SLC48 Sentral Loader Control - Conair Group · 2001. 3. 15. · 7Loader 6 8 In this example, the SLC48 monitors and controls conveying in a typical CDS application. Pump System 1

Sentral Loader Control

Instant Access Parts and Service

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

www.conairnet.com

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

SLC48 Touchscreen Conveying Controls

UGC003/0201

Installation

Operation

Maintenance

Troubleshooting

Disabled Enabled Demand Loading Alarm

SLC48 Sentral Loading Control

Return tomain screen

View pump /loader groups

View selecteddevice status

Enter devicesettings

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It’s a good idea to record the model, serial and software version numbers of your equipment and the date you receivedit in the User Guide. Our service department uses this infor-mation, along with the manual number, to provide help for thespecific equipment you installed.

Please keep this User Guide and all manuals, engineeringprints and parts lists together for documentation of yourequipment.

Date:

Manual Number: UGC003/0201

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 damagesin connection with the furnishing, performance or use of this infor-mation. Conair makes no warranty of any kind with regard to thisinformation, including, but not limited to the implied warranties ofmerchantability and fitness for a particular purpose.

Please record yourequipment’s model and

serial number(s) andthe date you received itin the spaces provided.

Copyright 2001 All rights reservedTHE CONAIR GROUP

UGC003/0201 SLC48 Sentral Loader Control

TABLE OFCONTENTS

INTRODUCTION .........................................1-1Purpose of the user guide ......................................................1-2How the guide is organized ...................................................1-2Your responsibilities as a user .............................................. 1-2ATTENTION: Read this so no one gets hurt ........................1-3

DESCRIPTION . . . . . . . . . . . . . . . . . . . .2-1What is the SLC48? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2Typical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3How it works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4Specifications: SLC48 . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

INSTALLATION . . . . . . . . . . . . . . . . . . . .3-1Unpacking the boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . .3-3Installing the SLC48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4Wiring considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4Mounting the control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5Connecting a keyboard (optional) . . . . . . . . . . . . . . . . . . .3-5Connecting remote touchscreen panels (optional) . . . . . . .3-5Wiring loaders to the SLC48 . . . . . . . . . . . . . . . . . . . . . . .3-6Wiring pumps to the SLC48 . . . . . . . . . . . . . . . . . . . . . . . .3-8Wiring purge valves to the SLC48 . . . . . . . . . . . . . . . . . . .3-9Wiring pocket conveying valves to the SLC48 . . . . . . . . . .3-9Wiring for material line proofing . . . . . . . . . . . . . . . . . . .3-10Connecting main power to the SLC48 . . . . . . . . . . . . . . .3-10Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11❒ Configuring loaders . . . . . . . . . . . . . . . . . . . . . . . . . .3-12❒ Entering pump and loader settings . . . . . . . . . . . . . . .3-14❒ Identifying loaders . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16❒ Setting the date and time . . . . . . . . . . . . . . . . . . . . . . .3-17❒ Recording the software version . . . . . . . . . . . . . . . . . .3-18❒ Setting security levels . . . . . . . . . . . . . . . . . . . . . . . . .3-19❒ Changing the Level 2 password . . . . . . . . . . . . . . . . . .3-20

OPERATION . . . . . . . . . . . . . . . . . . . . . .4-1SLC48 control features . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2Operating the conveying system . . . . . . . . . . . . . . . . . . . . .4-4Enabling and disabling loaders . . . . . . . . . . . . . . . . . . . . . .4-5Changing loader settings . . . . . . . . . . . . . . . . . . . . . . . . . .4-6Assigning a backup pump . . . . . . . . . . . . . . . . . . . . . . . . .4-8

MAINTENANCE . . . . . . . . . . . . . . . . . . . .5-1Preventive maintenance checklist . . . . . . . . . . . . . . . . . . . .5-2Recalibrating the touchscreen . . . . . . . . . . . . . . . . . . . . . .5-3

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SLC48 Sentral Loader Control UGC003/0201

TABLE OFCONTENTS

TROUBLESHOOTING . . . . . . . . . . . . . . . .6-1Before beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2A few words of caution . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2Identifying the cause of a problem . . . . . . . . . . . . . . . . . . .6-3Clearing conveying alarms . . . . . . . . . . . . . . . . . . . . . . . . .6-4Clearing CPU and I/O alarms . . . . . . . . . . . . . . . . . . . . . .6-5

