batching manual update eng new-2

8/4/2019 Batching Manual Update Eng New-2

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TAT ENERGY & ENGINEERING CO., LTD.____________________________________________________________

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1. System Menu Bin Dischage

Click right to show menu bindischarge detail as below;

- Manual Operate = To panel manual system.- Reset Error = To reset error.

-Under Repair = To not use this bin discharge.

- Parameter = To set Bin Parameter- Bin Inventory = To set Bin Inventory

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_______________________2. BIN PARAMETER

When you right click on the Popup menu, this will show the

BIN PARAMETER, select this field.

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Bin Code Number of Bin that you need to edit. (wecan use Alphabets or Numbers)

IngredientCode

Code of the material to be packed insidethe bin.

Pre-CutWeight

Weight on change bin dischage to stepjoging mode

Free FallWeight

Weight increases after the systemcommands the Stop Bin Feeder.

Very HighTolerance

Weight is over the limit but is stillacceptable. (if weight is over thelimit, the system will show an alarm ofOver Weight)

Very LowTolerance

Weight is not complete but it is stillacceptable. (if the weight is morethan the value you set, the systemwill jog for 6 times. After jogging, andthe weight is still below the requiredweight, it will show an alarm windowUnder Weight)

Jog Time(s)

This is the time wherein the system worksin Jogging Mode to open the BinFeeder.

Note: time of Jogging can be set at ScaleConfiguration and Jogging Max

Speed Jog(%)

% rate for Joging

SpeedHigh(%)

% rate for maximum speed joging

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SpeedLow(%)

% rate for minimum speed joging

Active Bin The system checks if this Bin can be used.

SubFeeder

Set RESERVE Bin

Main and Sub are used in the systemsupport to open more than 1 Binsimultaneously (max of 5 bins), this iscalledMulti-Bin Draw. When the

required weight is almost completed,the system stops the Sub-Feeder andruns the Main Feeder until it iscomplete. This method reduces thetime of Scaling but increasescorrectness.

Bin Code Number of Bin that you need to edit. (wecan use Alphabets or Numbers)

AutoCalculateFreeFall

The System automatically calculates forthe Free Fall weight.

Auto-FixFreeFall in

LastBatch

The system to use Free Fall Weight in lastbatch on next production(formula).

3. Manual Operate

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_______________________

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_______________________

3.1 Jogging Mode- Set Jog Speed, Jog Time

3.2 Manual- Set Jog Speed and click mouse down to jog and mouse

up to stop jog.

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_______________________4. System Menu Scale

System Menu after click mouse right to show menu detail as

below:

- Auto = To set auto mode- Manul = To set manual mode- Start Batch = To set new batch (Active Formul)- Formula Monitoring = To monitoring formula activeweight ingredient by item

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_______________________on scale.

- Change Batch Preset = To change batch preset on actualformual

- Reset Batch Queue = To reset batch queue after setBatch Queue- Parameter = To set parameter scale.- Hold slide = To set Hold/UnHold slide scale.

5. Scale Parameter

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_______________________Flow Time This is the time when the ingredient flows

after starting the Feeder. If the time is =flowtime and the ingredient does now

flow, (the Scale does not increase) theprogram shows an alarm Ingredient NotFlow.

Settle Time This is the time when the system waitsuntil the Scale stops. After a commandstops the Feeder.

Delay Time This is the time when the system waits foran open Slide. After completely weighingevery ingredient, it is now ready to send itto the next procedure (in case that wehave 2 scales that go to the same Mixer,only one slide can be open at a time).

Empty Weight Weight of ingredient that can be acceptedto remain in the Scale after Discharge.(not more than 1% of the Scalescapacity)

DischargeTime

Shows the time to open the Slide of theScale for discharging the ingredients forthe next procedure. When the discharge

time is complete, the system closes theSlide. The machine is not interested indischarging if the ingredient is not enough(normally set to 0.0 for this parameter,its used to check for an empty weight,but not if the parameter is unstable).

DischargeSettle Time

The scale discharges until the weight isless than the specified empty weight. Thesystem will wait until it is time for the

discharge to be complete.Delay to StartNext Batch (s)

The time the system waits after closingthe Slide Scale, before we can continuewith the process.

Max Weight Maximum capacity of scale.Time to HoldConveyor

Time in holding the Conveyor.

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_______________________Jog Max Times to joging

Suspend

WeightTime(s)

Time to stop scale system after mixer

discharging.

5. System Menu Mixer

System Menu after click mouse right to show menu detail asbelow:

- Auto = To set mode auto- Manual = To set mode manul- Formula Monitoring = To monitoring formula weight

ingredient by item on mixer. (HandAdd, Liquid, etc.)- Parameter = To set parameter mixer.- Hold slide = To hold/unhold slide gate mixer.

