CBT LW 4-PUMP ADD-ON INTERNATIONAL INSTALLATION GUIDE

Transcription

1 CBT LW 4-PUMP ADD-ON INTERNATIONAL INSTALLATION GUIDE

2 2 General information This manual contains technical information regarding Bayer SeedGrowth Equipment. Please read and understand these instructions completely before proceeding to install and operate the equipment. Bayer reserves the right to change specifications, models, components, or materials at any time without notice. For additional equipment information contact us at Please have this manual available when contacting Bayer. This manual uses signal words and symbols to help avoid personal injury. Danger, Warning, and Caution are signal words used to identify the level of hazard. Danger alerts that an extreme hazard will cause serious injury or death if operators or installers do not follow the recommended precautions. Warning alerts that a hazard may cause serious injury or death if operators or installers do not follow the recommended precautions. Caution alerts that a hazard may cause minor or moderate injury if operators or installers do not follow the recommended precautions. Always use caution and common sense when working with any chemical. Read the product label and SDS carefully and follow their instructions exactly as described. Optimal operating conditions for this piece of equipment requires an ambient temperature 32 F to +104 F (0 C to +40 C), relative humidity less than 90% (minimum condensation). Make necessary provisions to protect this piece of equipment against excessive dust, particles containing iron, moisture and against corrosive and explosive gases. Our technical information is based on Tip: calls attention to special information. extensive testing and is, to the best of our current knowledge, true and accurate but Note: emphasizes general information worthy of attention. given without warranty as the conditions of use and storage are beyond our control. Variables, such as humidity, temperature, Example: gives a problem or exercise that illustrates a method or principle. change in seed size or variety and viscosity of chemical products can all affect the accuracy of the chemical application and seed coverage. To ensure the desired application rate and optimum seed coverage, check the calibration periodically throughout the day, and make adjustments as needed. Bayer Crop Science Division 1451 Dean Lakes Trail Shakopee, Minnesota USA Phone: Toll Free: equipment@bayer.com Web: Bayer SeedGrowth TM and the Bayer Cross are registered trademarks of Bayer. SGRCBTLW4PUMPADDONINTERNATIONALINSTALLATIONGUIDE

3 CONTENTS 3 CONTENT #1 SYSTEM DIAGRAM 04 #2 EQUIPMENT INSTALLATION 05 Inspection 05 Add-on Box - Wall Mount 06 Main Control Panel 07 E-Stop Cable 08 Ethernet Cable 10 SLC Processor & Flash Drive 11 Chemical Inlet Assembly 15 Pump Stations & Chemical Tanks 16 HMI Boot Up 24 CBT Options Screen 46 CBT Bowl Graphics Screen 47 Batch Recipe Screen 49 Edit Batch Recipe Screen 50 Home Screen 51

4 4 System Diagram SYSTEM DIAGRAM CBT LW 4-PUMP ADD-ON, ref. Existing 4-Pump System 4-Pump Add-on CBT Treater Main Control 4-Pump Add-on Box E-STOP Signal ETHERNET External Power External Power Chemical J-Box Sensor J-Box Sensor Chemical 4-port Pico Block Power 4-port Pico Block Power Existing 20L Pump Stations (1-4) Additional 20L Pump Stations (5-8) EXPLANATORY NOTE The CBT LW 4-Pump Add-on increases pump capacity on an existing 4-Pump system to an 8-Pump system.

5 Equipment installation 5 Equipment Installation Several basic requirements are necessary to ensure proper equipment installation. Read through and understand this manual. Inspection Components of the 4-Pump Add-on will be shipped separately: 4-Pump Add-on Box, Pump Stations (1-4), Pump Station J-box, 4-port Pico Block and Chemical Inlet Add-on. Remove all components, check for damage that may have occurred during shipping and report any missing or damaged parts IMMEDIATELY!! Warning! Ensure a licensed electrician wires the system following the National Electrical Codes for the area. Wiring schematic drawings are enclosed inside the existing Main Control Panel and the new 4-Pump Add-on Box. Factory-supplied Components 4-Pump Add-on 4-Pump Add-on Box (1) 380V Pump Stations (1-4) Pump Station J-Box (1) 4-Port Pico Block (1) Chemical Inlet Add-on (1) 4-Pump Add-on Box Pump Stations (1-4) Chemical Inlet Add-on Pump Station J-Box 4-Port pico Block

6 6 Equipment installation 4-Pump Add-on Box - Wall Mount Locate the 4-Pump Add-on Box near the existing CBT Main Control panel. Use proper rigging and lifting techniques and lift lugs to ensure safety when installing the 4-Pump Add-on Box. Tabs on top and bottom are provided to fasten the 4-Pump Add-on Box to the wall with anchors. Customer to land service (power) to the 4-Pump Add-on Box, according to the Electrical Schematics (located inside the Box Door). TAB TAB LIFT LUG LIFT LUG power on/off TAB TAB Ensure the 4-pump add-on box Power on/off lever is OFF, AS SHOWN ABOVE!

