Conair B32 manual

Basic 32 Loader Cont rol Instant Access Parts and Service (800) 458-1960 (814) 437-6861 www.conairnet.com The Conair Grou p, Inc. One Conair Drive Pittsburgh, PA 15202 Phone : (412) 312-6000 Fax: (412)-312-6001 B32 Model UGC007/0702 Installation Operation Maintenance Troubleshooting[...]

It ’s a good idea to record the model, serial and software version numbers of your equipment and the date you received it in the User Guide. Our service department uses this infor - mation, along with the manual numbe r, to provide help for the specific equipment you installed. Please keep this User Guide and all manuals, engineering prints and p[...]

UGC007/0702 Basic 32 Loader Control T ABLE OF C ONTENTS I NTRODUCTION ......................................... 1-1 Purpose of the User Guide ..................................................... 1-2 How the Guide is Organized ................................................. 1-2 Y our Responsibility as a User ......................................[...]

Basic 32 Loader Control UGC007/0702 T ABLE OF C ONTENTS T ROUBLESHO OTING . . . . . . . . . . . . . . . . 6-1 Before Beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 A Few Words of Caution . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Identifying the Cause of a Problem . . . . . . . . . . . . . . . . . . 6-3 C[...]

1-1 UGC007/0702 Basic 32 Loader Control l Purpose of the User Guide .........1-2 l How the guide is organized ........1-2 l Your responsibilities as a user ...1-2 l ATTENTION: Read this so no one gets hurt .....................1-3 I NT RODUCTION[...]

Basic 32 Loader Control UGC007/0702 1-2 I NTRODUCTION This User Guide describes the Conair Basic 32 Loader Control and explains step-by-step how to install, operate, maintain and repair this equipment. Before installing this product, please take a few moments to read the User Guide and review the diagrams and safety infor - mation in the instructio[...]

UGC007/0702 Basic 32 Loader Control I NTRODUCTION 1-3 W e design equipment with the user ’s safety in mind. Y ou can avoid the potential hazards identified on this machine by fol - lowing the procedures outlined below and elsewhere in the User Guide. ATTENTION: R EAD THIS SO NO ONE GETS HURT WARNING: Improper installation , oper - ation or servic[...]

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2-1 UGC007/0702 Basic 32 Loader Control l What is the B32? . . . . . . . . . . . . 2-2 l Typical Applications . . . . . . . . . . 2-2 l How it Works . . . . . . . . . . . . . . . 2-3 l Specifications . . . . . . . . . . . . . . 2-4 D ESCRIPTION[...]

The control is mounted on the front of the I/O station. Inside is a processor with base, containing up to 8 input/output mod - ules. The number of input and output modules will vary with the number of vacuum receivers and conveying options. W HAT IS THE B32? Basic 32 Loader Control UGC007/0702 2-2 D ESCRIPTION T YPICAL A PPLIC ATIONS Backup Pump Pu[...]

UGC007/0702 Basic 32 Loader Control D ESCRIPTION 2-3 H OW IT W ORKS The B32 communicates with each pump, vacuum receiver and material valve wired to Input/Output modules within the con - trol enclosure. The B32 controls conveying operation based on settings the operator enters on the HMI. When receivers in a pump system demand material, the B32 tur[...]

S PECIFIC ATIONS Basic 32 Loader Control UGC007/0702 2-4 D ESCRIPTION MODEL B32 Performance characteristics Maximum number of vacuum receivers 32 Maximum number of vacuum pumps 8 (plus back-up) Programmable logic controller Allen Bradley Micrologix 1500 T ouchscreen operator interface Allen Bradley PV300 Micro Communications with master control DH4[...]

3-1 UGC007/0702 Basic 32 Loader Control l Unpacking the B ox es . . . . . . . . . . . 3-2 l Preparing for Installation . . . . . . . . 3-3 l Installing the B32 . . . . . . . . . . . . . . 3-4 l Wiring Considerations . . . . . . . . . . 3-4 l Mounting the Control . . . . . . . . . . 3-5 l Connecting to the B32 . . . . . . . . . . 3-6 l Wiring Loader[...]

