adaptive
CONTROL
SOLUTIONS
DDS3000
Dispensing and Distribution System
Copyright © Adaptive Control Solutions Ltd 2003
The entire contents of this document is the property and copyright of Adaptive Control Solutions Ltd and therefore may not be
reproduced in whole or part without the written permission of Adaptive Control Solutions Ltd.
DDS3000
Operating Manual
Contents
Introduction....................................................................................................................................................4
System Overview: ..........................................................................................................................................5
Operation and Alarms: ...................................................................................................................................7
Operation Bar: ...................................................................................................................7
Alarm Bar: .........................................................................................................................7
Stop: ...................................................................................................................................................8
Expert:................................................................................................................................................8
Clean: .................................................................................................................................................8
Work List: ......................................................................................................................................................9
New Dispense: ...........................................................................................................................................9
Edit Dispense: ..................................................................................................................10
Add Product: ....................................................................................................................10
Select: ..............................................................................................................................10
Order: ...............................................................................................................................11
Delete: ..............................................................................................................................11
Blocked: ...........................................................................................................................11
Current Tasks: ..........................................................................................................................................13
ReOrder Dispense: ...........................................................................................................13
Aborting / Deleting a Dispense: ......................................................................................14
Blocking and Unblocking Dispenses: ..............................................................................14
Ended Tasks: ............................................................................................................................................15
Fault: ................................................................................................................................16
Refresh: ............................................................................................................................16
Filter:................................................................................................................................16
Activity Log: ............................................................................................................................................17
Update: .............................................................................................................................17
Current: ............................................................................................................................17
Save: ................................................................................................................................17
History: ............................................................................................................................17
Load: ................................................................................................................................17
Mimic:..........................................................................................................................................................19
Products: ..................................................................................................................................................19
Notes: ...............................................................................................................................21
Restock: ...........................................................................................................................21
Ignore: ..............................................................................................................................22
Requires Priming: ............................................................................................................23
Undo Changes:.................................................................................................................24
Notes: ...............................................................................................................................24
Dispense:..................................................................................................................................................25
Flush: ...............................................................................................................................27
Full System Flush: ...........................................................................................................27
Product Line 1: ................................................................................................................27
Product Line 2: ................................................................................................................27
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Contents
Expert:..........................................................................................................................................................28
About: ..............................................................................................................................28
Engineer: ..........................................................................................................................28
Normal Mode: ..................................................................................................................29
Test Mode: .......................................................................................................................29
Simulation Mode: ............................................................................................................29
Parameters: ......................................................................................................................30
Inputs: ..............................................................................................................................30
Outputs:............................................................................................................................30
Aborting an Active Dispense: ......................................................................................................................31
Shutting The System Down: ........................................................................................................................32
System Start-up:...........................................................................................................................................34
Numeric Keypad: .........................................................................................................................................35
Index: ...........................................................................................................................................................36
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Introduction
Introduction
The DDS3000 is a simple but sophisticated dispensing and distribution system with the following
features:
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Designed for both batch and continuous operations.
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The system can have up to 6 groups each of products and destinations, and up to 30
products/destinations in each group.
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Works with the suppliers’ containers, in order to eliminate intermediate storage vessels.
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Only one variable speed chemical pump is used to extract the product from its storage
container and also to deliver it to the required destination.
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A high accuracy flow meter is used throughout the complete dispensing range.
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A single flooded distribution line, complete with 3-way destination valves, allows the
control software to operate the destination valves just before the chemical slug arrives at
the machine.
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After each dispense the complete destination line can be purged either with hot or cold
water, depending on the previous product dispensed.
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The system is controlled by an Adaptive touch screen industrial pc, which can be operated
in a stand-alone mode or can be connected to third-party recipe-formulation systems for
integrated dispensing.
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The windows based control system maintains stock of all products connected to the system
and will inhibit a dispense if there is insufficient product available.
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The system creates a history for each dispense in its industry standard database and past
dispense data can be viewed and can easily be interrogated by external systems.
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Multiple chemicals can easily be dispensed to each machine.
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Operators are informed of when to restock the products.
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System Overview
System Overview:
The Product Line consists of a series of 3-way pneumatic valves, one for each product. One end of the
product line connects to the double diaphragm pump and at the other end there is a hot and cold water
valve, used to flush or pre-heat the line. If there is more than one product line a 3-way valve is used to
select the correct product line for the product to be dispensed
A re-enforced flexible hose connects the 3-way pneumatic product valve to its dip tube. The dip tube is
placed into the suppliers’ storage container (IBC, barrel, bulk storage container, etc) for each product.
Each 3-way product valve is fitted with a micro switch, which is used to ensure the valve operates
correctly.
