OI Inventory Monitor Units

OI Inventory Monitor Units Bulletin Number: BF6-600 Effective: 9/14/07 Write Down Your Serial Numbers Here For Future Reference: We are committed to a continuing program of product improvement. Specifications, appearance, and dimensions described in this manual are subject to change without notice. DCN No. Copyright 2007 All rights reserved PREFACE

The information in this manual is based on current industry sources and is believed by the author to be correct and complete at the time of printing. It is possible that later changes have been made by the manufacturers of the equipment and are not included in this publication. Although every effort has been made to insure total accuracy, ACS cannot assume any liabilities for omission, errors or changes that have occurred in the production of this manual. It is not possible to anticipate all possible conditions in which this machinery may be utilized, maintained, or serviced. It is not possible to provide cautions for all possible hazards. Operators and maintenance personnel should use standard and accepted operating procedures and precautions. ACS accepts no responsibility for the damages resulting from the utilization of the information in this manual. Copyright ACS Group The material in this publication was compiled for the use of ACS. No part of this manual may be reproduced, stored, transmitted or distributed without the prior written consent of ACS. 1998 Patents Equipment is manufactured under the following patents. Other patents pending. US: 5,261,743-5,172,489-5,148,943-5,110,521-4,756,348-4,454,943-4,148,100-4,108,334 Canada: 1,305,951-1,104,558 UK: 2,256,931B - 2,010,231B France: 92 07272 2

Safety Recommendations The safety features of this machine should never be disconnected during machine start-up, operation, or for servicing. Changes in construction, mechanical or electrical functions, without the written agreement of ACS, will void all guarantees and warranties on this machine. Disconnect the power supply from the machine prior to servicing. Optimum OI Series inventory and density monitor systems are designed to provide safe and reliable operation when installed and operated within design specifications and national and local safety codes. To avoid possible injury or equipment damage when installing or operating this equipment, always use good judgment and follow these safe practices: Follow all SAFETY CODES. Keep fingers away from slide gates, augers, clean-out, and calibration hatches. Because automatic operation may start unexpectedly, A PINCH HAZARD CAPABLE OF CAUSING BODILY INJURY EXISTS ANY TIME THE POWER IS ON. Wear SAFETY GLASSES and WORK GLOVES. Use care when installing, operating or servicing this unit. Disconnect and/or lock out power before servicing or maintaining the blender. Use care when LOADING, UNLOADING, RIGGING, or MOVING this equipment. Operate this equipment within design specifications. OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment. You should remove the fuses and carry them with you. 3

Disconnect and lock out power and compressed air before attempting to clean out an auger and slide gate area. NEVER PUT FINGERS OR TOOLS IN AN AUGER OR SLIDE GATE AREA. Make sure the components are properly GROUNDED before you switch on power. Do not jump or bypass any electrical safety control. Do not jump or bypass any pneumatic safety control. Do not restore power until you remove all tools, test equipment, etc. and until the blender and related equipment is fully assembled. Only PROPERLY TRAINED personnel familiar with the warnings and instructions in this manual should work on this equipment. 4

Shipping Information OI Series 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 Shipping Damage According to the contract terms and conditions of the Carrier, the responsibility of the Shipper ends at the time and place of shipment. Notify the transportation company s local agent if you discover damage Hold the damaged goods and packing material for the examining agent s inspection. Do not return any goods before the transportation company s inspection and authorization. File a claim with the transportation company. Substantiate the claim by referring to the agent s report. A certified copy of our invoice is available upon request. The original Bill of Lading is attached to our original invoice. If the shipment was prepaid, write us for a receipted transportation bill. Advise customer service regarding your wish for assistance and to obtain an RMA (return material authorization) number. If the Shipment is Not Complete Check the packing list as back-ordered items are noted on the packing list. In addition to the equipment itself, you should have: Bill of lading Packing list Operating and Installation packet Electrical schematic and panel layout drawings Component instruction manuals (if applicable) Re-inspect the container and packing material to see if you missed any smaller items during unpacking. If the Shipment is Not Correct If the shipment is not what you ordered, contact parts and service department immediately at (847) 273-7700. Have the order number and item number available. Hold the items until you receive shipping instructions. 5

Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department. 6

Figure OV.1. Typical Model OI Series UPPER MATERIAL HOPPER (LOAD BY CUSTOMER) OPTIONAL PNEUMATIC KNIFE GATE ADJUSTABLE, SOLID STATE, HIGH LEVEL PROX. SENSOR 111 WEIGH HOPPER OPTIONAL FLOOR STAND WITH SURGE HOPPER OPTIONAL VACUUM TAKEOFF BOX 48 7

General Description of OI Series System The OI Series inventory control system is used for in line process system weighing and totaling of resin usage. The modular unit is equipped with a material supply hopper, with a discharge-metering valve, mounted over a batch weigh hopper. An adjustable level sensor is mounted on the weigh hopper. The OI Series system is mounted over a holding hopper or processing machine hopper and is provided with a proximity sensing level switch that is field mounted into the lower holding hopper. When the level switch is uncovered with material, the unit will start its cycle. 1. The pre-filled upper supply hopper dump valve will open. 2. Material will flow into the weigh hopper below until the level is reached at the proximity sensor. The level sensor proximity switch controls the batch size. 3. The computer control will shut off the upper material supply hopper dump valve, and read the weight in the weigh hopper after settling has occurred. 4. The computer will record and totallize the weight. 5. After the loaded weigh hopper has been weighed, the discharge valve on the bottom of the weigh hopper will open. The valve will stay open until the material has been emptied into the lower holding hopper. 6. When the scale has sensed that no material is remaining in the weigh hopper the discharge valve will close on the weigh hopper. 7. The computer control will check the level sensor in the holding hopper and when the sensor uncovers due to material leaving the holding hopper, the inventory unit cycle will repeat as in steps 1-6. The system can be tied into a central computer for total material flow monitoring, or can be used as a stand alone inventory unit. The standard unit is provided to work with any vacuum loading system, as the system will have its own level control to keep the upper supply hopper of the OI Series unit full. 8

Computer Control Panel The computer control panel is normally mounted on the OI Series frame and is connected to the components with plugs. The central computer is a modular embedded system controller. This design provides excellent system performance along with an easily replaceable control panel in case of failure of any computer or electronic component part. The display and keypad menu format is very simple. simply enter in the proper recipe and start the unit. After installation and setup, If it is desired to have a local display and control of the unit at the operator station, an optional RS485 serial communications RCP (Remote Control Panel) is available at extra cost. Back Up key (Recipe Adjustment) Abort Cycle Enter key Start cycle key Stop at end of cycle Clear key Numeric Entry keys 9

OI Series Menu Structure Layout MAIN MENU: 1.) STARTUP 2.) SETUP 3.) CALIBRATION 4.) INVENTORY 5.) DIAGNOSTICS 6.) PRINTER 1.) STARTUP 1.1) NEW BATCH 1.2) RESUME BATCH 2.) SETUP 2.1) SET TOLERANCE WEIGHT 2.2) SET BAUD/ID 3.) CALIBRATION Quick Keys To reach any of the menu items shown when viewing the 1.) STARTUP menu, simply key in the number shown in the box preceding the item. Press the BACKUP key several times to return to the 1.) STARTUP screen, if necessary. 3.1) CALIBRATE SCALE 3.2) DIRECT SCALE READOUT 4.) INVENTORY 4.1) VIEW INVENTORY 4.2) CLEAR INVENTORY 4.3) SET INVENTORY SHUTDOWN 5.) DIAGNOSTICS 5.1) DISPLAY SCALE A/D 5.2) OPERATE LOADER 5.3) OPERATE DUMP VALVE 5.4) OPERATE KNIFE GATE 5.5) LEVEL SWITCH STATUS 6.) PRINTER 6.1) BATCH INTERVAL 6.2) JOB NUMBER 6.3) PRINT INVENTORY 6.4) DISPLAY TIME/DATE 6.5) SET TIME 6.6) SET DATE 6.7) PRINTER TEST 10

