Conair Basic 32 Loader Control B32 User Manual Download

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Basic 32
Loader Control

Instant Access

Parts and Service

(800) 458-1960
(814) 437-6861

www.conairnet.com

The Conair Group, Inc.
One Conair Drive
Pittsburgh, PA 15202
Phone: (412) 312-6000
Fax: (412)-312-6001

B32 Model

UGC007/0702

Installation

Operation

Maintenance

Troubleshooting

Summary of Contents for Basic 32 Loader Control B32

Page 1: ...cess Parts and Service 800 458 1960 814 437 6861 www conairnet com The Conair Group Inc One Conair Drive Pittsburgh PA 15202 Phone 412 312 6000 Fax 412 312 6001 B32 Model UGC007 0702 Installation Oper...

Page 2: ...er UGC007 0702 Model number Serial number s Software version number s DISCLAIMER The Conair Group shall not be liable for errors con tained in this User Guide or for incidental consequential damages i...

Page 3: ...Mounting the Control 3 5 Connecting to the B32 3 6 Wiring Loaders to the B32 3 7 Wiring Pumps to the B32 3 7 Wiring Purge Valves to the B32 3 7 Connecting Main Power to the B32 3 8 Initial Setup 3 9 S...

Page 4: ...Problem 6 3 Clearing Interface Alarms 6 4 Clearing CPU and I O alarms 6 5 Conveying System Alarms 6 6 Operator Interface Problems 6 8 Processor and power problems 6 8 CPU faults 6 9 I O errors 6 9 AP...

Page 5: ...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 INTRODUCTION...

Page 6: ...dous to users or could damage equipment Read and take precautions before proceeding Numbers within shaded squares indicate tasks or steps to be performed by the user A diamond indicates the equipment...

Page 7: ...th electrical codes in your region Always maintain a safe ground Do not operate the equipment at power levels other than what is specified on the the equipment serial tag and data plate WARNING Electr...

Page 8: ......

Page 9: ...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 DESCRIPTION...

Page 10: ...lexible Individual vacuum receivers can be assigned to any one of the eight loading systems Each receiver can be configured for one of the following l Single material loading l Ratio loading with or w...

Page 11: ...I When receivers in a pump system demand material the B32 turns on the vacuum pump and dust collector in the appropri ate pump system It then opens the correct vacuum and mater ial valves to convey ma...

Page 12: ...ltages Total amps 115V 1 phase 60Hz master control 10 CALCULATING CABLE LENGTH Total the distances from the Input output Station s location to each vacu um receiver on the system Be sure to account fo...

Page 13: ...siderations 3 4 l Mounting the Control 3 5 l Connecting to the B32 3 6 lWiring Loaders to the B32 3 7 lWiring Pumps to the B32 3 7 lWiring Purge Valves to the B32 3 7 l Connecting Main Power 3 8 l Ini...

Page 14: ...e software version number and electrical power specifi cations in the blanks provided on the back of the the User Guide s title page The information will be helpful if you ever need service or parts Y...

Page 15: ...ations high ambient temperature power line fluctuations caustic fumes or excessive amounts of dust dirt vibration shock and moisture could harm performance and reduce the life of this equipment r Prov...

Page 16: ...wiring diagrams supplied with your control before making electrical connections The diagrams show the most accurate electrical component information Protect communication cables from sources of stati...

Page 17: ...nclosure Connect a ground wire to the control Follow procedures outlined by your regional electrical codes and the wiring diagrams included with this manual MOUNTING THE CONTROL 1 2 WARNING Improper i...

Page 18: ...GC007 0702 3 6 INSTALLATION WARNING Improper installation may result in equipment damage or personal injury Always refer to the wiring diagrams that came with your controls before making electrical co...

Page 19: ...LOADERS TO THE B32 IMPORTANT Always refer to the wiring diagrams that came with your controls before making electrical connections The diagrams show the most accurate electrical component infor matio...

Page 20: ...cord s into a grounded 115 VAC outlet rated for at least 15 Amp service Make sure the control enclosure is grounded WARNING Electrical shock hazard Failure to provide proper grounding can cause contr...

Page 21: ...econds When the control has initialized the Main Screen displays UGC007 0702 Basic 32 Loader Control INSTALLATION 3 9 Before you can begin conveying you must configure and identify the loaders and con...

Page 22: ...roll to move the cursor to the Loader field Use the up down arrows to select loader Use the Scroll Down Up buttons to set the loader parameters loader number virgin time in seconds dump time in second...

Page 23: ...Use the up down arrows to increase and decrease the loader number Use the scroll down up buttons to enable disable the loader 1 2 3 To enable the pumps from the main screen Use the Up Down arrows to...

Page 24: ...7373 Supervisor 2 54647 Change these passwords and record the new passwords in a safe place Press the Enter arrow The Factory Configuration screen displays Use the scroll up down buttons to scroll to...

Page 25: ...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 Assigning Pumps and Loaders 4 7 l Assigning a Backup Pump 4 8 l Con...

Page 26: ...n Allows you to Configure a loader Assign a loader to a pump Assign a backup pump Configure loader alarms Backup PLC program and settings Restore a program Display and clear PLC errors System Configur...

Page 27: ...screen displays Use the up down arrows to scroll to Loader 1 16 Press the Enter arrow The Loader Status screen displays The current status of each loader and pump displays The status choices include...

Page 28: ...the device are locked out and tagged r Before removing lockout devices or enabling pumps loaders or material valves make sure that all personnel are clear of the machine tools have been removed and an...

Page 29: ...r the Main button to return to the Main screen 1 2 3 ENABLING AND DISABLING PUMPS WARNING Develop and follow procedures for safe operation of the system to avoid pos sible injury or equipment damage T...

