Basic 32 Loader Control B32 Model Installation Operation Maintenance Troubleshooting Instant Access Parts and Service (800) 458-1960 (814) 437-6861 www.conairnet.com The Conair Group, Inc.
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INTRODUCTION .........................................1-1 Purpose of the User Guide.....................................................1-2 How the Guide is Organized .................................................1-2 Your Responsibility as a User .............................................. 1-2 ATTENTION: Read this so no one gets hurt ........................1-3 TABLE OF CONTENTS DESCRIPTION . . . . . . . . . . . . . . . . . . . .2-1 What is the B32? . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS TROUBLESHOOTING . . . . . . . . . . . . . . . .6-1 Before Beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 A Few Words of Caution . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 Identifying the Cause of a Problem . . . . . . . . . . . . . . . . . .6-3 Clearing Interface Alarms . . . . . . . . . . . . . . . . . . . . . . . . .6-4 Clearing CPU and I/O alarms . . . . . . . . . . . . . . . . . . . . . .6-5 Conveying System Alarms . . . . . . . . . . . . . .
INTRODUCTION l l l l UGC007/0702 Purpose of the User Guide .........1-2 How the guide is organized ........1-2 Your responsibilities as a user ...1-2 ATTENTION: Read this so no one gets hurt .....................
PURPOSE OF THE USER GUIDE HOW THE GUIDE IS ORGANIZED 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 information in the instruction packet. You also should review manuals covering associated equipment in your system.
We design equipment with the user’s safety in mind. You can avoid the potential hazards identified on this machine by following the procedures outlined below and elsewhere in the User Guide. ATTENTION: READ THIS SO NO ONE GETS HURT WARNING: Improper installation, operation or servicing may result in equipment damage or personal injury.
DESCRIPTION l What is the B32? . . l Typical Applications l How it Works . . . . . l Specifications . . . . UGC007/0702 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic 32 Loader Control . . . . . . . . .2-2 .2-2 .2-3 .
WHAT IS THE B32? The control is mounted on the front of the I/O station. Inside is a processor with base, containing up to 8 input/output modules. The number of input and output modules will vary with the number of vacuum receivers and conveying options. Pump System 1 Pump System 5 Pump System 2 Pump System 6 B32 Pump System 3 Pump System 7 Pump System 4 Pump System 8 Backup Pump The controller and control automatically turn on when power is applied to the I/O station.
The B32 communicates with each pump, vacuum receiver and material valve wired to Input/Output modules within the control enclosure. The B32 controls conveying operation based on settings the operator enters on the HMI. HOW IT WORKS When receivers in a pump system demand material, the B32 turns on the vacuum pump and dust collector in the appropriate pump system. It then opens the correct vacuum and material valves to convey material to satisfy the demand.
SPECIFICATIONS C 3 inch screen standard A 5.
INSTALLATION l Unpacking the Boxes . . . . . . . . . . .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 Loaders to the B32 . . . . . . .3-7 l Wiring Pumps to the B32 . . . . . . . .3-7 l Wiring Purge Valves to the B32 . . .3-7 l Connecting Main Power . . . . . . . . .3-8 l Initial setup . . . . . . . . . .
UNPACKING THE BOXES The B32 central loading control comes in one box. The box should include: 1 Carefully remove the B32 components from their shipping containers, and set upright. 2 Remove all packing material, protective paper, tape and plastic. 3 Carefully inspect all components to make sure no damage occurred during shipping. Notify the shipper immediately if damage is found.
You should plan the location of the B32 control to ensure easy access and minimal wiring. 1 Select a mounting location for the control. PREPARING FOR INSTALLATION The interface and Input/Output enclosure can be mounted on a wall or other stable vertical surface. Select a location that: r Is central to loaders that the B32 will control. Keep the B32 Input/Output station as close as possible to the loading stations to minimize the amount of wire needed to connect the vacuum receivers to the control.
INSTALLING THE B32 WIRING CONSIDERATIONS 3-4 INSTALLATION 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. WARNING: Improper installation may result in equipment damage or personal injury.
WARNING: Improper installation may result in equipment damage or personal injury. ● Always maintain a safe ground. Follow the safe grounding procedures in the wiring diagram package. Ground the shielded cable inside the Input/Output enclosure only. ● Do not operate the equipment at power levels other than those specified on the the equipment data plate.
CONNECTING TO THE B32 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 connections. The diagrams show the most accurate electrical component information. Use shielded cable unless you run wires in metal conduit. Failure to use a metal shield will expose the controls to static electricity, which can damage electronic components.