Product Line
Product Valve
Valve Feedback
Micro Switch
Flexible Hose
Flush Valves
Dip Tube
Figure 1: Product Line.
Opening the product valve and turning the pump on dispense products. The pump, a double diaphragm
pneumatic pump, energises and sucks the product out of its container. As well as sucking the product
out of the storage container the pump also pushes the product through the flow meter down the
Destination line to the desired destination. The pump will operate at different speeds throughout the
dispense.
Pump drain
Figure 2: Pump and flow meter.
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System Overview
The Destination line is stainless steel and runs around the factory past all the destinations and to a
drain at the end of the line. A 3-way valve (with a micro switch) fitted in-line with each destination
opens and allows the product to be dispensed to the selected machine.
Figure 3: Destination line.
Once the required amount of product has been dispensed water pushes the slug of product down the
destination line to the selected destination (machine). Once the product has dispensed to machine the
system flushes, cleans the product and destination lines.
Both lines remain flooded at all times.
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Operation and Alarms
Operation and Alarms:
Figure 4: Operating screen.
The operation and the alarms bars are located at the top of the screen.
Figure 5: Operation and alarm bar.
Operation Bar:
The left hand Bar shows what operation the system is currently performing.
Figure 6: Operation bar.
Alarm Bar:
The right hand bar shows any alarms that are active or any problems with the system.
Figure 7: Alarm bar.
If there is an alarm, a window displaying what the problem is will display and the beacon and siren will
operate. Pressing the
button will silence the siren and stop the beacon flashing. The stop
button will automatically operate. Until the fault is cleared the stop button will not operate (See page 8).
Figure 8: Alarm boxes.
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Operation and Alarms
Stop:
The ‘Stop’ button can be pressed if there is a problem or you wish to shutdown the system (See page 32).
When an alarm becomes active, due to their being a system failure, the emergency stop has been pressed or
a dispense has been aborted, the ‘Stop’ button will automatically engage
, the siren and beacon will
operate to alert the operator and a message box displaying the failure is will display.
Figure 9: Alarm message box.
Pressing the
button will silence the siren and stop the beacon flashing.
This will not remove the fault it merely silences the alarm. Only when the fault has been rectified can the
stop button be depressed again and normal operation resumed.
Note:
If during a dispense the
button is pressed, the dispense will pause.
Figure 10: Dispense paused.
The dispense will restart once the
button has been pressed again.
Expert:
See Expert Section.
Clean:
As the Adaptive Control System uses a touch screen it maybe necessary from time to time to clean the
screen.
The
disables the touch screen and allows it to be cleaned.
Figure 11: Clean screen.
Once the time has elapsed for cleaning the screen will revert back to being a touch screen.
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Work List- New Dispense
Work List:
The ‘Work List’ button enables the operator to add new dispenses’, view any dispenses scheduled up, view
dispenses that have ended, and view the activity log.
Figure 12: Work List.
New Dispense:
This button is used .to create a new dispense.
Select the ‘Destination’ by pressing the button for the machine you want to dispense to.
Now press the tick at the bottom right of the screen.
Figure 13: Select destination.
The screen will change and ask you to select the “Product” you wish to dispense.
Figure 14: Select product.
Select the product by pressing the appropriate button, then the tick at the bottom right of the screen.
Note:
At any time the dispense can be cancelled by pressing the cross at the bottom left of the screen
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Work List- New Dispense
You will be prompted to enter the required amount of product to be dispensed. Using the numeric keypad
(to the right) enter the amount of product to be dispensed (For help using keypad see page 35). Once
correct press the green tick at the bottom right of the screen.
Figure 15: Amount of product.
Edit Dispense:
If you make an error, use the “Edit” buttons to change the product or change the amount of product.
Figure 16: Edit dispense.
Add Product:
The “Add Product” button allows you to add another product to the current dispense. You can dispense as
many products as you wish.
Figure 17: Add another product.
Select:
Use the Select button to move up and down the list of products to be dispensed.
Note:
At any time a dispense can be cancelled by pressing the cross at the bottom left of the screen.
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Work List- New Dispense
Order:
The “Order” buttons change the order of the products. Whichever product is selected, using the up and
down arrows will move that product up and down the dispense order (Use the Select up and down arrow to
select the product whose order you wish to change).
Figure 18: Change product order.
Delete:
The Delete button will delete the selected product from the list.
Figure 19: Delete a product.
Blocked:
Ticking the Blocked box stops the dispense you have just created from being started. It will stay in the
dispense queue until all dispenses in front of it have gone and it is Unblocked (See page 13).
If blocked is not ticked the dispense will schedule itself as the next dispense to start.
Figure 20: Blocked.