Page 30: ...e Loader Configuration screen displays Use the up down arrows to scroll to Option Config Press the Enter arrow The Option Configuration screen displays Use the up down arrows to increase and decrease...

Page 31: ...oader Config Press the Enter arrow The Loader Configuration screen displays Use the up down arrows to scroll to Pump Assign Press the Enter arrow The Pump Assignment screen displays Use the up down ar...

Page 32: ...ess the Enter arrow The Loader Configuration screen displays Use the up down arrows to scroll to VP Back Up Select Press the Enter arrow The Pump Back up Select screen displays Use the scroll down up...

Page 33: ...the Enter arrow The Loader Configuration screen displays Use the up down arrows to scroll to Alarms Press the Enter arrow The Alarm Configuration screen displays Use the scroll down up buttons to choo...

Page 34: ...ow The Program Mode screen displays Use the up down arrows to to select Save to EEPROM The screen displays message when transfer is complete Use the Up Down arrows to select Run Mode NOTE All pumps mu...

Page 35: ...5 1 UGC007 0702 Basic 32 Loader Control l Maintenance checklist 5 2 MAINTENANCE...

Page 36: ...the material change Pay particular attention to load times and dump times See CHANGING LOADER SETTINGS in the Operation section l Quarterly r Check power and cable connections and wires Over time the...

Page 37: ...ds 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 Conveying System alarms 6 6 l Operator Interface Problems 6 8 l Processor...

Page 38: ...pment as well as access to the electrical enclosure while power is on Only qualified electrical techni cians trained in the use of this equipment and in avoiding exposure to voltage hazards should per...

Page 39: ...or Problems These tables focus on power supply and processor problems indicated by Micrologix 1500 LEDs located inside the I 0 enclosure These problems cause the B32 control to stop r CPU Faults These...

Page 40: ...Up Down arrows to scroll to Alarm List Press Enter to display alarms The alarm list displays up to 25 alarms starting with the most current All acknowledged alarms have a check mark next to the text A...

Page 41: ...rrow The Errors screen displays The alphanumeric error code is listed The error code is reported in hexidecimal format with the first two digits identifying a specific I O module slot If the digits ar...

Page 42: ...to fill the receiver Adjust as needed r Verify that the Alarm Check allows a sufficient number of loading cycles to fill the receiver Adjust as needed r Verify that the loader is assigned to the corre...

Page 43: ...hes are connected correctly at the loader or hopper and at the control r Verify that fill and demand sensors are set at the correct height and adjusted proper ly Refer to manuals sup plied with the fi...

Page 44: ...of PV300 Micro 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 t...

Page 45: ...e cause Solution See APPENDIX D FAULT MESSAGES AND ERROR CODES for a complete listing of input output errors causes and solutions CPU FAULTS WARNING Electrical shock hazard Diagnosing electrical and p...

Page 46: ......

Page 47: ...checklist before calling Conair r Make sure you have all model serial and parts list numbers for your particular equipment Service personnel will need this information to assist you r Make sure power...

Page 48: ...exercise one of the following options l Inspect the equipment and perform alterations or adjust ments to satisfy performance claims Charges for such inspections and corrections will be waived unless f...

Page 49: ...fig Press the Enter arrow The Loader Configuration screen displays Use the up down arrows to scroll to Save Config Press the Enter arrow The Save Configuration screen displays Use the scroll up down b...

Page 50: ......

Page 51: ...troller is not in Run mode or REM Run green controller is in Run mode or REM Run green flashing system is not in Run mode memory module transfer is in progress FAULT off no fault detected red flashing...

Page 52: ...r Power Supply Overloaded This problem can occur intermittently if power supply is overloaded when output loading and temperature varies Power and FAULT LEDs on solid Hardware faulted Processor Hardwa...

Page 53: ...ble cause and recommended action Clear fault Test and verify system operation Is the error hardware related Is the Power LED on Are the wire connections tight Is the RUN LED on Is the Fault LED on See...

Page 54: ...after cycling power the controller re enters the fault mode For more information on status bits refer to the MicroLogix 1200 and MicroLogix 1500 Instruction Set Reference Manual Manually Clearing Faul...

Page 55: ...the Fault Override at Power Up bit S 1 8 is set in the status file You can also configure the controller to clear faults and go to RUN every time the controller is power cycled This is a feature that...

Page 56: ...dule RAM integrity test failed FLASH integrity test failed MicroLogix 1200 only Non User Re download or transfer the program Verify battery is connected MicroLogix 1500 only Contact your Conair Servic...

Page 57: ...OR CORRUPT The operating system required for the user program is corrupt or missing Non User Download a new OS using ControlFlash Contact your local Rockwell Automation representative for more informa...

Page 58: ...ND OF SCAN DETECTED A minor fault bit bits0 7 in S 5 was set at the end of scan Recoverable Correct the instruction logic causing the error Enter the status file display in your programming software a...

Page 59: ...space Recoverable Correct the program to ensure that the length and position parameters do not point outside data file space Re compile reload the program and enter the Run mode 0033 BSL BSR FFL FFU...

Page 60: ...ect to the hardware that is specified in the user program or Reconfigure the program to match the attached hardware 0052 MINIMUM SERIES ERROR The hardware minimum series selected in the user program c...

Page 61: ...one was not found or The expansion I O module configuration data size for a module was greater than what the module is capable of holding Non User Either correct the user program I O configuration to...

Page 62: ...t Non User Correct the user program I O configuration so that the object types match the actual configuration and Re compile reload the program and enter the Run mode Or Correct the actual configurati...

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