Carefully remove the B32 components from their shipping containers, and set upright. Remove all packing material, protective pape r, tape and plastic. Carefully inspect all components to make sure no damage occurred during shipping. Notify the shipper immediately if damage is found. Take a moment to record serial numbers, the software version numbe[...]

P RE PARING FOR I NS TALLATION UGC007/0702 Basic 32 Loader Control I NS TALLATION 3-3 Y ou should plan the location of the B32 control to ensure easy access and minimal wiring. Select a mounting location for the control. The interface and Input/Output enclosure can be mounted on a wall or other stable vertical surface. Select a location that: r Is [...]

W IRING C ONSIDER ATIONS Installation of the B32 control consists of: r Mounting the enclosure. r Wiring loaders to the control. r Wiring pumps to the control. r Wiring material valves to the control. r Connecting the control to a main power source. r Initial setup of the system control. I NS TALLING THE B32 Basic 32 Loader Control UGC007/0702 3-4 [...]

UGC007/0702 Basic 32 Loader Control I NS TALLATION 3-5 The B32 Input/Output enclosure should be mounted on a wall, or other secure vertical surface, at a height providing easy access and a clear view of the touchscreen panel. Bolt the control to the mounting surface. Use the mounting brackets on the I/O enclosure. Ground the control enclosure. Conn[...]

Each vacuum receive r, pump and material valve in the system must be wired to power or common/ground terminals and Input/Output modules inside the B32 control enclosure. Each loader requires at least six wire connections to the Input/Output enclosure. One additional wire is required for each option or for a three-wire sensor used for either demand [...]

The loader wires connect to power terminals or terminals on the I/O modules inside the control enclosure. The number of loaders and options in the conveying system will determine the number of connections that are required. Refer to the electrical prints included with this manual for all electrical connections to the loader control. All loader outp[...]

Basic 32 Loader Control UGC007/0702 3-8 I NS TALLATION C ONNECTING M AIN P OWER TO THE B32 The B32 Input/Output enclosure is equipped with a three- prong plug and power cord. Each optional remote touchscreen panel also has its own plug and power cord. Plug the power cord(s) into a grounded 115 VAC outlet rated for at least 15 Amp service. Make sure[...]

To begin Initial Setup: Turn on power to the B32. The Power ON/OFF switch is on the left side of the con - trol enclosure. Wait for the control to boot. Do not touch the control until it completes the bootup and initialization process. Process takes a few seconds. When the control has initialized, the Main Screen displays. UGC007/0702 Basic 32 Load[...]

Basic 32 Loader Control UGC007/0702 3-10 I NS TALLATION S ETTING L OADER P ARAMETERS The loader must be correctly installed and wired before setting parameters. To set loader parameters from the main screen: Use the Up/Down arrows to scroll to Loader Settings. Press the Enter arro w . The Loader Settings screen displays. Use the up/down arrows to s[...]

UGC007/0702 Basic 32 Loader Control I NS TALLATION 3-11 E NABLING L OADERS To enable the loaders from the main screen: Use the Up/Down arrows to scroll to Loader Settings. Press the Enter arro w . The Loader Settings screen displays. Use the up/down arrows to scroll to Loader Enable. Press the Enter arro w . The Loader Enable screen displays. Use t[...]

S ELECTING A P ASSWORD Basic 32 Loader Control UGC007/0702 3-12 I NS TALLATION The B32 provides password security to prevent unauthorized changes to loader or system settings. Use the Up/Down arrows to scroll to System Config. Entering the System Configuration screen requires a Supervisor 2 password. Enter the password. To enter the password use th[...]

4-1 UGC007/0702 Basic 32 Loader Control l B32 Control Features . . . . . . . . . . . 4-2 l Viewing Loader Status . . . . . . . . . . 4-3 l Enabling and Disabling Loaders . . . . . . . . . . . . . . . . . . . . . 4-4 l Enabling and Disabling Pumps . . . . . . . . . . . . . . . . . . . . . 4-5 l Configuring Loaders . . . . . . . . . . . 4-6 l Assigni[...]

Basic 32 Loader Control UGC007/0702 4-2 O PER ATION B32 C ONTROL F EATURES The B32 operator interface allows you to view the status of the vacu - um receivers and pumps in your conveying system at a glance. It also provides access to screens to enter settings for each loading sta - tion, view alarms and change system parameters. Loader Configuratio[...]