Once you are sure all the information for the dispense is correct, press the green tick at the bottom right of
the screen.
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Work List- New Dispense
If the amounts of product are acceptable the dispense will be scheduled up, and you will be prompted to
“Add Another Dispense”.
Figure 21: Add New Dispense.
If the minimum and maximum amounts of product are out of the preset limits for each destination, then an
error message will display.
Figure 22: Dispense amount errors.
The product that is causing the error will be the one that is now selected.
You must change the amount for the product that is incorrect.
Press the green tick at the bottom right of the screen again.
Note:
At any time the dispense can be cancelled by pressing the cross at the bottom left of the screen
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Work List – Current Tasks
Operating Manual
Current Tasks:
Figure 23: Current Tasks
The ‘Current Tasks’ screen shows dispenses that have been scheduled in.
Figure 24: Scheduled dispenses.
Above we can see that there are dispenses to 4 machines scheduled. Dispenses will only begin if the
‘Blocked’ column is set to no. Although the last dispense above is set to No it will not dispense unless it is
at the beginning of the list.
By highlighting a dispense (Then Jet 6, above) we can see the products and the amounts programmed to be
dispensed.
Figure 25: Dispense information.
ReOrder Dispense:
The order of the dispenses can be changed by selecting a dispense
and using the ‘Reorder’ buttons. This will move the dispense up and
down the schedule.
Figure 26: Reorder buttons.
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If in the ‘Alarm Bar’ at the top there is an alarm informing you the ‘Requested dispense (s) blocked’, it
means the next dispense in the schedule cannot be dispensed as it is ‘Blocked. You cannot change the order
of this dispense without first pressing the
button. This is due to the fact that the system loads the
details for the first dispense in the queue ready for dispensing.
Figure 27: Requested dispense blocked.
Aborting / Deleting a Dispense:
As it is possible to Abort a dispense once it has commenced dispensing, a dispense must be aborted before
it can be deleted (even if it has not started).
Select the appropriate dispense and press the ‘Abort’ button (Figure 27). You will be asked if you are sure
you want to abort (Figure 28) the dispense, press the tick. The dispense is now aborted and will have
moved to the end of the list. You can only actually delete the dispense if it is blocked. Once the dispense is
blocked the ‘Delete’ button becomes active. ‘Press the ‘Delete’ button (Figure 29). You will be asked if
you are sure you want to delete (Figure 30).
Figure 28
Figure 29
Figure 30
Figure 31
Blocking and Unblocking Dispenses:
As it can be seen below some of the dispenses are “Blocked” and some are not. When a New Dispense
(See page 9) is created you can select whether the dispense is “Blocked” or not.
Figure 32: Blocking and unblocking
To “Block” or “Unblock” a dispense simply select the appropriate dispense and press the
button.
To “Block” or “Unblock” all the dispenses use the ‘All (Unstarted)’
and
buttons.
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Work List - Ended Tasks
Ended Tasks:
The ‘Ended Tasks’ screen shows dispenses that have ended. All the information for each dispense is stored
in the database and this is where the information is displayed. Select the dispense you wish to view the
information for.
Figure 33: Ended Tasks.
The ‘Destination’, the ‘Started’ date - time, the ‘Ended’ date - time, and any ‘Makeup’ litres used are
shown here for each dispense. ‘Makeup’ is used on a system that requires extra water to be added to a
dispense. This feature is traditionally used on continuous operations where a batch of chemicals is
dispensed, followed by a pre-programmed amount of ‘makeup’ water.
Figure 34: Ended dispense destination.
The ‘Product’ and the ‘Amount’ to be dispensed can be seen at the bottom left side.
Figure 35: Ended dispense product.
Select the product you wish to view the information for. . . . .
The actual ‘Amount dispensed’ the ‘Excess’ and the ‘Shortfall’ (if any) are shown on top line. If the line
had to be primed first you can see the ‘Priming amount used’. ‘Water Used’ is the total water used for the
whole dispense (all the products). ‘Startup delay’ is the time after the dispense was created until it actual
started to dispense (either queued up or blocked). ‘Duration’ is the total time for all products and flushes
for the whole dispense to be completed. ‘Id’ is the identification number of the dispense in the database and
‘Fault’ shows any faults present during the dispense.
Figure 36: Ended dispense data.
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Work List - Ended Tasks
Fault:
If there is a fault during a dispense, the dispense will automatically be Aborted. The system will alarm and
the
button will energise (See page 8). The
button will not de-energise until the fault has
been cleared. Before the next dispense is started the system will automatically flush the product and
destination lines. The reason for the fault can be seen in the ‘Fault’ box.
Figure 37: Ended dispense fault.
