 Verify Action Options These options enable or disable the “Are you su re…” prompts after ce rtain operations. Hard Drive Options This option allows the user to configure t he minimum allowed hard drive space to allow saving. The minimum value that c an be entered here is 2000 MB (2 GB).
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 53 Virtual Control Panel The virtual control panel is accessed by double clicking on the icon of the blender from the main page..
Page 54 The Virtual Control Panel. Push to immediately sto p blende r 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 .
Page 55 The Alarm Log Change Recipe Page. Enter new values and hit “Load” or cancel to qui t. If a box shows “******” then this is the automatically calculated entry and does not need to be entered. On newer AB OS/OA blenders you then need to hit “Accept” from the Virtual Control Panel to finish loading the recipe.
Page 56 If the recipe is not correct, an error mess age 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% .
Page 57 Total not 100% error message.
Page 58 The following are error messages given wh en using the older proprietary blenders: Recipe Not Totaling 100%.
Page 59 The following is the successful message given when using the older proprietary blenders: Recipe Transferred message.
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 61 Batch Data Page. The Batch Data Page shows the actual weight of every component of every batch made (up to 5000 batches). Clicking on the “Show these Hoppers” boxes only effects what is displayed and does not effect the data in the log. The gr aph is automatically scaled for the hoppers you have chosen to be displayed.
Page 62 Uptime Data Page The Uptime Data page is accessed by select ing “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 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 l ong it takes for each device to poll all of the configured parameter s.
Page 64 Memory Status Page. The Memory Status Page is accessed by se lecting “View/Memory Status” from the dropdown menu. This page is useful in det ermining the amount of memory you have consumed with the current conf iguration and is also usef ul when configuring systems with up to 1000 devices.
Page 65 Data Parameters Page The Data Parameters Page is accessed by se lecting “View/Data Parameters” from the dropdown menu. This page shows all of the av ailable data parameter s for each device.
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).
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 what ever is appropriate for your blender.
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).
Page 69 You will also need to set the SUBNET MASK for the blender. This needs to be set to “255.255.255.0”. Once confi gured, you will need to make sure you have connected the Ethernet Module and Cable (see “Networkin g instructions for the newer AB OS/OA Blender” for details).
Page 70 Here are some quick trouble shooting answers: • Power light is off: Check t hat the “Cable/External” switch is set to “Cable” and that you are using the correct cable (see “Net working instructions for the newer AB OS/OA Blender”).
Page 71 Configuring an Older Propri etary 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.
Page 72 Step 2: press “6” Step 3: press “back up” Step 4: press “1” or “2” to increas e or decrease Serial ID, then Backup.
Page 73 Step 5: press “1” or “2” to change Baud Rate, then Backup The SERIAL SETUP section is the same fo r all proprietary devices on the network (changing the settings here means changing it fo r all devices). The COM Port should be set to whatever the USB RS422/485 is set to.
Page 74 Step 2: Click the “Hardware” tab and then click “Device Manager” Step 3: Expand the “Ports” and obs erve the Kontron Port # If you do not see the Kontron entry, then see “Networking in structions for the newer AB OS/OA Blender”.
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.
Page 76 You should click “No” unless you know that the device is not hooked up (your setting up the system before t he network is in place). If the dev ice is communicating, the icon will be added.
Page 77 Device States Each icon has different states to i ndicate 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.
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 • Editin.
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”.
Page 80 Creating a stored recipe 1. Edit the RECIPE DATA fi elds to appropriate values. 2. Click “Save New” and enter in a name in the “File Name” box and click Save.
Page 81 Editing Existing stored recipes 1. Click on an AVAILABLE RECIPE and the RECI PE 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.
Page 82 Loading a stored recipe into a device • Access the Virtual Control Panel by doubl e clicking on the devic e from the main page. • Click on “Recipe Book”.
Page 83 Total not 100% error message.
Page 84 The following are error messages given when using the older proprietary blenders: Recipe Not Totaling 100%.
Page 85 The following is the successful message given when using the older proprietary blenders: Recipe Transferred message.
Page 86 Chapter 6 Working with the Report Manager This chapter explains: • What is the Report Manager • Accessing the Report Manager • Automatic vs.
Page 87 What is the Report Manager The A3 Report Manager is a utility that allo ws the user to generat e reports for each device that contain: • Inventory Usage information • Uptime Percentage inf.
Page 88 Automatic vs. Manually generated reports The report manager can be configured to eit her automatically generate reports based on a time interval (from 1-8760 hours) or ma nually generate reports based on “Jobs”.