DIAGNOSTICSConveying system alarms . . . . . . . . . . . . . . . . . . . . . . . . . .6-6❒ No Material Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6❒ Pump Overload Alarm . . . . . . . . . . . . . . . . . . . . . . . . .6-7❒ Sourcing Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

Power and processor problems . . . . . . . . . . . . . . . . . . . . . .6-8CPU faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10I/O errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

APPENDIXCustomer service information . . . . . . . . . . . . . . . . . . . . . .A-1Warranty information . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2Installing slots and loaders . . . . . . . . . . . . . . . . . . . . . . . .B-1

PARTS/DIAGRAMSWiring DiagramsRecommended Spare Parts

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1-1UGC003/0201 SLC48 Sentral Loader Control

�� 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 .....................1-3

INTRODUCTION

SLC48 Sentral Loader Control UGC003/02011-2 INTRODUCTION

This User Guide describes the Conair SLC48 Sentral LoaderControl and explains step-by-step how to install, operate,maintain and repair this equipment.

Before installing this product, please take a few moments toread the User Guide and review the diagrams and safety infor-mation in the instruction packet. You also should review man-uals covering associated equipment in your system. Thisreview won’t take long, and it could save you valuable instal-lation and operating time later.

Symbols have been used to help organize the User Guide andcall your attention to important information regarding safeinstallation and operation.

Symbols within triangles warn of conditions that couldbe hazardous to users or could damage equipment.Read and take precautions before proceeding.

Numbers within shaded squares indicate tasks or stepsto be performed by the user.

A diamond indicates the equipment’s response to anaction performed by the user.

An open box marks items in a checklist.

A shaded circle marks items in a list.

You must be familiar with all safety procedures concerninginstallation, operation and maintenance of this equipment.Responsible safety procedures include:

� Thorough review of this User Guide, paying particularattention to hazard warnings, appendices and related dia-grams.

� Thorough review of the equipment itself, with carefulattention to voltage sources, intended use and warninglabels.

� Thorough review of instruction manuals for associatedequipment.

� Step-by-step adherence to instructions outlined in thisUser Guide.

PURPOSE OFTHE USERGUIDE

HOW THEGUIDE ISORGANIZED

1

�

❒

�

YOURRESPONSIBILITYAS A USER

UGC003/0201 SLC48 Sentral Loader Control INTRODUCTION 1-3

We design equipment with the user’s safety in mind. You canavoid the potential hazards identified on this machine by fol-lowing the procedures outlined below and elsewhere in theUser Guide.

ATTENTION:READ THIS SO NO

ONE GETS HURT

WARNING: Electrical shock hazard

This equipment is powered by electrical voltageas specified on the machine serial tag and dataplate.

A properly sized conductive ground wire fromthe incoming power supply must be connectedto the chassis ground terminal inside theInput/Output enclosure. Improper groundingcan result in personal injury and erraticmachine operation.

Always disconnect and lock out the incomingmain power source before opening the electri-cal enclosure or performing non-standard oper-ating procedures, such as troubleshooting orroutine maintenance. Only qualified personnelshould perform troubleshooting procedures thatrequire access to the electrical enclosure whilepower is on.

WARNING: Improper installation,operation or servicing may result inequipment damage or personal injury.

This equipment should be installed, adjusted,and serviced by qualified technical personnelwho are familiar with the construction, opera-tion and potential hazards of this type of equip-ment.

All wiring, disconnects and fuses should beinstalled by qualified electrical technicians inaccordance with electrical codes in your region.Always maintain a safe ground. Do not operatethe equipment at power levels other than whatis specified on the the equipment serial tag anddata plate.


�� What is the SLC48? . . . . . . . . . .2-2�� Typical applications . . . . . . . . . .2-3�� How it works . . . . . . . . . . . . . . .2-4�� Specifications: SLC48 . . . . . . . .2-6

DESCRIPTION

The touchscreen panel is mounted on the front of the I/O station. Inside are one or two racks, containing up to 24input/output modules (slots) connected to a PLC controller.The number of input and output modules will vary with thenumber of vacuum receivers and conveying options.

The controller and touchscreen panel automatically turn onwhen power is applied to the I/O station. After a bootupsequence, the Home Screen is displayed. From the HomeScreen, you can view the operating status of all vacuumreceivers connected to the system. Color-coded icons indicate whether each receiver is:

� Disabled = Black � Demanding material = Blue� Enabled = White � Alarming = Red� Loading = Green

Touch one of the iconsor one of the naviga-tion buttons along theright side of the screen

WHAT IS THESLC48?