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_______________________

7. Mixer Parameter.

Dry MixTime

Mixing the ingredients without liquids.Example, no water or oil.

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_______________________Wet Mix

Time

Start time for mixing and how long to mix withliquids.

Acture

time (s)Time AfterLiquid

After wet mix, the machine will hold the

ingredients before discharging. The process ofmixing the ingredients is completed.

DischargeTime

Time of discharge, the Mixers gate is open.

CycleDelayTime

A gap between the batching process.

DelaySurgeLow

Waiting time for the Mixer Surge Low signal(hopper is empty) and before the Mixerdischarges the ingredients to the Hopper whenthe mixing process is complete.

8. System Menu Liquid.

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_______________________

System Menu after click mouse right to show menu detail asbelow:

- Manual Operate = To set manual liquid from ManualOperate Panel.

- Reset Error = To reset error.- Under Repair = To not use pump liquid.- Reset Pluse = To reset pluse on liquid system by item.- Parameter = To set parameter liquid.

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_______________________9. Liquid Parameter.

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IngredientCode

Code of the material to be packed insidethe bin.

Flow Rate Number of pules per kilo / Time. (belowoption Liquid Pules/Time

Jog Time Times to joging mode.

Free FallWeight

Weight increases after the systemcommands the Stop Bin Feeder.

Very High

Tolerance

Weight is over the limit but is still

acceptable. (if weight is over the limit,the system will show an alarm of OverWeight)

Very LowTolerance

Weight is not complete but it is stillacceptable. (if the weight is more thanthe value you set, the system will jogfollow Jog Max. After jogging, and theweight is still below the requiredweight, it will show an alarm windowUnder Weight)

Jog Max This is the time wherein the system worksin Jogging Mode to open the BinFeeder.

Note: time of Jogging can be set at ScaleConfiguration and Jogg Max

Delat Time(s) Time to delay liquid to spuirt after startmixing time.

Flow Time(s) Time to check liquid pluse no flow afterstart motor. System show alarmLIQUID NOT FLOW

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Liquid FlushTime(s)

Time to fluse liquid line.

LiquidCompleteTime(s)

Time to check liquid completed .

OPTION

Active Liquid = Check Active Liquid whento use.

Auto-Cal Free Fall = Set system auto calculate free

fall.Liquid Pules/Time = Set system to use flow rate kilo

per 1 pules or kilo per 1 sec.Liquid Flush Every Batch = Set system to auto flush

line every batch.Liquid Flush Every Last Batch = Set System to auto

flush line every in last batch.

10. System Menu HandAdd

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_______________________- Manual Open = To open slide handadd- Manual Close = To close slide handadd- Reset Error = To reset error

-Under Repair = To not openslide handadd

- Parameter = To set parameter handadd5. HANDADD PARAMETER.

Hand Add

Delay Time

Time to hold slide handadd to open after

slide scale opened.Hand AddDischarge

Time

Time to open slide handadd after HandAddAckownlage

11. System Alarm.

System Alarm

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_______________________Alarm Cause Repair

HandAdd

not Acknow.

- Hand Add

Acknowledge switchis not pushed.- PLC is notreceiving signal(Hand AddAcknowledgesignal).- PLC. Input to be

damaged.

- Tell Hand Add Station to push

the switch.- Change switch.- Check Cable, check LampHand Add Acknowledge PanelBoard.- See PLC Input and Output

Topic.

HandAddnotcomplete.

- HandAddComplete switch isnot pushed.- PLC is notreceiving signalfrom Hand AddComplete.- PLC Input to bedemaged.

- Tell HandAdd Station to pushthe switch.- Change switch.- Check Cable, check LampHand Add Complete PanelBoard- See PLC Input and Outputtopic.

Slide

HandAddNot Open.

- Slide Hand Add is

not working.- Air Valve not open.- Solenoid ofPneumatic systemis broken.- PLC Output forControl CoilSolenoid not work.- Slide is open but

Limit Slide Open isnot working.- PLC Input signal itreceives from theLimit Open is error.

- Check the Air System of the

Slide H.A.because the slide is jammed

by dust. Youcan use oil to make the Slide

work again.- Open Air Valve, check AirPressure.- Check the resistance of thecoil if it is an open circuit. Check

the electric line.- Check Limit Switch.- See PLC Input and Outputtopic.

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Slide

HandAddNot Close.

- Slide HandAdd is

not working.- Air Valve is notclosed.- PLC Output forControl CoilSolenoid is notworking.- Slide is closed butLimit Slide Close isnot working.- PLC Input Error.