7 Equipment installation 7 Existing CBT Main Control Panel Ensure the following devices are in the OFF position prior to opening the Main Control Panel Door, to avoid possible shock! Also, ensure the Treater and Pump Stations are not running. Ensure the Control Switch is in the OFF position, as shown. Ensure the Power Lever is in the OFF position, DOWN as shown.

8 8 Equipment installation E-Stop Cable Use a slotted screwdriver to open the Main Control Panel Door (on Handle). Land the customer-supplied E-STOP cable leads (16 gauge 2-wire cable) inside the Main Control Panel Terminal Block, according to the Electrical Schematics.

9 Equipment installation 9 4-Pump Add-on Box - E-Stop Cable Use a slotted screwdriver to open the 4-Pump Add-on Box Door. Land the other end of the E-STOP cable leads inside the 4-Pump Add-on Box, according to the Electrical Schematics. 4-Pump Add-on Box

10 10 Equipment installation Main Control Panel - Ethernet Cable Connect a customer-supplied CAT5 Ethernet cable inside the Main Control Panel to the Ethernet switch. Remove the Cap and connect the other end of the Ethernet cable to the side of the 4-Pump Add-on Box, marked COMMUNICATION PORT.

11 Equipment installation 11 4-Pump Add-on Box - SLC Processor & Flash Drive Remove the new SLC Processor (box). Remove the new SLC Processor and key from the box. SLC PROCESSOR

12 12 Equipment installation Main Control Panel - SLC Processor - Existing Disconnect the Ethernet cable from the existing the SLC Processor from inside the Main Control Panel. Remove the existing key (turn left & pull out) from the SLC Processor from inside the Main Control Panel. Remove the existing SLC Processor from inside the Main Control Panel (push in on top & bottom buttons and slide straight out). ETHERNET CABLE KEY Note: the key should stay with the SLC Processor once it is removed.

13 Equipment installation 13 Main Control Panel - SLC Processor - New Insert the new SLC Processor inside the Main Control Panel (top & bottom buttons will snap in place). Insert the new key (shipped in box with processor) and lock in place (turn key right). Connect the Ethernet cable from the Ethernet Switch to the new SLC Processor. SLC PROCESSOR KEY ETHERNET CABLE

14 14 Equipment installation 4-Pump Add-on Box Land external power to the 380V 4-Pump Add-on Box. 4-Pump Add-on Box External Power

15 Equipment installation 15 Chemical Inlet Assembly Step 1: Remove new 4-port Add-on Assembly from package. Step 3: Insert the new 4-port Add-on Assembly onto the existing Chemical Inlet tube. Completely push it all the way on. Orient and align inlet elbows to be the same as the existing chemical inlet assembly, as shown below. Step 2: Remove the rubber cap on top of the existing Chemical Inlet tube (on top of Treater Bowl). Step 4: Then use a slot screwdriver to tighten the stainless steel bands on the flexible rubber coupling around the inlet tube.

16 16 Equipment installation Pump Stations & Chemical Tanks Number each new Pump Station used 1-4. The new Pump Station Junction Box connects to the 4-Pump Add-on Box. Each new Pump Station connects to the new Pump Station Junction Box. New Chemical Supply Tanks (PSD or CBP) connect to each new Pump Station. Step 1: Remove each Pump Station and Chemical Supply Tank from their shipping crates and place them in close proximity to the Treater. BT Transfer Pump (from Chemical tanks) 625 Dosing Pump (to Treater chemical Inlet) Step 3: Connect one end of the factory supplied 3/4 ID Clear Vinyl Tubing with #8 SS Hose Clamp onto the Chemical Tank Premium Filter OUT Brass Hose Barb. Tighten in place with a screwdriver. Ancillary Pump Station, PSD Tank, CBP Tank, ref. Step 2: Connect customer supplied 1/4 Tubing into the Press Lock Fitting on the Filter Regulator Assembly (front side of the Pump Station). Set the Filter Regulator to 30psi. Step 4: Cut to fit and connect the other end of Tubing and a #8 SS Hose Clamp to the lower BT Pump Plumbing Assembly Brass Hose Barb. Tighten in place with a screwdriver.