SLC48 Sentral Loader Control UGC005/07982-2 DESCRIPTION






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10-inch diagonal screen

6-inch diagonal screen

BackupPump

PumpSystem 1

PumpSystem 2

PumpSystem 4

PumpSystem 3

PumpSystem 5

PumpSystem 6

PumpSystem 8

PumpSystem 7

I/O andControl

UGC005/0798 SLC48 Sentral Loader Control DESCRIPTION 2-3

TYPICALAPPLICATIONS






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The SLC48 has been designed for central material conveyingapplications, including Conair’s CDS Central Drying andDistribution System.

Loader-pump assignments are completely flexible. Individualvacuum receivers can be assigned to any one of the eightloading systems. Each receiver can be configured for:� Single-material loading.� Ratio loading, with or without automatic material layering.� Positive (air-operated) receiver discharge.� Material line purging.� Material line proofing.� Pocket conveying from a drying hopper or other vessel.� Loader fill alarm to work with an optional fill sensor

mounted in the receiver body or direct feed chamber.� Hopper fill alarm to work with an optional demand sensor

mounted in a drying hopper or other material vessel.

PumpSystem 1

PumpSystem 2

RatioLoading

LineProofing

PocketConveying

LinePurging

LoaderFill

HopperFill

Loader1

Loader2

Loader3

Loader7 Loader

8Loader

6

In this example, the SLC48 monitorsand controls conveying in a typicalCDS application.

Pump System 1 conveys material tothe drying hoppers from three differ-ent material sources.

Pump System 2 conveys materialfrom the drying hoppers to three processing machines as it is needed.

HOW IT WORKS


The SLC48 communicates with each pump, vacuum receiverand material valve wired to Input/Output modules within thecontrol enclosure. The SLC48 controls conveying operationbased on settings the operator enters on a touchscreen panel.

When receivers in a pump system demand material, theSLC48 turns on the vacuum pump and dust collector in theappropriate pump system. It then opens the correct vacuumand material valves to convey material to satisfy the demand.

In the example below, the operator has specified that Loader 1draw material from Material Source 12, a drying hopper witha pocket conveying valve installed at the hopper discharge.


Touch Screen

Pumps

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1Loader Settings

Next

Home

Enabled Disable

Load Time (secs.)

Pump Number

Purge Time (secs.)

Status

Material Source

Dump Time (secs.)

Alarm CheckSet Set

Set

Set Set

Push Set to change values

20

1

10

3Set

10 12Loader 10

Pump System 2 Material Source 12

Loader 1

Pump System 1

The SLC48 receives amaterial demand signal(input) from the fill sensor in Loader 1.

The SLC48 closes the pocket conveying valve after 20 seconds, shutting off material flow from the hopper. The vacuum valve at the receiver remains open for 10 seconds (purge time) to continue pulling material from the line into the receiver.

1The SLC48 opens the vacuumsequencing valve in Loader 1 andthe pocket conveying valve atMaterial Source 12. The vacuumcycle remains on for 30 seconds.(Cycle Time = Load Time + Purge Time)

2

3

Vacuum Flow

Material Flow

The SLC48 will signal an alarm if:

� Demand for material at Loader 1is not satisfied within 3 loadingcycles (Alarm Check triggers aNo Material Alarm).

� Material cannot be pulled from theassigned Material Source 12(Sourcing Error).

The SLC48 Home Screen lets the operator monitor the statusof all vacuum receivers at a glance. Color-coded icons indicatethe real-time status of each receiver.

Other screens allow you to change system settings or to viewpump systems, loader details, alarm histories and Help screensthat provide instructions pertaining to the specific screen.

HOW IT WORKS

UGC003/0201 SLC48 Sentral Loader Control DESCRIPTION 2-5








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6Loader 6 Status

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Enabled Disable

Edit

AlarmSummary

Loader assigned to:

Demanding Material

Connected to Pump 1

Pump Currently Loading 4

Machine 1 - PET


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Security ScreenHome

****] KeyPad

SetDate and

Time

Enter Security Code

Back-upPump

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LoaderSettingsScreen

LoaderFeaturesScreen

ChangeUser

Password


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Next

The control has four security levels.