UGC007/0702 Basic 32 Loader Control O PER ATION 4-3 V IEWING L OADER S TA TUS To view loader status from the main screen: Use the Up/Down arrows to scroll to Loader Settings. Press the Enter arro w . The Loader Settings screen displays. Use the up/down arrows to scroll to Loader 1-16. Press the Enter arro w . The Loader Status screen displays. The [...]

E NABLING AND D ISABLING L OADERS Basic 32 Loader Control UGC007/0702 4-4 O PER ATION WARNING: Develop and follow procedures for safe operation of the system to avoid pos - sible injury or equipment damage. The B32 allows operators and maintenance personnel to disable and enable conveying system components from remote locations . Unexpected energiz[...]

UGC007/0702 Basic 32 Loader Control O PER ATION 4-5 To enable the pumps from the main screen: Use the Up/Down arrows to scroll to Loader Settings. Press the Enter arro w . The Loader Settings screen displays. Use the up/down arrows to scroll to Pump Enable. Press the Enter arro w . The Pump Enable screen displays. Use the up/down arrows to increase[...]

Basic 32 Loader Control UGC007/0702 4-6 O PER ATION C ONFIGURING L OADERS Y ou may need to change loader settings whenever you change materials or to obtain the best conveying performance. To configure loaders from the main screen: Use the Up/Down arrows to scroll to Loader Config. Press the Enter arro w . The Loader Configuration screen displays. [...]

UGC007/0702 Basic 32 Loader Control O PER ATION 4-7 A SSIGNING L OADERS AND P UMPS Y ou may need to change loader and pump assignments to match the conveying system vacuum and XXXX To assign loaders and pumps from the main screen: Use the Up/Down arrows to scroll to Loader Config. Press the Enter arro w . The Loader Configuration screen displays. U[...]

A SSIGNING A B ACKUP P UMP Basic 32 Loader Control UGC007/0702 4-8 O PER ATION A backup pump can be assigned to replace any of the eight pump systems during operation. To assign a backup pump: Use the Up/Down arrows to scroll to Loader Config. Press the Enter arro w . The Loader Configuration screen displays. Use the up/down arrows to scroll to VP [...]

C ONFIGURING THE A LARM UGC007/0702 Basic 32 Loader Control O PER ATION 4-9 Te loader can be configured for demand alarm, fill alarm or no alarm. To configure the alarm from the main screen: Use the Up/Down arrows to scroll to Loader Config. Press the Enter arro w . The Loader Configuration screen displays. Use the up/down arrows to scroll to Alarm[...]

To back up the PLC program and save the configuration: Use the Up/Down arrows to scroll to Loader Config. Press the Enter arro w . The Loader Configuration screen displays. Use the up/down arrows to scroll to Save Config. Press the Enter arro w . The Save Configuration screen displays. Use the up/down arrows to scroll to Program Mode Press the Ente[...]

5-1 UGC007/0702 Basic 32 Loader Control l Maintenance checklist . . . . . . . . 5-2 M AINTENANCE[...]

Y ou should develop a preventive maintenance schedule for all components in the conveying system to ensure optimum operation and performance. The B32 may require the following maintenance checks: l Whenever you change materials r Verify the loader settings for pump systems or loaders effected by the material change. Pay particular attention to load[...]

6-1 UGC007/0702 Basic 32 Loader Control l Before Beginning . . . . . . . . . . . . 6-2 l A Few Words of Caution . . . . . . 6-2 l Identifying the Cause of a Problem . . . . . . . . . . . . . . . 6-3 l Clearing Interface Alarms . . . . . 6-4 l Clearing CPU and I/O alarms . . . 6-5 l Co nveying System alarms . . . . . 6-6 l Operator Interface Problem[...]

Before you begin troubleshooting: o Find the manuals and wiring diagrams that were shipped with your equipment. These materials contain details you will need to diagnose and repair problems in specific components, including custom wiring, features or I/O options not covered in this User Guide. B EFORE B EGINNING Basic 32 Loader Control UGC007/0702 [...]