17 Equipment installation 17 Step 5: Turn the Operation Switch (located on the front end of the Pump Station Frame) to the UP position to raise the cover. Step 8: Connect one end of the factory supplied 3/4 ID Clear Vinyl Tubing with #8 SS Hose Clamp onto the Discharge Tube (right side) on top of the Tank Cover. Tighten in place with a screwdriver. Step 6: Connect one end of the factory supplied 3/4 ID Clear Vinyl Tubing with #8 SS Hose Clamp to the upper BT Pump Plumbing Assembly Brass Hose Barb. Tighten in place with a screwdriver. Step 9: Cut to fit and connect the other end of Tubing with #8 SS Hose Clamp onto the Flow Equalizer Brass Hose Barb connected to the Riser Tube (backside of the Pump Station). Tighten in place with a screwdriver. Tip: Raising the Supply Tank Cover helps to ensure adequate length of tubing will be adjusted for in the installation process. Don t connect the tubing while the Supply Tank Cover is in the lowered position! Step 7: Cut to fit and connect the other end of Tubing with #8 SS Hose Clamp onto the Discharge Tube (left side) on top of the Tank Cover. Tighten in place with a screwdriver. Step 10: Turn the Operation Switch to the DOWN position to lower the cover.

18 18 Equipment installation Step 11: Connect one end of the factory supplied 5/8 ID Clear Vinyl Tubing with #8 SS Hose Clamp onto the Flow Equalizer Brass Hose Barb connected to the Riser Tube (backside of the Pump Station). Tighten in place with a screwdriver. Pins hold the Pump Element in place on the Pump Rollers Place Pump Element on Pump Rollers Connect Tubing Left Side Outlet Connect Tubing Right Side Inlet Step 12: Lift the four pins to open the 625 Dosing Pump Head and remove the Cover. Place the Pump Element on the internal rollers and over the two pins on each side. Replace the Pump Head Cover. Push the four pins down to close the Pump Head on the Pump Element. Cut to fit and connect the other end of Tubing with #8 SS Hose Clamp onto the Pump Element (right side - inlet). Tighten in place with a screwdriver. Step 13: Connect one end of the factory supplied 5/8 ID Clear Vinyl Tubing with #8 SS Hose Clamp onto the 625 Dosing Pump Element (left side - outlet) shown above. Tighten in place with a screwdriver. Step 14: Cut to fit and connect the other end of Tubing with #8 SS Hose Clamp onto the Flow Equalizer (near the Filter Regulator) bottom Brass Hose Barb. Tighten in place with a screwdriver.

19 Equipment installation 19 Step 15: Connect one end of the factory supplied 3/4 ID Clear Vinyl Tubing with #8 SS Hose Clamp onto the Flow Equalizer (near the Filter Regulator) side Brass Hose Barb. Tighten in place with a screwdriver. Step 17: Connect the gray 24 pin Male Connector marked: PUMP JUNCTION BOX and the 16 pin Male Connector marked: VFD LIQUID PUMPS from the Pump Junction Box on the Pump Station to the 4-Pump Add-on Box. PUMP JUNCTION BOX VFD LIQUID PUMPS Step 16: Cut to fit and connect the other end of Tubing with #8 SS Hose Clamp onto the Chemical Inlet Tube (on top of the Treater Cover). Tighten in place with a screwdriver. CONNECT Repeat steps 1-16 for each Pump Station used (up to four). CONNECT

20 20 Equipment installation Step 18: Connect each Tank Sensor Cable (located on top of the Supply Tank Cover) to the 4-port Pico Block (start with the bottom port, see photo below). Step 20: Land each (1-4) gray Load Cell Cable (from the top of the Load Cell Junction Box on the backside of each Pump Station) through a connector on the side of the 4-Pump Add-on Box. CONNECT 1,2,3, Pump Add-on Box CONNECT 1,2,3,4 Step 19: Land the Pump Station Pico Block 20 meter Home-run Cable leads (bottom cable) through a connector on the side of the 4-Pump Add-on Box. Step 21: Land each (1-4) Pump Station White Signal Cable through a connector on the side of the 4-Pump Add-on Box. CONNECT 1,2,3,4 CONNECT 4-Pump Add-on Box