You can view the status of pumps andreceivers, or enable and disable a receiver without entering a security code (Level 1access). You must enter a security code to change or enter all other loader, pumpand system settings. To enter a code:

1. Press the KEYPAD button.2. Enter a security code (up to 5 digits).

Depending on the security level, the followingaccess buttons will be displayed:

LOADER SETTINGS SCREEN (Level 2) - Press toaccess screens for entering load times, dump


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HomeTIME DESCRIPTION

O3:22:36 Loader No. 6 No Material Alarm

03:25:45 Alarm Summary

O2:10:07 Loader No. 4 No Material AlarmO2:05:45 Loader No. 6 Sourcing Error

23:05:15 Pump No. 2 Pump Overload

23:45:10 Loader No. 9 No Material Alarm23:35:10 Loader No. 7 No Material Alarm23:25:15 Loader No. 8 No Material Alarm23:10:30 Loader No. 10 No Material Alarm

23:55:30 Loader No. 11 No Material Alarm

AcknowledgeAlarm

ClearAlarm

SPECIFICATIONS


MODELS SLC48Performance characteristics

Maximum number of vacuum receivers 48Maximum number of vacuum pumps 8 (plus back-up)Maximum number of source valves 32Maximum number of proofing loaders 48Programmable logic controller Allen Bradley SLC503Touchscreen operator interface CTC/Parker Automation Communications with master control DH485Screen size diagonal inches {mm}

standard 5.7 {145}optional 10.4 {264}

User interface method standard resistive touchscreen optional keyboard, mouse

Output voltage to receivers/valves 24 VACSensor voltage to receivers 24 VDCOutput voltage to pumps 115 VAC

Dimensions inches {mm}Master control cabinet A - Height 34 {864}B - Width 36 {914}C - Depth 10 {254}Optional remote controlA - Height 12 {305}B - Width 16 {406}C- Depth 6 {152}

Weight lb {kg}Installed 75 {34}Shipping 90 {41}Optional remote control Installed 20 {9.1}Shipping 22 {10.0}

Voltages Total amps115V/1 phase/60Hz (master control) 10115V/1 phase/60 Hz (remote control) 5

A

B

CALCULATING SENTRAL SYSTEM CABLE LENGTH:

Total the distances from the Input/output Station(s) location to each vacu-um receiver on the system. Be sure to account for reasonable slack ateach loading station for connections, cable routing, etc.

APPLICATION NOTES:Conair vacuum receivers come equipped with a quick-disconnect connec-tor set that includes 10 feet of cable. Junction boxes must be provided toconnect the system cable and each vacuum receiver’s connector set.

SPECIFICATION NOTES:Sentral loader control cable: 18 gauge shielded, 8-conductor may beused for standard vacuum receivers with up to one optional output andinput, otherwise 10-conductor cable is required.

Specifications can change without notice. Check with a Conair representative for the most current information.

C

A

BC

Optional RemoteControlSLC48 Master Control

10.4 inch screen (optional)

6 inch screen standard


�� Unpacking the boxes . . . . . . . . . . .3-2�� Preparing for installation . . . . . . . .3-3�� Installing the SLC48 . . . . . . . . . . . .3-4��Wiring considerations . . . . . . . . . .3-4�� Mounting the control . . . . . . . . . . .3-5�� Connecting a keyboard . . . . . . . . .3-5�� Connecting remote panels . . . . . .3-5��Wiring loaders to the SLC48 . . . . .3-6��Wiring pumps to the SLC48 . . . . . .3-8��Wiring purge valves to the SLC48 .3-9��Wiring pocket conveying valves . .3-9��Wiring for material line proofing .3-10�� Connecting main power . . . . . . . .3-10�� Initial setup . . . . . . . . . . . . . . . . . .3-11

❒❒ Configuring loaders . . . . . . . . . . . . . . . . . .3-12❒❒ Entering pump and loader settings . . . . .3-14❒❒ Identifying loaders . . . . . . . . . . . . . . . . . . .3-16❒❒ Setting the date and time . . . . . . . . . . . . . .3-17❒❒ Recording the software version . . . . . . . .3-18❒❒ Setting security levels . . . . . . . . . . . . . . . .3-19❒❒ Changing the Level 2 password . . . . . . . .3-20

INSTALLATION

The SLC48 central loading control comes in one or moreboxes, depending on the options ordered. The boxes shouldinclude:

Carefully remove the SLC48 components fromtheir shipping containers, and set upright.