Refresh:
The yellow background on the ‘Refresh’ button indicates that there are dispenses that have finished but not
been updated in the list, or a filter (see below) has been applied and the list requires updating. Press the
‘Refresh’ button, the dispense listing will update and the Refresh button will now be greyed out. .
Figure 38: Ended dispense list refresh.
Filter:
A dispense filter has been provided to make it easier to view certain dispenses.
Selecting
will display all the dispenses stored in the database.
Selecting
will display all dispenses with no fault stored in the database.
Selecting
will display only dispenses with faults stored in the database.
You can also filter the dispense by days or between dates.
Selecting
will display all the dispenses during the Last day.
Selecting
will display all dispenses during the last 7 days.
Selecting
will display all in the dispenses during the last 30 days.
Selecting
will allow the start and end dates to be selected.
The top box is the start date
The bottom box the end date.
Figure 39: Dispense filter.
Use
to open the calendars.
Figure 40: Calendar.
Select both dates and press the
will be displayed.
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(Refresh) button and a listing of all the dispenses between the two dates
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Work List – Activity Log
Activity Log:
An ‘Activity Log’ is generated with every dispense. Every time the system performs an operation during a
dispense it is logged. A parameter (save log files) in the “Schedule “ section of “Parameters” determines
whether every dispense log is stored manually, manually and dispenses with faults, only dispenses with
faults or all dispenses.
Figure 41: Activity Log.
Update:
Whenever the ‘Update’ button has a yellow background, it means
that the current data displayed is not the latest. Press to update.
Current:
Pressing the ‘Current’ button followed by the
(Update) button, will display the data for the current
dispense. If the ‘Update’ button does not have a yellow background
the data currently displayed is
that for the latest dispense.
Save:
Pressing the ‘Save’ button will save the current log to a file.
History:
The ‘History’ button gives access to any dispense log that have been saved (as above).
After pressing the ‘History’ button a ‘Load’ button will appear (see below).
Load:
The ‘Load’ button will open up a window
showing all the saved dispenses.
Figure 42: Activity log history.
.
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Activity Log – Ended Tasks
If there is a particular dispense log you wish to view, the easiest way is to locate it in the ‘Ended Task’ list
(see page 15) and note its Id (shown at the bottom right), back to ‘Activity Log’
and look
for the saved log file with the same Id number.
Figure 43: Activity log saved files.
When you have selected the log file you wish to view and press
log files. You can now view the detail for the dispense.
. Pressing
closes the list of saved
Figure 44: Activity log history data.
From the log file we can see the following data.
Lapsed: Is the time to 1/100th of a second, from when the dispense started till when the next operation in
the dispense occurred.
State: Tells us what the dispenser was doing.
Flow: Tells us the flow rate from the flow meter.
Vol: Shows us what the volume is of whatever is has gone through the flow meter.
H20: Shows us when either the hot or cold water output is on. 1 = on, 0 = off.
ProdV: Indicates a product valve is open, 1 = on, 0 = off.
ProdL: Indicates which product line is open.
Pump: Shows us what speed the pump was running at 1,2 or 3. 0 = pump is off.
LoFlo: Indicates if the flow rate is low.
PDrn: Indicates when the pump drain valve is open, 1 = on, 0 = off.
DestL: Indicates which destination line is used.
DestV: Shows us when the destination valve is open. 1 = open, 0 = closed.
LDrn: Shows us when the drain at the end of the line is open. 1 = open, 0 = closed
MkUp: Shows when the makeup valve is open. 1 = open, 0 = closed
Figure 45: Activity log details.
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Mimic - Products
Mimic:
The ‘Mimic’ button enables the operator to view the information relating to each product, to re-stock them
and to view what is happening on the system with the animated mimic.
Figure 46: Product mimic.
Products:
The ‘Products’ button enables the operator to view all the products and see how much of each is left and
which need re-stocking. He can also view the notes about the products and enter the re-stocking
information. By the right hand side of the storage container is a level indicator, indicating the amount of
product left on the container.
Below we can see that the CETAPLEX storage container has 439kg and CHROMAQUEST 245kg of
product. The CERACLEAN 119 barrel is nearly empty, a red warning indicator is visible. The
CHROMATECH barrel is also nearly empty, but with an amber warning indicator visible.
Amber Warning Indicator
The amber warning indicator will come on first, when the amount of product left in the storage container is
below the value set in ‘Restock’. (Usually set at 10% of the total) See page 24.
Red Warning Indicator
The red warning indicator will come on next, when the amount of product left in the storage container is
below the value set in ‘Restock’. (Usually set at 7% of the total) See page 24.
Figure 47: Product restock warning.
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Product Warnings
Whenever a products stock weight drops below values set in ‘Restock’ not only do we first get the amber
warning light, then the red one, but we also get an alarm informing us which products stock is low.