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 outputs are 24 VDC and all demand and fill sensor inputs are 24 VDC. A general list of loader electrical connections is included in the appendix.
CONNECTING MAIN POWER TO THE B32 The B32 Input/Output enclosure is equipped with a threeprong plug and power cord. Each optional remote touchscreen panel also has its own plug and power cord. 1 Plug the power cord(s) into a grounded 115 VAC outlet rated for at least 15 Amp service. 2 Make sure the control enclosure is grounded. WARNING: Electrical shock hazard Failure to provide proper grounding can cause control malfunctions and could result in personal injury from electrical shock.
Before you can begin conveying, you must configure and identify the loaders and conveying features you want to use. INITIAL SETUP Procedures on the following pages will explain how to: r Set loader parameters r Enable pumps and loaders r Select security password To begin Initial Setup: 1 Turn on power to the B32. The Power ON/OFF switch is on the left side of the control enclosure. 2 Wait for the control to boot. Do not touch the control until it completes the bootup and initialization process.
SETTING LOADER PARAMETERS CAUTION: Incorrect configurations will cause the B32 control to stop. Before enabling loaders and loading functions, make sure the loader, valve or option has been installed in the system. Each loader and feature must be wired to a correctly installed and enabled input or output module. The B32 will fault and the loading control will stop if the required I/O module has not been installed for the feature you enabled.
To enable the loaders from the main screen: 1 Use the Up/Down arrows to scroll to Loader Settings. 2 ENABLING LOADERS Press the Enter arrow. The Loader Settings screen displays. Use the up/down arrows to scroll to Loader Enable. 3 Press the Enter arrow. The Loader Enable screen displays. Use the up/down arrows to increase and decrease the loader number. Use the scroll down/up buttons to enable/disable the loader.
SELECTING A PASSWORD The B32 provides password security to prevent unauthorized changes to loader or system settings. 1 Use the Up/Down arrows to scroll to System Config. Entering the System Configuration screen requires a Supervisor 2 password. 2 Enter the password. To enter the password use the up/down arrows to scroll through the alphanumeric list. When the correct letter/number is highlighted use the right Select arrow to move to the next digit. Continue until the whole password is selected.
OPERATION 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 Assigning Pumps and Loaders . . .4-7 l Assigning a Backup Pump . . . . . .4-8 l Configuring the Alarm . . . . . . . . . .4-9 l Backing up PLC Program . . . . . .
The B32 operator interface allows you to view the status of the vacuum receivers and pumps in your conveying system at a glance. It also provides access to screens to enter settings for each loading station, view alarms and change system parameters.
To view loader status from the main screen: 1 Use the Up/Down arrows to scroll to Loader Settings. 2 Press the Enter arrow. VIEWING LOADER STATUS The Loader Settings screen displays. Use the up/down arrows to scroll to Loader 1-16. 3 Press the Enter arrow. The Loader Status screen displays. The current status of each loader and pump displays.
ENABLING AND DISABLING LOADERS WARNING: Develop and follow procedures for safe operation of the system to avoid possible injury or equipment damage. The B32 allows operators and maintenance personnel to disable and enable conveying system components from remote locations. Unexpected energization of these components could result in equipment damage or injury.
WARNING: Develop and follow procedures for safe operation of the system to avoid possible injury or equipment damage. The B32 allows operators and maintenance personnel to disable and enable conveying system components from remote locations. Unexpected energization of these components could result in equipment damage or injury.
CONFIGURING LOADERS You may need to change loader settings whenever you change materials or to obtain the best conveying performance. To configure loaders from the main screen: 1 Use the Up/Down arrows to scroll to Loader Config. 2 Press the Enter arrow. The Loader Configuration screen displays. Use the up/down arrows to scroll to Option Config. 3 Press the Enter arrow. The Option Configuration screen displays. Use the up/down arrows to increase and decrease the loader number.
You 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: 1 Use the Up/Down arrows to scroll to ASSIGNING LOADERS AND PUMPS Loader Config. 2 Press the Enter arrow. The Loader Configuration screen displays. Use the up/down arrows to scroll to Pump Assign. 3 Press the Enter arrow. The Pump Assignment screen displays. Use the up/down arrows to choose the loader number.
ASSIGNING A BACKUP PUMP A backup pump can be assigned to replace any of the eight pump systems during operation. To assign a backup pump: 1 Use the Up/Down arrows to scroll to Loader Config. 2 Press the Enter arrow. The Loader Configuration screen displays. Use the up/down arrows to scroll to VP Back-Up Select. 3 Press the Enter arrow. The Pump Back-up Select screen displays. Use the scroll down/up buttons to select a backup pump (pumps 1 through 8) or no backup pump.