Remove all packing material, protective paper, tapeand plastic.

Carefully inspect all components to make sure nodamage occurred during shipping. Notify the shipperimmediately if damage is found.

Take a moment to record serial numbers, thesoftware version number and electrical power specifica-tions in the blanks provided on the back of the the UserGuide’s title page. The information will be helpful if youever need service or parts.

You are now ready to begin installation.Follow the preparation steps on the next page, paying par-ticular attention to all wiring consideration and recom-mendations.

UNPACKINGTHE BOXES

SLC48 Sentral Loader Control UGC003/02013-2 INSTALLATION








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Remote Touchscreen Panels(Optional)

5

Touchscreen Interface Paneland Input/Output Enclosure

PREPARING FORINSTALLATION

UGC003/0201 SLC48 Sentral Loader Control INSTALLATION 3-3

You should plan the location of the SLC48 control to ensureeasy access and minimal wiring. Remote touchscreen panelscan be connected to the control via an ethernet port inside thecontrol enclosure of the primary touchscreen interface.

Select a mounting location for the control. The touchscreen interface and Input/Output enclosure canbe mounted on a wall or other stable vertical surface.

Select a location that:❒❒ Is central to loaders that the SLC48 will control.Keep the SLC48 Input/Output station as close as possibleto the loading stations to minimize the amount of wireneeded to connect the vacuum receivers to the control.

❒❒ Provides adequate clearance for safe operation andmaintenance. The control should be mounted at a heightthat allows the operator to easily see and touch the screen.An external keyboard, if used, should be located on a sta-ble horizontal surface within sight of the panel. Maintainat least 3 feet (1 m) clearance in front of the control forsafe access to the Input/Output enclosure.

❒❒ Provides a clean, dry, vibration-free environment. Exposure to wide temperature variations, high ambienttemperature, power line fluctuations, caustic fumes orexcessive amounts of dust, dirt, vibration, shock andmoisture could harm performance and reduce the life ofthis equipment.

❒❒ Provides a grounded source of 115 VAC power. The three-prong power cord supplied with the SLC48control requires a grounded 115 VAC outlet rated for atleast 15 amp service.

Plan the power/communication cable routes.❒❒ Review all wiring guidelines and diagrams providedin the manuals and electrical diagrams supplied with theSLC48 control and your conveying equipment beforebeginning installation. See WIRING CONSIDERATIONS.❒❒ Keep communication wires away from sources ofstatic electricity. Static electricity can damage the con-trols.Communication cables should not be run near thematerial lines and hoses, which produce large amounts ofstatic electricity when material is conveyed. You shoulduse shielded cable unless you run wires through metalconduit.

❒❒ Avoid running communication cables across powerfeed lines. If you must run the cable across power feedlines, run the cable at right angles to the lines.

1

2

WIRINGCONSIDERATIONS

Installation of the SLC48 control consists of:❒ Mounting the touchscreen and Input/Output enclosure.❒ Connecting remote touchscreen panels (optional).❒ Connecting an external keyboard (optional).❒ Wiring loaders to the control.❒ Wiring pumps to the control.❒ Wiring material valves to the control.❒ Connecting the control to a main power source.❒ Initial setup of the system control.

INSTALLINGTHE SLC48


WARNING: Improper installation may resultin equipment damage or personal injury.

� Disconnect and lock out the main power supply toequipment in the conveying system before attempting towire power and communication cables between the SLC48control, vacuum receivers, pumps, dust collectors and mate-rial valves.

� Install all wiring, disconnects and fuses in accordancewith electrical codes in your region. All electrical installationsshould be done only by qualified electrical technicians.

� Always refer to the wiring diagrams supplied with yourcontrol before making electrical connections. The diagramsshow the most accurate electrical component information.

� Protect communication cables from sources of staticelectricity and electrical noise.

❒ Use shielded cable or run wire through a contiguousmetal conduit or wireway. Failure to use a metal shieldcan expose the controls to static electricity, which candamage electronic components.

❒ Do not run communication cables near material linesand hoses, which produce large amounts of static elec-tricity when conveying material.

❒ Keep communication cables at least 5 ft. (1.5 m) fromelectric motors, transformers, rectifiers, arc welders,generators, induction furnaces and sources microwaveradiation.