Figure 48: Product low alarm.
Pressing the
button will silence the siren and stop the beacon flashing. Until the product is restocked
the alarm message will appear at the top of the screen in the Alarm Bar.
Figure 49: Product low alarm bar.
Insufficient stock for a dispense.
If a dispense tries to start but there is not enough product in its storage container to complete the dispense
an alarm box will appear informing us of this.
Figure 50: Insufficient product alarm.
The
button will also de-energise, and the dispense will stop and put a block on itself.
Figure 51: Dispensed automatically stopped.
You can re-energise the
button, but the dispense will remain blocked. Re-stock the products
storage container, enter the new stock into the system (see Restock: page 21) you can now remove the
block from the dispense and it will continue.
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Product Notes/Restock
When a product is being dispensed, a green indicator appears next to it, the weight of the product in the
storage container will decrease as it is dispensed to the destination.
Figure 52: Product dispensing indicator.
Notes:
By selecting a product
and pressing the
button information about the product
including first aid measures can be viewed. Press
when viewing is completed.
Figure 53: Product Notes.
Restock:
‘Restock’ is used to inform the system a product storage container has been changed or re-stocked.
Select the product
you with to restock and press the ‘Restock’ button.
Figure 54: Products restock.
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Product Restock
When a product is being dispensed, a green indicator appears next to the “Restock” button, which is
disabled. You cannot restock a product whilst it is dispensing.
Figure 55: Product restock inhibited.
The left side of the screen shows is where we Restock the system. Enter the amount of product added to the
product container in the ‘Added to:’ box using the numeric keypad. If the product has been changed it may
be necessary to ‘Ignore’ any ‘Current stock:’
If the product container has been changed it will need “Priming” (see Requires Priming: page 23).
Current stock:
This should be the amount of product is left in the product container.
Added to:
This is where we enter how much product we have restocked the product container with. Or if we have
replaced the container, how much the new one contains.
New stock:
This is the total stock, the ‘Current stock’ with the ‘Added to’ added together. This should be how much is
now in the product container.
Figure 56: Restocking.
Ignore:
If there is already ’Current stock’, and instead of topping the product container up we change it for another
one, we will loose the ‘Current stock’ (the amount of product left in the replaced container). The ‘Ignore’
button resets the current reading in the ‘New stock’ box to zero. In other words it removes the stock left in
the old container from the system.
Figure 57: Restock Ignore current stock
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Priming
Requires Priming:
Whenever one of the dip tubes is removed from its container the product inside it will drain out and the dip
tube and pipe work to the valve will fill with air. The air must be removed from the dip tube and pipe
work. This is done by ‘Priming’ the product.
Product Line
Dip tube and pipe
full of product.
Dip tube and pipe
full of air.
Product.
Figure 58: Product needs priming.
If the container for the product has been changed, it is essential that the
button be pressed.
A window informing you that the product has been scheduled to be primed appears.
The system will now generate a dispense that will fill the dip tube and pipe work (to the product valve)
with product. This dispense will start immediately if there is nothing being dispensed at present, else it will
scheduled itself as the next dispense on then list.
You can set the ‘Requires Priming’ to ‘Set as “Blocked”. This will schedule the priming as the next
dispense on the schedule and put a block on it, so it will not start.
Figure 59: Requires Priming.
Figure 60: Priming on the scheduler list.
Once the information is correct press the green tick at the bottom right of the screen. ‘Restock’ can be
cancelled by pressing the cross at the bottom left of the screen.
Figure 61: Finish / cancel restock.
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Products Details
The right side of the screen shows the ‘Other data’.
Specific Gravity:
The value in this box should be that of the specific gravity for the product. It is used to calculate the
amount of product dispensed.
Cost per Kg:
The value in this box should be that of the cost of the product per Kg. This can be used to calculate the cost
of the dispense.
Stock when full:
The value in this box should be that amount of product in the storage container when full. It is used to
display the level in the container and calculate how much product is left (see ‘Products’ screen, page 19).
Low stock (amber):
If the amount of product left in the container falls to less than this value, then the Amber warning indicator
will come on, informing the operator that the product is running out, and needs restocking (See page 19).
Critical stock (red):
If the amount of product left in the container falls to less than this value, then the Red warning indicator
will come on. Alerting the operator that the product has nearly run out, and needs restocking immediately
(See page 19).
Minimum stock:
This is the minimum amount of product that must be kept in the product container. If there is less than this
then it is possible that the system will start sucking in air through the dip tube.
Figure 62: Restock other data.
Undo Changes:
Pressing the ‘Undo changes’ button will undo any changes you have made to any of the boxes in the ‘Other
data’ section. Once the green tick has been pressed you cannot ‘Undo changes’.