21 Equipment installation 21 Step 22: Land each (1-4) BT & 625 Pump Motor Lead to the Pump Station Junction Box (blue connectors). Step 23: Land each (1-4) 625 Pump gray VFD FWD/REV cable to the Pump Station Junction Box (white connectors). CONNECT 1,2,3,4 CONNECT 1,2,3,4 New Pump Station J-Box Note: Pump Weigh Scales are very susceptible to wind and can cause scale readout to fluctuate +/- 10g. It is recommended to enclose the Pump Station with cardboard or some type of material, to create a wind block. On the Main Control Panel HMI graphic display, weight fluctuations will display +/- 10g difference on the Pump Station graphic, LT1-4.

22 22 Equipment installation Step 24: Turn UP the Operation Switch to raise the cover. Step 27: Use a 1/2 crescent wrench to screw the four nuts on the four bolts up to the bottom of the bolt head. Then screw down the four bolt heads to the bottom of each nut. Use a level to ensure the Scale Top Plate is level. Adjust feet for flatness of scale on the Pump Station table top. Step 25: Remove the Supply Tank from the Scale Cover. Step 28: Replace the Scale Cover on the Scale Top Plate. Replace Remove Step 29: Replace the Supply Tank on the Scale Cover. Step 26: Remove the Scale Cover from the Scale Top Plate. Replace Remove Step 30: Turn DOWN the Operation Switch to lower the cover. Repeat steps for each Pump Station used (1-4).

23 Equipment installation 23 Main Control Panel - Power ON Flip the Main Power Switch ON (as shown in the UP position). Turn the screen controller switch ON (shown in the OFF position). The Main Power Light will turn ON. Control Power Switch ON Control Power Light

24 24 Equipment installation Default English Portuguese 1 HMI Touch Screen - Boot Up The HMI program will boot up and navigate to the MENU SCREEN. Step 1: Select a language: touch either the ENGLISH or PORTUGUESE button icon

25 Equipment installation 25 1 ***** HMI Touch Screen - Login Screen Step 1: Touch the Login Button icon, top left hand corner HMI Touch Screen. Login screen pop-up appears. Step 2: Touch in the User name and Password fields to enter user name and password (use current 4-pump system). Step 3: Touch the OK button icon. Login Screen pop-up closes

26 26 Equipment installation Default 1 HMI Touch Screen - Close Project Step 1: Touch the Close Project button icon: shuts down the RSView 32 Program; SEED COATER - project. The SEED COATER - Project pop-up screen appears, as shown right SEED COATER project pop-up screen

27 Equipment installation 27 4-Pump Add-on Box - Flash Drive Step 1: Open the 4-Pump Add-on Box Door and remove the new Flash Drive (inside yellow envelope). The 8-pump program is pre-loaded onto the flash drive REMOVE FLASH DRIVE Pre-loaded Flash Drive

28 28 Equipment installation HMI - New Flash Drive Step 1: Open the Main Control Door and insert the new flash drive into the backside of the HMI, as shown 1

29 Equipment installation 29 1 HMI Touch Screen - Seed Coater - Project Step 1: Touch the X symbol in the top right hand corner of the Screen message bar to close the RSView 32 program. The Desktop will appear. Note: if the program is not closed, you will not be able to copy the new program from the flash drive. CLOSE THE PROGRAM!

30 30 Equipment installation 1 2 HMI Touch Screen - Removable Disk Wizard The Removable Disk Pop-up Wizard will appear. Step 1: Touch the folder option entitled: Open folder to view files using Windows Explorer. Step 2: Then touch the OK button Icon

31 Equipment installation 31 1 HMI Touch Screen - Open Folders to View Files Step 1: Touch the Folders Icon at the top of the screen message bar

32 32 Equipment installation 1 HMI Touch Screen - Removable Disk Step 1: Touch the Removable_Disk option

33 Equipment installation 33 1 HMI Touch Screen - Open RSView Folder Step 1: Touch the RSView_R _POR option

34 34 Equipment installation 1 2 HMI Touch Screen - Copy Folder Step 1: Touch Edit at the top of the screen message bar. Step 2: Then touch Copy from the menu

35 Equipment installation 35 1 HMI Touch Screen - Open Local Disk C Step 1: Touch Local Disk (C:) option

36 36 Equipment installation 1 HMI Touch Screen - Open Project Folder Step 1: Touch Project folder icon from the menu