The T ROUBLESHOOTING section explains how to clear an alarm, and provides diagnostic tables to help you determine the cause of the alarm. Diagnostic tables have been divided into: r Conveying System Alarms. These tables focus on the “No Material” and “Pump Overload” alarms that the B32 displays on the Alarm Summary screen. The B32 continues[...]

When a conveying problem occurs, the screen displays the alarm message and the audible alarm sounds. To silence the alarm and fix the problem: Press the Enter button. This acknowledges the alarm. The alarm text is removed from the screen. The screen returns to the Main screen. NOTE: pressing the Enter button only acknowl - edges the alarm; it does [...]

C LEARING CPU AND I/O A LARMS UGC007/0702 Basic 32 Loader Control T ROUBLESHOOTING 6-5 CPU and Iinput/Output errors will stop the B32 control. These errors may be caused by problems with the power sup - pl y , processor or Input/Output modules. The error is indicated by error codes on the PLC Error screen or by LEDs on the B32 MicroLogix1500 CPU an[...]

C ONVEYING S YSTEM A LARMS Basic 32 Loader Control UGC007/0702 6-6 T ROUBLESHOOTING Alarm No Material Alarm Possible cause There is no material at the source. Loader Settings are incorrect. There is a leak in the vacuum system. Solution r V erify that there is enough material at the source, including regrind sources if a ratio valve is used. r V er[...]

C ONVEYING S YSTEM A LARMS UGC007/0702 Basic 32 Loader Control T ROUBLESHOOTING 6-7 Alarm No Material Alarm (continued) Pump Overload Possible cause Vacuum pump is not working correctl y. The fill/demand sensor or demand switch is not working properl y. Compressed air lines are not connected correctl y. The vacuum pump overload has tripped. Solutio[...]

P ROCESSOR AND P OWER P ROBLEMS Fault Possible cause Solution O PER AT OR I NTER FA CE P ROBLEMS Basic 32 Loader Control UGC007/0702 6-8 T ROUBLESHOOTING Fault Terminal does not power up. Possible cause Improper connection to power source Incorrect input voltage level. DC power wires reversed (DC terminals only). Power terminal block not fully seat[...]

UGC007/0702 Basic 32 Loader Control T ROUBLESHOOTING 6-9 I/O E RRORS WARNING: Electrical shock hazard Diagnosing electrical and processor problems require access to the electrical enclosure while power is on . Only qualified electrical technicians, who are trained in how to avoid voltage hazards, should perform troubleshooting procedures that requi[...]

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UGC007/0702 S ERVICE I NFORM ATION A PPENDIX A1 Conair has made the largest investment in customer support in the plastics industr y . Our service experts are available to help with any problem you might have installing and operating your equipment. Y our Conair sales representative also can help analyze the nature of your problem, assuring that it[...]

W ARRANTY I NFORM ATION IMS0003/0796 A2 A PPENDIX E QUIPMENT G UARANTEE P ERFORMANCE W ARRANTY W ARRANTY L IMI TA TIONS Conair guarantees the machinery and equipment on this orde r, for a period as defined in the quotation from date of shipment, against defects in material and workmanship under the normal use and service for which it was recommende[...]

UGC007/0702 R ESTORING THE P ROGRAM A PPENDIX B1 The program can be restored to the plant configuration if for some reason the program has been interrupted. To restore the program: Use the Up/Down arrows to scroll to Loader Config. Press the Enter arro w . The Loader Configuration screen displays. Use the up/down arrows to scroll to Save Config Pre[...]

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Basic 32 Loader Control UGC007/0 7 02 Appendix C T r oubl es hoot ing Y our Sy st em This chapter d escribes h o w to troubl eshoot you r controller . T opi cs includ e: • unders tanding the controller LED status • con troller er ror recovery m odel • identify ing co ntrol l er faults • callin g Rockwell Automation for assi stance Underst a[...]

Basic 32 Loader Control UGC007/0 7 02 C-2 T roub lesho ot ing Y our Sy stem W h en O per atin g No rm ally T h e PO WER and RUN LEDs are on. If a force condition is active, the FORCE LED turns on and rema ins on until all forces are removed. W h en an Er ror Ex ists If a n error e x ists within th e controller , the controll er LE D s operate as de[...]