Page 89 Configuring what is included in the Reports The user can select what information will be included in each r eport by enabling or disabling the following check box es (also what is cleared): Re.
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 direct ory, and then click “Save”. The path will automatic ally be calculated for you.
Page 91 Using Manually generated Re ports (Job Report Manager) To access, double click on the icon of the devi ce from the main page, then click on “Job Report Manager”: Click to Start a Job, Inventori es and logs will clear at this point Click to Finish a Job, be sure to enter in all of the data first.
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 st amped for reference.
Page 93 Sample Reports using Manua l Generation (Job Reports) 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, and job number stamped for reference.
Page 94 Sample Reports Here are some sample reports. All number are only shown as an example: Automatically Generated Inventory and Uptime report Manually Generated Inventory and Uptime Report.
Page 95 Alarm Log (same for auto or manual, just name would be different) It is important to note that w henever the inventory is cleared ei ther at the blender or the PC an entry of what the inv entory was prior to clearing is added.
Page 96 Batch data report (same for auto or m anual, just name would be different).
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 previ.
Page 98 Setting the system back to defaults The system can be set back to the original def aults by selecting “File/Set Config to Default” from the dropdown menu.
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.
Page 100 What is logged in the file • Any communications error (tim e of alarm and time cleared). • Time the program was started • Time the program was stopped • Printer error messages • Set.
Page 101 The location of the file The A3 system log file is always named “a3_system_log.txt” and is located in the installation path. By default the file will be found in “c:p rogram filesa3 system management software a3_system_log.txt” and c an be as large as 5 MB in size depending on the number of entries.
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 underst and how to properly trouble shoot the A3 System Management Software.
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 t hen asks you to reboot. After rebooting and running the installation again you will receive the same message.
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.
Page 105 How to trouble shoot a communication problem The approach to trouble shooting varies wit h the type of communications the device uses, so this section is divi ded up into multiple sections.
Page 106 Step 3: Examine the “Power” light on the PLC’s Ethernet module. If it is not on then check the cable that connects the device to t he plc and ensure that it is plugged in fully and is the correct cable (1761-CB L-AM00). Also make sure that the power switch for the device is set to “Cable”.
Page 107 Step 5: If all of the previous steps have been satisfied, then examine the “LINK” light on the Ethernet module. It should be green. If it is not then first make sure that the Ethernet cable is hooked up at both ends. Re member that you must use straight through standard CAT5 cables when going bet ween the blender and a hub or switch.
Page 108 Problem You’ve configured more than one Ethernet device and some are communicating, but others aren’t. Solution It is easy to trouble shoot when you have some devices communicating (at least one). The quickest way to resolve the problem is to first examine t he lights on the PLC and Ethernet module for a device that is working.
Page 109 Trouble shooting network problems with older HydReclaim units Problem You’ve configured more serial devices and are having problems establishing communications. Solution Step 1: Disconnect the cable from all of th e blenders except for th e first one.
Page 110 You should see a response on the screen from the blender that looks something like: 01T00BTest String6C If this works than communications is worki ng. Try starting the blender and then perform the same test. If when the blender is runni ng this test fails, then the problem is noise from within the blender (consult service).
Page 111 Trouble shooting network problems with Sterling SGB blenders Problem You’ve configured more than one Ether net device and none of them are communicating. Solution It is easy to trouble shoot when you have so me devices communicating (at least one), but with none communicating you’re going to have to start from the beginning.
Page 112 Step 4: If all of the previous steps have been satisfied, then examine the “LINK” light on the Ethernet module. It should not be red. If it is, then first make sure that the Ethernet cable is hooked up at both ends. Remember that you must use straight through standard CAT5 cables when going between the blender and a hub or switch.
Page 113 Problem You’ve configured more than one Ethernet device and some are communicating, but others aren’t. Solution It is easy to trouble shoot when you have some devices communicating (at least one). The quickest way to resolve the problem is first examine the lights on the PLC and Ethernet module for a device that is working.
Page 114 - Notes -.
Page 115 - Notes -.
Page 116 Other service problems or questions can be answered by contacting the ACS Service Department. Service Notes.
Page 117 Service Notes.
Page 118 Parts Department Call [ 630 ] 595-1060 Parts shipped from the Wood Dale, IL facility available for Next Day Air shipment only up to 3 pm CST. The ACS Parts Department at ACS, Inc. is ready to pr ovide the parts to keep your s y stems up and run ning.
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