37 Equipment installation HMI Touch Screen - Paste Folder Step 1: Touch Edit button icon on message bar. Step 2: Then touch Paste from the menu

38 38 Equipment installation 1 HMI Touch Screen - Confirm Folder Replacement Step 1: Touch the Yes to All button icon to confirm folder replacement

39 Equipment installation 39 1 HMI Touch Screen - Confirm Folder Replacement Step 1: Touch the Yes to All button icon to confirm folder replacement

40 40 Equipment installation 1 HMI Touch Screen - Safely Remove Hardware Icon Step 1: Touch the Safely Remove Hardware icon on the task bar

41 Equipment installation 41 HMI Touch Screen - Confirm Folder Replacement 1 Step 1: Touch the Safely remove USB Mass Storage Device - Drive(F:) to confirm message

42 42 Equipment installation HMI - Remove New Flash Drive Step 1: Open the Main Control Door and remove the new flash drive from underneath the HMI (on the backside of the Main Control Door 1 Note: If the Flash Drive is left connected to the HMI after installing the program, the HMI will not properly boot up. ENSURE TO REMOVE THE FLASH DRIVE WHEN FINISHED WITH PROGRAM UPLOAD!

43 Equipment installation 43 4-Pump Add-on Box - Power Step 1: Ensure the 4-Pump Add-on Box Power Lever is turned ON. Power is ON when the lever is in the DOWN position, as shown 1 POWER ON

44 44 Equipment installation 1 ***** HMI Touch Screen - Login Screen Step 1: Touch the Login Button icon, top left hand corner HMI Touch Screen. Login screen pop-up appears. Step 2: Touch in the User name and Password fields to enter user name and password (use current 4-pump system). Step 3: Touch the OK button icon. Login Screen pop-up closes

45 Equipment installation 45 Default Menu Selection Equipment Options Processor Status Project Setup 1 Batch Recipe Batch Recipe Edit CBT-200 Bowl Graphic Reports 2 Active Alarms Fault Reset Clear Clean Screen Clear All HMI Touch Screen - Menu Screen Step 1: Touch the Equipment Options button icon, lower left hand corner of Menu Screen. Options screen appears (see next page, 46). Step 2: Or skip the Options step above and touch the CBT 200 BOWL GRAPHIC button icon on the Menu Screen above, navigates to: Home Screen as shown on page 47

46 46 Equipment installation Default Menu Selection Equipment Options 1 Processor Status Project Setup Batch Recipe Batch Recipe Edit CBT-200 Bowl Graphic Reports 2 Active Alarms Fault Reset Clean Screen Clear Clear All HMI Touch Screen - CBT 200 Options Screen The program from the factory (now installed from the flash drive) has all options enabled and ready for use, as shown above. Step 1: Touch each button to disable any of the Options you will not be using (when touched, each enabled button becomes disabled, as shown > ). If all eight pump stations will be used, then skip disable. Step 2: Or skip the Disable step and leave all of the options enabled above and touch the CBT 200 BOWL GRAPHIC button icon on the Menu Screen above, navigates to: Home Screen as shown on page 47

47 Equipment installation HMI Touch Screen - Home - CBT 200 Bowl Graphic Screen Step 1: Touch Pumps 1-4 or Pumps 5-8 button icons on the Menu Screen below. Toggle to display either Pump Stations 1-4 or 5-8 (The screen above displays 5-8 and the title at the top indicates that Pump Stations LT 5-8 are being displayed). The screen will not display all eight Pump Stations at the same time

48 48 Equipment installation 1 HMI Touch Screen - Home Screen Step 1: Touch the Batch Recipe Button icon on the Home Screen

49 Equipment installation 49 1 HMI Touch Screen - Batch Recipe Screen The Batch Recipe Screen above displays all eight Pump Stations (LT1-8) enabled and ready to use. Step 1: Touch the Edit Batch Recipe button icon on message bar

50 50 Equipment installation 1 HMI Touch Screen - Edit Batch Recipe Screen The Edit Batch Recipe Screen above allows operators to create new recipes. Step 1: Touch the Home Screen button icon on message bar

51 Equipment installation 51 HMI Touch Screen - Home Screen The 4-Pump Add-on Program installation is now complete.

52 Bayer Crop Science Division 1451 Dean Lakes Trail Shakopee, Minnesota USA For fast and easy access to our website scan the code with your smartphone and an appropriate app.