Notes:
Pressing the ‘Notes’ button will display the information about the product, including first aid information
(see Notes: page 21). Press the
buton to close notes.
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Mimic - dispense
Dispense:
The mimic dispense screen shows the real-time operation of the dispense system.
Whenever the dispense system is dispensing this screen will show you exactly what is happening in the
system.
Figure 63: Dispenser Mimic.
Product select
valve
Product line 1
or 2 selector Pump Amount of product or
valve
speeds water left to dispense
Destination
Select valve
Cold and
hot water
valves
Product
Line
End of line.
Drain
Destination
Line
Product
storage
container
Product being
dispensed
Product lines
& pump drain
Destination
(machine)
Amount of product
left to dispense
Amount of product
in storage container
Product storage
container level indicator
Speed of dispense
Litres/minute
Total product or water
dispensed
Figure 64: Mimic key.
From the mimic screen above we can see exactly what valves are open. We can see which “product line” is
being used, which product and how much has dispensed and at what speed. What speed the pump is
operating at and to which destination the product is going.
We can also see from the mimic when the product has finished dispensing and how much and at what
speed the flush water is cleaning the system.
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Mimic - dispense
Down the left hand side of the mimic screen is a series of indicators.
These turn green to indicate at what stage the dispense is.
Below the indicators is a circular timer.
The timer operates a various times during different system operations.
Figure 65: Timer.
Figure 66: Mimic indicators.
Initial checks
Initial Checks are performed before every dispense, the system checks all valves are in the correct
position.
Ready
Once the Initial Checks are completed the system is ready.
Flush 1
Before every dispense the system will flush the product line down the pump drain. Also if the system
requires flushing, after an aborted dispense or when a ‘Flush’ has been requested, flush 1 will operate.
Pre-heat
If the product requires the line to be warm the system will perform a pre-heat. The product and dispense
line will be purged with hot water.
Purge
Priming
Priming operates when a product has been restocked and the ‘Requires Priming’ button was pressed.
All the air in the dip tube and hose to the product valve must be removed.
Introduce water
If there is any ‘makeup’ this is when it will be added.
Dispense Product
This indicator shows when product is dispensing.
Chase
Chase is the water put into the system to push the product to the destination after the correct amount of
product has dispensed.
Flush 2
Once the chase water has pushed the entire product to the destination, the system flushes all the pipe-work
to remove any contamination.
Paused
The ‘Paused’ indicator illuminates when the
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Flush
Flush:
The ‘Flush’ button allows you to schedule a system flush or just a product line flush.
Useful if you think there might be some contamination caused by a leaking valve or a leak somewhere in
the system.
Figure 67: Schedule a system flush.
Select the type of flush you require:
Full System Flush:
Selecting a ‘Full System Flush’ will flush both product lines to drain and then flush the destination line.
Product Line 1:
Selecting a ‘Product Line 1’ will flush product line 1 only, to drain.
Product Line 2:
Selecting a ‘Product Line 2’ will flush product line 2 only, to drain.
Once you have selected the Flush type you require, press the green tick button to schedule the selected
flush.
To cancel pressing the red cross button.
The flush will now appear at the top of the schedule list at the top of the list unless there is already a
dispense queued.
Figure 68: Flush in the scheduler queue.
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Expert/About/Engineer
Expert:
When you press Expert you will be asked for a password.
Only when the correct password has been entered
can “Expert” be entered. A number of new buttons
will now appear at the bottom of the screen.
Figure 69: Expert screen password.
Figure 70: Expert buttons.
About:
Pressing this button brings up a window displaying the copyright information and the software version the
controller is running. Press the
button to clear the window.
Figure 71: About.
Engineer:
Used by the Adaptive engineers to view system variables and check computer operations.
The
button is also located here (see page 32).
Figure 72: Engineer Screen.
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Operation Modes
Normal Mode:
Normal mode is the normal running mode of the system. The inputs and outputs are controlled via the
software in the correct sequence.
Important Notice:
Adaptive Control Solutions does not accept any responsibility what so ever as a result of the control
system being switched to any other Mode other than NORMAL.
Test Mode:
Test mode is used to test the digital outputs. When this mode is activated all the digital outputs turn off,
allowing them to be tested individually. If we now press the
button, we can see the screen has
changed (see below).
Figure 73: Test mode output screen.
When Test mode is selected, it overrides any interlocks and should only be used by a supervisor who
understands all the system.
Important Notice:
By selecting Test you are taking full responsibility for any actions carried out.
Adaptive Control Solutions does not accept any responsibility what so ever as a result of any actions
performed when the Test Mode is used.