Basic 32 Loader Control UGC007/0 7 02 T rou bl eshoo ting Y our Sys tem C-3 Controller Error Recov ery Model Use the following error recovery model to he l p you dia gnose software and hardw are problem s in the micro controll er . The model provides commo n questions y ou migh t ask to help troub l e s hoot your s ystem. Refer to the recomme nded [...]

Basic 32 Loader Control UGC007/0 7 02 C-4 T roub lesho ot ing Y our Sy stem Ident ifying Controll er Fau lts Wh ile a prog r am i s executi ng, a fault may occ ur within the operating syst em or your program. When a fault oc curs, you have variou s optio ns to determ ine what the fau l t is and how to correct it. This section describ es how to clea[...]

Basic 32LoaderControl UGC007/0702 Appendix D Fa ult Mes sag es a nd Erro r C odes This chap ter describes ho w to trou blesh oot you r contr olle r. Topics include: • identifyi ng contr oller faults • contac ting Ro ckwell Autom ation f or assistan ce Identif y i ng Control ler Faults While a prog ram is execu ting, a f ault may occur within th[...]

UGC007/0702 Basic 32 Loader Control D - 2 Fa u l t Me s sages and E r r o r C o des Manual ly Clear in g F aul ts Us ing t he Fault Routin e The occu r rence of recoverab le or non-recoverab le user faults can cause the user fault subr outine to b e ex ecuted . If the fa ult is re cove rable, the subro utine can be use d to corr ect t he pro blem a[...]

Basic 32 Loader Control UGC007/0702 F au lt Me ssa ge s an d E rror C od e s D-3 000 6 MEM ORY M ODULE HARDW ARE F AUL T The me mor y mo dule har dwa re fau lte d or the me mor y mo dule i s incomp atible wit h OS . Non- Use r • U pgra de th e OS to be compatible with memory module. • Obt ain a ne w memory module. 000 7 MEM ORY M ODULE TRANSFE [...]

Basic 32 Loader Control UGC007/0702 D-4 Fau lt Mes sages and Erro r Codes 0016 ST AR TUP PR OT EC TION F A UL T T he us er fault r out ine was exe cute d at po wer -up , prio r to t he main lad der pro gram . Bit S:1/ 13 (Maj or Err or Hal ted) was not c lea red at the end o f the U ser Fa ult R out ine. Th e Us er Fa ult Ro utin e r an bec ause b [...]

Basic 32 Loader Control UGC007/0702 F au lt Me ssa ge s an d E rror C od e s D-5 0028 IN V A LID OR NO NEXI S T ENT US ER FAUL T ROUTIN E VA L U E • A fa ult r out ine number was ente red in the stat us fi le, nu mb er (S: 29), but ei ther th e fau lt rou ti ne was not phy sically create d, or • the f ault ro ut ine numbe r w as less tha n 3 or[...]

Basic 32 Loader Control UGC007/0702 D-6 Fau lt Mes sages and Erro r Codes 003 D INV ALID S EQUENCER LENG TH/POSITI ON A se que ncer instruc tion (SQO, S QC, SQL ) le ngth /po sit ion param eter is grea ter than 255. Rec ov era bl e Cor re ct t he u ser pr og ra m, t hen re- co mpile, rel oa d the p rogram and enter the Run m ode. 003E INV ALI D B I[...]

Basic 32 Loader Control UGC007/0702 F au lt Me ssa ge s an d E rror C od e s D-7 0083 M AX I/O CABLES EXCEED ED Th e maxim um nu m b er of ex pan sion I/O cabl e s a llo wed was ex ce ed ed. Non- Use r • Rec onfig ure th e exp ansi on I/ O syst em s o that i t ha s an allow able num ber o f c ables. • Cyc le powe r. 0084 MAX I /O PO W E R SUPPL[...]

Basic 32 Loader Control UGC007/0702 D-8 Fau lt Mes sages and Erro r Codes xx8B (1 )(2 ) EXP ANSION I/O POWER SUP P LY CONF IG UR A TIO N MISMA T CH ER ROR • Eith er an expa nsion I/O p ower su pply is con figur ed i n t he us er prog ram, b ut no p ow er su pply i s pres en t, or • an ex pa nsion I/O pow er supp ly i s co nfig ured in t he us e[...]