- Check the Air System of the

SlideHandAdd because the Slide isjammed

by dust.- Open Air Valve, check Air

Pressure.- Check the resistance of the

coil if it is aclosed circuit. Check the

electric line.- Check Limit Switch Close.- See PLC Input and Output

topic.Mix routenot ready.

- the way oftransport fromMixer to somemachines does notwork.- the PLC Output

makes the CoilSolenoid work, orthe Motor Starterdoes not work.- PLC Input error.

- Check the Limit Switch of theMotor Conveyor System and theMotor Starter, to see if thetransport from mixer is correct.- See PLC Input and Output

Topic.

Discharge inhold. (Mixersystem)

- Slide hold- Switch is notpushed but LED ofInput PLC is shown.

- release Switch Hold Mixer.

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Slides Gate

Mixer is notOpen.

- Slide in not

working.- Air Valve is notopen.- Solenoid ofPneumatic Systemis broken.- the PLC Outputthat makes the CoilSolenoid work is notworking.- Slide is open butLimit Slide Open isnot working (LampSlide Open is notshown on the Panel)- PLC Input error.

- check the Air System of the

Slide Bin because the Slide maybe jammed by dust. Use oil intothe Air System.- open the Air Valve and checkthe Air Pressure.- check resistance of the CoilCircuit. If it is not complete,check the wire or change theCoil Solenoid.- change the Limit Switch atSlide Open position or LimitSwitch touching position.- See PLC Input and Output

Topic.

Slides GateMixer is notClose.

- Slide is notworking.- Air Valve is not

closed.- Slide is closed butLimit Slide Close isnot working (nosignal Lamp SlideClose on Panel)- PLC Input Error.

- Check the Air System of theSlide Bin because the Slide maybe jammed by dust. Use oil into

the Air System.- Open the Air Valve and checkthe Air Pressure.- Change the Limit Switch atSlide Open position or LimitSwitch touching position.- See PLC Input and Output

Topic.

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Mixer surge

not low.(Hopperunder theMixer is notempty)

- Hopper is not

empty or ingredientsticks to the Sensor.- the Conveyorunder the Mixer isslow.- Set Delay SurgeLow in MixerParameter to beover.

- In case that the Sensor has a

problem every time that wechange it, clean the Hopperunder the Mixer and Sensor.- Increase the efficiency of theConveyor- Reduce time of Parameter.

Scale MeterError.

- Reader has aproblem.- Signal line fromReader is broken.- If it shows UL, OV,Error on ScaleMeter, check theLoad Cells weight ifit is over or under.- PLC

CommunicationCard has a problem.

- Check the Readersparameter.- Check Cable of Reader (WeightIndicator) and PLC.- Check resistance of Load Celland compare it with itsCertificate. Also check thesignal (mV) from Load Cell if it iscorrect.- Check Card and See PLC Input

Topic..

Scale notempty(Hopper ofScale is notempty)

- The weight in theHopper Scale ismore than what wasset in EmptyWeight.- The ScaleParameter set in

Empty Weight isvery low.- The ingredientsent off fromHopper is very slow.

- Clean the Hopper Scale ormake a new calibration(recalibrate).- Change Parameter.at EmptyWeight.- Increase Dischage Time inScale Parameter.

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Scale over

shutdown(weight inScale ismore thanwhat wasset)

- weight in Scale is

more than the MaxCapacity of Scale inScale Configuration.- ingredient weightin formula is over.

- Send off ingredient from Scale

or change the Max Capacity inScale Configuration.- Edit formula for all ingredientswith weight less than the MaxCapacity.

Slide Scaleis not open.

- Slide is notworking.- Air Valve is notopen.- Solenoid ofPneumatic isbroken.- Slide is openedbut Limit Slide Openis not working (nosignal Lamp SlideOpen on Panel)- PLC Input or

Output Error.

- Check the Air System of theSlide Bin because the Slide maybe jammed by dust. Use oil intothe Air System.- Open the Air Valve and checkthe Air Pressure.- Check resistance of the CoilCircuit. If it is not complete,check the wire or change theCoil Solenoid.- See PLC Input and Output

Topic.- Change the Limit Switch at

Slide Open position or LimitSwitch touching position.

Slide Scaleis not Close

- Slide is notworking.- Air Valve is notclosed.- Slide is closed butLimit Slide Close is

not working (nosignal Lamp SlideClose on Panel)- PLC Input/Outputerror.

- Check the Air System of theSlide Bin because the Slide maybe jammed by dust. Use oil intothe Air System.- Open the Air Valve and checkthe Air Pressure.

- Change the Limit Switch atSlide Open position or LimitSwitch touching position.- See PLC Input and Output

Topic.

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Ingredient is

not Flow.