Pressing any output will now activated it. The box alongside the output will turn from purple to turquoise
indicating the output is on. Press the output again to turn it off.
Once testing has been finished press the
button to resume automatic operations, then press the
button now to stop unauthorised access.
Simulation Mode:
Simulation mode is used to test the software. None of the inputs and outputs actually function in this mode.
Once simulation has finished press the
button to resume automatic operations then
press the
button now to stop unauthorised access.
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Parameters/Input/Output
Parameters:
This is where some of the parameters for setting up the system are located. These should not be altered
without first discussing any changes with one of the Adaptive engineers.
Figure 74: Parameter screen.
Inputs:
The “Inputs” screen shows the current state of all the signals coming back to the controller from dispensing
system. From here we can see if a valve is not operating correctly, if the box is green by the valve it means
the system is expecting it to the position it is in. If the box is red then the valve is either open when it
should be shut or vice versa.
Figure 75: Inputs screen.
Outputs:
The “Outputs” screen shows the current state of all the signals going to the dispensing system. From here
we can see if a valve is operating. If the box is green by the valve it means the system is telling the valve to
operate.
Figure 76: Outputs screen.
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Aborting A Dispense
Aborting an Active Dispense:
If there is a dispense running and it needs to be stopped and aborted, the easiest way is to press the
button. The dispense will now pause.
Figure 77: Dispense Paused.
Select the
followed by the
button. Select the current batch (top of the list) and press the
button (see page 14). You will be asked if you are sure you want to abort, press ‘Yes’. The dispense is now
aborted.
Figure 78: Aborting a dispense.
An alarm box will appear informing you of the Manual Abort, press
, another alarm box will appear
informing you the ‘Stop’ button is pressed. The “Stop” button automatically de-energises when a dispense
is aborted. This is to stop the next dispense starting, until you are ready.
Figure 79: Manual abort.
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Shutting down the system
Shutting The System Down:
The APC is basically a Personal Computer, and like any computer it must be shut down correctly.
Firstly you must exit the dispensing system program.
Press the
button and enter the password.
A new set of buttons will appear.
Figure 80: Expert screen buttons.
Press the
button, and a new screen will appear.
Figure 81: Engineer screen.
Press the
button. You will be asked if you are sure, press the tick.
Figure 82: Engineer screen shutdown.
The dispensing system program will now shutdown and you will find yourself on Windows desktop.
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Press the
Operating Manual
Shutting down the system
button at the bottom left of the screen,
Figure 83: Windows Shut Down.
Select the
option.
The Shut Down Windows box will appear.
Figure 84: Shut down the computer.
Make sure
is selected. Press
and Windows will start to shut down.
The screen will go blank; a short time later a message box with “Please Wait While System saves Data” is
displays. Finally the Shut down Computer window appears “It is now safe to turn off your computer”
Open the panel and turn the on /off switch on the back of the computer to the “off” position.
There is UPS (uninterruptible power supply) supplying power to the computer (located in the bottom of the
panel). There is an on/off push button (illuminated green) on the front of these units. Press the on/off push
button to turn the UPS off; it will no longer be illuminated green.
It is best to power down the UPS on long shutdown periods.
Note: If the supply to the UPS is removed it will emit an audible signal indicating the controller is running
on battery backup.
Turn the compressed air off to the pneumatic panel.
Turn the power on to the control panel.
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System Start-up
System Start-up:
Ensure the hot and cold water supplies are turned on to the product lines and the compressed air is turned
on to the pneumatic panel.
Turn the power on to the control panel.
Open the control panel door and turn the UPS on (uninterruptible power supply, located in the bottom of
the panel). There is an on/off push button on the front of these units to turn the UPS on.
On the back of the computer is an on/off switch. Turn the switch to the “On” position.
The controller will now power up.
It will automatically start Windows and run the dispensing system program.
If the dispensing system program does not start-up, double press the Adaptive DDS3000 icon on the
desktop.
Figure 85: Start-up Icon.
There is a white illuminated push button on the panel door “Control/Reset”. This indicates there is power
on to the control systems.
If the Emergency Stop button has been pressed or power to the panel has been lost the white illuminated
push button will not be illuminated, instead the red lamp on the door “Emergency” will be illuminated.
Press the white illuminated push button and power should be restored. If not check the Emergency Stop
button has not been pressed.
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Numeric Keypad
Numeric Keypad:
Select the box where you want to enter the numbers, the cursor should now be flashing in the box. Press the
numbers you require. There are a few extra keys, see below
Moves then cursor right.
Moves then cursor left.
Deletes the last digit.
Deletes the entire number.
Figure 86: Numeric keypad.