Installation and Setup of the OI Series Unit 1) Install the weigh system on the top of an intermediate storage bin or on the top of a processing machine. 2) Use care to ensure that the frame is mounted in a level position, to insure that the weigh hopper will not bind and is weighing accurately. 3) Connect the compressed air line with a proper 5 micro filter and regulator. 4) Set the compressed air pressure at approximately 40-50 PSI. 5) Plug in the power plug into a 110V receptacle. It is important that the power supply for the unit be checked to ensure that it is Clean power. An uninterrupted power supply may be required (not included). 6) If voltage spikes are causing problems with the unit in operation, such as random stopping and reverting back to the startup menu, install an uninterrupted power supply that can be purchased at any local computer store. 7) Turn on the control panel. The display should show the 1) STARTUP menu. 8) Calibrate the weigh scale by pressing the 3 and the 1 key (3,1) to enter the menu. Follow the menu prompts to set the zero tare weight and the calibration weight values. The display will verify correct calibration. 9) Set the desired tolerance weight value by pressing 2 and then 1 from the main start up menu. This is a control window value to monitor possible bulk density changes from batch to batch. For example, this value could be set at 2 pounds. If the weight of material dumped into the weigh hopper (to the level sensor) varies by more than the tolerance weight value entered, from batch to batch, the system will trigger a Possible Material Bulk Density Change alarm. 10) Position the weigh hopper level sensor. To properly position the adjustable proximity sensor on the weigh hopper, place the unit in direct scale read out (Calibration menu) or press (3,2) from the 1) STARTUP screen. Manually fill the weigh hopper, looking at the scale read out, until the scale A/D reading is approximately 3800 or until the weigh hopper is physically full. Do not overfill the weigh hopper. This will ensure that the unit is operating at maximum capacity. 11

11) Clear the inventory and set the inventory shut down value (if desired). If inventory shut down is not needed, set this value to zero (0) to disable this feature. 12) Check the field installed lower hopper level switch for proper operation and then the unit is ready to be started. Quick Startup 1. Ensure that the supply hopper is filled with material. 2. Press the number 1 key when the display is showing 1) STARTUP. 3. Then press the 1 key again to start up the unit in New Batch mode. The New Batch mode will open the dump valve if material is in the hopper and start out with a new batch. This is typically used for a new inventory run where the material has been changed and the inventory has been cleared. If the unit is running and stops due to a power failure, or by pressing the End of Cycle key, the unit should be started in the Resume Batch mode. Inventory in the weigh hopper will be recorded. 12

Display Description The OI Series Inventory System uses a standardized menu format. Throughout the menu structure, the top line of the display is used to provide the operator with menu information. The bottom line is used to provide the operator with possible key press options. Main Menu: 1) Startup Press 1 or <ENTER> to see more A typical menu entry is shown in the figure above. The top line of the display includes the menu name, the menu item number and the menu function. Any time the "Main Menu" is displayed in the upper left portion of the display, and the "1" key is pressed, the startup function will be executed. Batch Size The OI Series Inventory System is a gravimetric batch system. The system will weigh a batch of material each cycle. This batch size is determined by the placement of the adjustable proximity sensor mounted on the weigh hopper. Because the system must handle a variety of materials, with varying bulk densities, the actual amount of weight of material the weigh hopper will hold can vary dramatically from application to application. The weigh hopper size selected should be one that approaches the maximum capacity of the load cells (A/D reading in diagnostics of a maximum of 4095), and does not allow the weigh hopper to physically overfill. During the initial setup of each system, the weigh hopper size setting (proximity switch location) should be checked to ensure that the weigh hopper is not overfilling due to a large percentage of lightweight material. The position of the proximity sensor on the weigh hopper will probably vary. 13