Te loader can be configured for demand alarm, fill alarm or no alarm. To configure the alarm from the main screen: 1 CONFIGURING THE ALARM Use the Up/Down arrows to scroll to Loader Config. 2 Press the Enter arrow. The Loader Configuration screen displays. Use the up/down arrows to scroll to Alarms. 3 Press the Enter arrow. The Alarm Configuration screen displays.
BACKING UP PLC PROGRAM (OPTIONAL) To back up the PLC program and save the configuration: 1 Use the Up/Down arrows to scroll to Loader Config. 2 Press the Enter arrow. The Loader Configuration screen displays. Use the up/down arrows to scroll to Save Config. 3 Press the Enter arrow. The Save Configuration screen displays. Use the up/down arrows to scroll to Program Mode 4 Press the Enter arrow. The Program Mode screen displays. Use the up/down arrows to to select Save to EEPROM.
MAINTENANCE l Maintenance checklist . . . . . . . .
PREVENTIVE MAINTENANCE CHECKLIST You 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 times and dump times. See CHANGING LOADER SETTINGS in the Operation section.
TROUBLESHOOTING 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 Conveying System alarms . . . . .6-6 l Operator Interface Problems . . . . . . . . . . . . . . . . .6-8 l Processor and Power Problems. . . . . . . . . . . . . . . . . 6-8 l CPU faults . . . . . . . . . . . . . . . . .6-9 l I/O errors . . . . . . . . . . . .
BEFORE BEGINNING A FEW WORDS OF CAUTION 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. WARNING: Improper installation, operation or servicing may result in equipment damage or personal injury.
The TROUBLESHOOTING 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. IDENTIFYING THE CAUSE OF A PROBLEM These tables focus on the “No Material” and “Pump Overload” alarms that the B32 displays on the Alarm Summary screen. The B32 continues to control the system and the alarming loading station will load. r Power and Processor Problems.
CLEARING INTERFACE ALARMS When a conveying problem occurs, the screen displays the alarm message and the audible alarm sounds. To silence the alarm and fix the problem: 1 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 acknowledges the alarm; it does not fix the problem. 2 View Alarm list. From the Main screen use the Up/Down arrows to scroll to Loader Settings. Press Enter.
CPU and Iinput/Output errors will stop the B32 control. These errors may be caused by problems with the power supply, 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 and power supply modules. CLEARING CPU AND I/O ALARMS To clear and fix a CPU or I/O error from the Main screen: 1 Use the Up/Down arrows to scroll to Loader Config. 2 Press the Enter arrow. The Loader Configuration screen displays.
CONVEYING SYSTEM ALARMS The No Material Alarm can be triggered in two ways: l The Alarm Check signals an alarm after the operator-set number of consecutive loading attempts fails to satisfy the receiver’s demand for material. l The optional fill sensor in the receiver or hopper is not satisfied after one loading cycle. Alarm Possible cause No Material Alarm There is no material at the source. Loader Settings are incorrect. There is a leak in the vacuum system.
CONVEYING SYSTEM ALARMS Alarm Possible cause Solution No Material Alarm (continued) Vacuum pump is not working correctly. Verify that the vacuum pump is on, connected to the B32 and working correctly. Refer to the pump manual. Pump Overload UGC007/0702 The fill/demand sensor or demand switch is not working properly. r Verify that sensors and switches are connected correctly at the loader or hopper and at the control.
OPERATOR INTERFACE PROBLEMS 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 require access to the B32 Input/Output enclosure while power is on. Solution Fault Possible cause Terminal does not power up.
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 require access to the B32 Input/Output enclosure while power is on. Error/Alarm Possible cause See APPENDIX D: “FAULT MESSAGES CPU faults, causes and solutions.
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EQUIPMENT GUARANTEE Conair guarantees the machinery and equipment on this order, 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 recommended (except for parts that are typically replaced after normal usage, such as filters, liner plates, etc.). Conair’s guarantee is limited to replacing, at our option, the part or parts determined by us to be defective after examination.
The program can be restored to the plant configuration if for some reason the program has been interrupted. To restore the program: RESTORING THE PROGRAM 1 Use the Up/Down arrows to scroll to Loader Config. 2 Press the Enter arrow. The Loader Configuration screen displays. Use the up/down arrows to scroll to Save Config 3 Press the Enter arrow. The Save Configuration screen displays. Use the scroll up/down buttons to select Program Mode. 4 5 Press the Enter arrow to save the change.