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Index
Index:
A
E
Aborting a dispense .............................................31
About .................................................................28
Activity Log .......................................................17
Actual amount dispensed .....................................15
Add another product to a dispense ........................10
Air in the dip tube ...............................................23
Alarm Bar .............................................................7
Amber warning indicator .....................................19
Amount of product added.....................................22
Edit a product or amount of a dispense..................10
Engineer .............................................................28
Excess dispensed .................................................15
Expert.............................................................8, 28
Expert buttons .....................................................28
B
Blocking a new dispense ......................................11
Blocking and unblocking dispenses ......................14
C
Cancel new dispense......................................12, 27
Change the order the products are dispensed .........11
Changing the order of scheduled dispenses ...........13
Changing the storage container.............................22
Chase water indicator ..........................................26
Clean ....................................................................8
Cleaning the screen ...............................................8
Cost of product per kg .........................................24
Creating a new dispense.........................................9
Critical stock red warning indicator ......................24
Current dispense information, activity log .............17
Current stock ......................................................22
Current Tasks ......................................................13
Faults during a dispense .......................................16
Filter by dates, calendar selectable ........................16
Filter the ended dispense by fault or days ..............16
Flexible hose .........................................................5
Flow meter............................................................5
Flush 1indicator ..................................................26
Flush 2 indicator .................................................26
Flush valves ..........................................................5
Flushing the system .............................................26
Forcing outputs ...................................................29
Full system flush .................................................27
I
Ignore .................................................................22
Ignore the Current stock.......................................22
Initial checks indicator .........................................26
Inputs .................................................................30
Insufficient stock alarm .......................................20
Introduction ..........................................................4
K
Keypad operation ................................................35
D
Deleting a dispense..............................................14
Destination Line ....................................................6
Dip tube..............................................................23
Dip Tube ..............................................................5
Dispense amount below minimum error ................12
Dispense amount exceeded error ..........................12
Dispense data table labels ....................................18
Dispense Id .........................................................15
Dispense shortfall ................................................15
Dispense status indicators ....................................25
Dispense system mimic .......................................25
Dispenses in the scheduled queue .........................13
Double diaphragm pump ........................................5
Drain -flush........................................................27
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F
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L
Level indicator ....................................................19
Load historical dispense information ....................17
Low stock amber warning indicator ......................24
M
Makeup ..............................................................15
Manual abort .......................................................31
Micro switch feedback ...........................................5
Micro switches ....................................................30
Mimic.................................................................19
Mimic indicators .................................................25
Mimic key ..........................................................25
Mimic Product screen ..........................................19
Mimic timer ........................................................26
Minimum stock in each product container .............24
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Restock Red warning indicator .............................19
N
New dispense completed ......................................11
Normal ...............................................................29
Numeric keypad operation ...................................35
O
Operation and Alarms ............................................7
Operation Bar .......................................................7
Outputs ...............................................................30
Over-ride warnings ..............................................29
P
Parameters ..........................................................30
Password ............................................................28
Paused indicator ..................................................26
Pre-heat indicator ................................................26
Pre-heat the dispense line .....................................26
Priming...............................................................23
Priming indicator.................................................26
Product being dispensed indicator...................21, 26
Product level indicator .........................................19
Product line ..........................................................5
Product line 1 flush .............................................27
Product line 2 flush .............................................27
Product line divert .................................................6
Product notes ......................................................24
Product notes and safety information ....................21
Product select valve (product valve) .......................5
Product stock low alarm.......................................20
Pump drain ...........................................................5
Pump speeds .........................................................5
Purge indicator ....................................................26
R
Ready indicator ...................................................26
Red warning indicator..........................................19
Refresh the ended dispense list .............................16
Requested dispense blocked alarm ........................14
Requires Priming.................................................23
Restock Amber warning indicator.........................19
Restock products .................................................21
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S
Safety information ...............................................21
Safety notes ........................................................24
Save the current dispense information ...................17
Selecting a destination to dispense to. .....................9
Selecting a product from a new dispense list .........10
Shutdown .....................................................28, 32
Shutting down Windows ......................................33
Shutting the system down ....................................32
Simulation ..........................................................29
Software reference...............................................28
Specific gravity of a product ................................24
Stock when full ...................................................24
Stop button ...........................................................8
Stop pressed ........................................................20
Stopping a new dispense from starting ..................11
System checks .....................................................26
System Overview ..................................................5
System paused ....................................................26
System ready ......................................................26
T
Test ....................................................................29
Testing valves .....................................................29
Timer .................................................................26
Total product in the storage container ...................24
Total product stock ..............................................22
U
Undo changes to product information ...................24
Uninterruptible power supply ...............................33
Update the activity log .........................................17
V
View historical dispense information ....................17
W
Water used ..........................................................15
Work List .............................................................9