- Ingredient does

not flow- Bin dischage is notrunning.- the PLC Outputthat controls theMotor Starter is notworking.- Flow Time in theScale Parameter isvery low.- Scale Motion inthe Weight Indicatoris very low.

- Check the Conveyor System,

for the flow and quantity of theingredient in the Bin.- See PLC Input and Output

Topic.- Check the Motor Starter of theFeeder.- Add value to Flow Time.- Add value to Scale motion.

Ingredient isOver VeryHigh.

- Ingredient overweight on targetweight.

- return some ingredient fromthe Hopper in Scale or Acceptan Alarm Window.

Ingredient isVery Low

- Ingredient underweight on target

weight.

- Retry to auto jogging orManual Jogging of ingredient

again.- Set new Jog Time in BinParameter (read in Topic Binparameter, how to set Jog Time)- Add the value of Jogging Maxin Scale Configuration.- In case the ingredient is oftenover weight or under weight,please check the value of Free

Fall. The change could be:1. Ingredient is very sticky.2. Ingredient is often empty,increase ingredient.3. In case of Scaling Ingredient.

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Scale is

hold(Scale willnotdischarge)

- Slide is on hold - UnHold Scale.

Scale surgenot Low.(Hopperunder Scaleis notempty)

- Hopper underScale is not emptyor doesnt have aningredient stick atthe Sensor.- Conveyor underthe Scale worksslowly (in case theMixer is under theScale).- Have aningredient in theMixer.

- Clean the Hopper under theMixer and Sensor in case theSensor often have problems,please change the Sensor.- Add the efficiency of theConveyor System under theScale.- Checking the Mixing Systemuses more time than the ScalingSystem. But in a normalprocess, the Mixing Systemconsumes lesser time than theScaling System.

Ingredient is

Out off Bin.(the Bindoesnthave theingredientin theformula)

- Ingredient is not

found inside the BinParameter

- Check formula or Bin

Parameter- Change bindischage.

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Liquid is not

flow

- Liquid is empty.

- Valve or LiquidPump is notrunning.- The PLC Outputthat controls theValve is notrunning.- Liquid is notflowing.- The Liquid but stillhas an Alarm.- PLC Input/OutputError.- In this case, it isthe same of theLiquid Scale, pleaseconsider the Scale ifit doesnt have anyflow.

- Check the quantity of the

Liquid inside the Bin.- Check the PLC Output of theValve Liquid (Pump Liquid) andMotor Starter- See Topic: Check PLC Inputand Output.- Check the flow of Liquid.- Check the Pulse signal fromthe Flow meter, and check thesignal cable from the FlowMeter.

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Liquid is

Over VeryHigh.

- Liquid is over

more than targetweight.

- An acceptable case.

- In case that the quantity of theLiquid is too much, and cant beaccepted anymore, that batchshould be re-mixed. Find aprotection method to avoid thisfrom happening again.1. Does the Valve Liquid open orclose slowly?2. Flow of Liquid is too highwhen compared to the use of itsquantity.3. Does the Systemcommanding Close Valve shouldstop the Liquid from flowing?4. If the Valve is closed, thePump should stop running too.(dont include in the system aLiquid that doesnt flow;Example: Molasses)

Liquid isUnder VeryLow.

- Liquid is lowerthan target weight.

- Please retry for JoggingSystem.- Press Accept in case theweight is not enough but can beaccepted.- If Under Weight oftenhappens, please check Free FallValue and Jog Time Value inLiquid Parameter. Also include

Bin Parameter.

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Liquid Meter

Error.

- Weight Indicator

wave problem.- Signal cable fromthe weight Indicatoris abnormal.- Have UL, OV, ErrorMessage or ------ onMonitor of weightIndicator, pleasecheck the Load Cellif its weight is toohigh or too low.- PLCCommunicationCard Error.

- Check the weight Indicator

Parameter value.- Heck the Cable that isconnected between the weightIndicator and PLC- Check the resistance in LoadCell and compare it with itsCertificate. Also check thesignal (mV) from Load Cell if it iscorrect.- Check Card A1SJ71 LoopBack

Tester method.

Liquid notActive(Liquid isnotworking)

- Liquid Active Flagin Liquid Parameteris not turned On.- System is Refilling.

- Set Liquid Active in LiquidParameter for On and Savedata.- turn off Switch Liquid RefillRequest.

Commerror(Communication Error)

- the signal betweenthe PLC andCOMPUTER is notcomplete.

- check Cable between PLC andCOMPUTER.- check Switch position on CardA1SJ71C24.- check LED signal on CardA1SJ71C24.- CPU of PLC must RUN.- Loop Back Test on CardAISJ71C24 and PLC.

- try to Download the Programon the COMPUTER again.

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