Appendix C Troubleshooting Your System This chapter describes how to troubleshoot your controller. Topics include: • understanding the controller LED status • controller error recovery model • identifying controller faults • calling Rockwell Automation for assistance Understanding Controller LEDs The controller status LEDs provide a mechanism to determine the current status of the controller if a programming device is not present or available.
C-2 Troubleshooting Your System When Operating Normally The POWER and RUN LEDs are on. If a force condition is active, the FORCE LED turns on and remains on until all forces are removed. When an Error Exists If an error exists within the controller, the controller LEDs operate as described in the following tables.
Troubleshooting Your System Controller Error Recovery Model Identify the error code and description. C-3 Use the following error recovery model to help you diagnose software and hardware problems in the micro controller. The model provides common questions you might ask to help troubleshoot your system. Refer to the recommended pages within the model for further help. No Is the error hardware related? Start Yes Refer to page C-2 for probable cause and recommended action.
C-4 Troubleshooting Your System Identifying Controller Faults While a program is executing, a fault may occur within the operating system or your program. When a fault occurs, you have various options to determine what the fault is and how to correct it. This section describes how to clear faults and provides a list of possible advisory messages with recommended corrective actions.
Appendix D Fault Messages and Error Codes This chapter describes how to troubleshoot your controller. Topics include: • identifying controller faults • contacting Rockwell Automation for assistance Identifying Controller Faults While a program is executing, a fault may occur within the operating system or your program. When a fault occurs, you have various options to determine what the fault is and how to correct it.
D-2 Fault Messages and Error Codes Manually Clearing Faults Using the Fault Routine The occurrence of recoverable or non-recoverable user faults can cause the user fault subroutine to be executed. If the fault is recoverable, the subroutine can be used to correct the problem and clear the fault bit S:1/ 13. The controller then continues in the Run or test mode. The subroutine does not execute for non-user faults. See User Fault Routine on page 18-6 for information on creating a user fault subroutine.
Fault Messages and Error Codes D-3 Error Code (Hex) 0006 Advisory Message Description Fault Classification Recommended Action MEMORY MODULE HARDWARE FAULT The memory module hardware faulted or the memory module is incompatible with OS. Non-User • Upgrade the OS to be compatible with memory module. • Obtain a new memory module. 0007 MEMORY MODULE TRANSFER ERROR FATAL INTERNAL SOFTWARE ERROR Failure during memory module transfer. An unexpected software error occurred.
D-4 Error Code (Hex) 0016 0017 0018 001A 0020 0021 0022 0023 Fault Messages and Error Codes Advisory Message Description Fault Classification Recommended Action • Either reset bit S:1/9 if this is consistent The user fault routine was executed Recoverable at power-up, prior to the main ladder with the application requirements, and program.
Fault Messages and Error Codes Advisory Message Description INVALID OR NONEXISTENT USER FAULT ROUTINE VALUE Non-User • A fault routine number was entered in the status file, number (S:29), but either the fault routine was not physically created, or • the fault routine number was less than 3 or greater than 255. • Either clear the fault routine file number (S:29) in the status file, or • create a fault routine for the file number reference in the status file (S:29).
D-6 Error Code (Hex) 003D 003E 003F Fault Messages and Error Codes Advisory Message Description Fault Classification INVALID SEQUENCER A sequencer instruction (SQO, SQC, Recoverable LENGTH/POSITION SQL) length/position parameter is greater than 255.
Fault Messages and Error Codes Advisory Message Description MAX I/O CABLES EXCEEDED The maximum number of expansion Non-User I/O cables allowed was exceeded. • Reconfigure the expansion I/O system so that it has an allowable number of cables. • Cycle power. 0084 MAX I/O POWER SUPPLIES EXCEEDED • Reconfigure the expansion I/O system so that it has the correct number of power supplies. 0085 MAX I/O MODULES EXCEEDED The maximum number of expansion Non-User I/O power supplies allowed was exceeded.
D-8 Fault Messages and Error Codes Error Code (Hex) Advisory Message Description Fault Classification Recommended Action xx8B(1)(2) EXPANSION I/O POWER SUPPLY CONFIGURATION MISMATCH ERROR • Either an expansion I/O power Non-User supply is configured in the user program, but no power supply is present, or • an expansion I/O power supply is configured in the user program and a power supply is physically present, but the types do not match.