Auto Inventory Shutdown In many applications, the user of the OI Series System produces large runs of blended material on the same recipe during production. An example may be a 40,000 lb run of a certain specification plastic extrusion. Others may wish to fill a 1,000 lb. gaylord box in a central blending application. In either case, the manufacturer has provided a means to automatically stop the blending system when the blended material has reached a preset total blended weight. This is known as Automatic Inventory Shutdown. When the Auto Inventory shutdown value is reached, the system will finish the current batch of material. It will then stop, and display to the operator that the inventory value has been reached. To enable this feature, simply program in a desired shutdown weight value into the Auto Inventory Shutdown display line, following the keystroke instructions on the second line. To disable this feature, simply program in a (0) Zero Value. Printer Menu The OI Series Inventory System may be purchased with an optional printer. When this option is specified, an additional printer menu is available to the operator. This menu is displayed in the OI Series Menu structure shown in this manual. The printer menu is accessed by selecting #6 from the main menu. The printer is used to obtain batch ticket and inventory information. A batch ticket contains the time & date information, the job number, and the accumulated inventory numbers. It should be noted that the printed inventory might not match the percentage shown, as the percentage shown is the actual system percentage running the current recipe. The inventory, depending on when it was manually cleared, may or may not reflect the current recipe inventory. Some customers like to run an accumulated inventory on ingredients coming from silos, etc., although several different recipes have been run on the system. Others like to clear the inventory every time the recipe is changed. The system gives the operator the choice of either method. 14

The Printer Menu contains the following sub-menu options. Batch Interval Job Number Print Inventory Display Time & Date Set Time Set Date Printer Test Batch Interval The batch Interval item under the printout menu allows the operator to set the number of batches. Simply enter in the desired batch interval. The printouts will occur each time that the number of batches programmed is produced. This is done by pressing "START" to change, enter the number of batches between printouts, and press the "ENTER" key. Job Number Some applications call for tracking a job number. The OI Series System will provide this by allowing the operator to assign a job number. This job number may be up to 8 digits long. It is held in memory and will be printed out on every batch ticket until it is changed to the next job number. This number is simply a reference number for the operator, or management. Print Inventory The print inventory menu item is used to produce on demand, inventory printouts. Before selecting this item, be sure that the printer is properly connected and ready. This function will generate an inventory printout with the current date & time information. Display Time & Date The display Time and Date item on the printer menu is used to verify the current time and date information. 15

Set Time The set time item located in the printer menu allows the operator to set the OI's internal time clock. The clock data must be entered in the traditional: Set Date HH = Hours MM = Minutes SS = Seconds The set date item located in the printer menu allows the operator to set the OI's time clock date. This internal clock must be entered in the traditional: MM = Month DD = Day YY = Year (Last 2 digits) 16

Technical Assistance Parts Department Call toll-free 7am 5pm CST [800] 423-3183 or call [847] 273-7700 Fax: [847] 273-7812 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications, which will maximize your equipment s performance and efficiency. To assist in expediting your phone or fax order, please have the model and serial number of your unit when you contact us. A customer replacement parts list is included in this manual for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service. Service Department Call toll-free 8am 5pm CST [800] 423-3183 or call [847] 273-7700 Emergencies after 5pm CST, call [847] 439-5655 We have a qualified service department ready to help. Service contracts are available for most products. Service contracts are available for most of our products. www.acscustomerservice.com Sales Department Call [847] 273-7700 Monday Friday, 8am 5pm CST Our products are sold by a world-wide network of independent sales representatives. Contact our Sales Department for the name of the sales representative nearest you. Contract Department Call [847] 273-7700 Monday Friday, 8am 5pm CST AEC, Inc. 1100 E. Woodfield Road Suite 588 Schaumburg, IL 60173 17

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