❒ Avoid running communication cable across power feedlines. If you must run cable across power lines, run thecable at right angles to the line. Keep the cable at least6 inches (0.15 m) from AC power lines of less than 20A; 1 foot (0.30 m) from lines of 20A to 100 kVA; and 2feet (0.60 m) from lines of 100 kVA or more.

� Always maintain a safe ground. Follow the safe ground-ing procedures in the wiring diagram package. Ground theshielded cable inside the Input/Output enclosure only.

� Do not operate the equipment at power levels otherthan those specified on the the equipment data plate.


The SLC48 Input/Output enclosureshould be mounted on a wall, or othersecure vertical surface, at a heightproviding easy access and a clearview of the touchscreen panel.

Bolt the control to themounting surface. Use the mounting brackets on the I/O enclosure.

Ground the control enclosure.Connect a ground wire to the control. Follow proceduresoutlined by your regional electrical codes and the wiringdiagrams included with this manual.

An alphanumeric keypad is built into the 10-inch touchscreeninterface. If you have the 6-inch screen size and want to enteradditional information about loaders connected to the system,you will need an external keyboard.

A keyboard can be connected to the PS/2 port on the back ofthe touchscreen interface panel. Use a strain relief, if you runthe keyboard cable through a hole in the I/O enclosure.

Open the SLC48 controlenclosure.

Plug the keyboard into the available PS/2 port.

You can monitor or control the conveyingsystem from an optional remote touch-screen panel located within 328 feet (100 m) of the I/O enclosure.

The remote panel connects to an ether-net/ LAN port inside the I/O enclosureon the back of the touchscreen control.

Open the SLC48 control enclosure.

Insert the network cablethough a knockout in theI/O enclosure. Secure witha strain relief.

Plug the cable into theethernet/LAN port.

MOUNTINGTHE CONTROL

CONNECTINGREMOTE PANELS(OPTIONAL)








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CONNECTINGA KEYBOARDTO THE SLC48(OPTIONAL)

PS/2 port

Ethernet/LAN port

12 NOTE: More than one

remote panel will require anetwork hub. Remote panelslocated greater than 328 feetfrom the I/O enclosure willrequire an amplifier in thenetwork line.

Hub

3

Each vacuum receiver, pump andmaterial valve in the system must bewired to power or common/groundterminals and Input/Output slots onup to two racks inside the SLC48control enclosure.

Each loader requires at least sevenwire connections to theInput/Output enclosure.

One additional wire is required for each option or for a three-wire sensor used for either demand or loader full inputs.Connect the loader cable wires to the I/O station according tothe color codes:

WIRING LOADERSTO THE SLC48


WARNING: Improper installationmay result in equipment damage orpersonal injury.

Always refer to the wiring diagrams that camewith your controls before making electrical con-nections. The diagrams show the most accurateelectrical component information.

Use shielded cable unless you run wires inmetal conduit. Failure to use a metal shield willexpose the controls to static electricity, whichcan damage electronic components.

When using shielded cable, make sure theshield is grounded inside the I/O stations only.It is also important to keep the communicationwires away from conveying lines, which canproduce large amounts of static electricity.

Orange Sensor Power (Input/Output)Pink Sensor Common (Input/Output)Yellow Demand Sensor InputRed/Black Fill Sensor InputRed 24 VAC PowerWhite AC Power NeutralGreen GroundBlack Load SolenoidBrown Ratio SolenoidRed/Yellow Air Discharge SolenoidRed/Green Purge Solenoid

ShieldBlue Filter Blowback — NO CONNECTIONViolet Alarm — NO CONNECTIONGray Bin Level — NO CONNECTIONTan Spare — NO CONNECTION

Cable fromLoader

(Universal Terminal Box)

Rack 1

Rack 2

Slot

1Slot

12Slot

11Slot

10Slot

4Slot

3Slot

2Slot

7Slot

6Slot

5

PowerSupply Slot

9Slot

8

Slot

13Slot

24Slot

23Slot

22Slot

16Slot

15Slot

14Slot

19Slot

18Slot

17Slot

21Slot

20

Slot

0

Slot

25PowerSupply

Input/Output slots

The loader wires connect to power terminals or terminals onthe I/O slots inside the control enclosure. The number of loaders and options in the conveying system will determinethe number of connections that are required.

Refer to the electrical prints included with this manual for allelectrical connections to the loader control. All loader outputsare 24 VAC and all demand and fill sensor inputs are 24 VDC.

A general list of loader electrical connections are as follows:


WIRING LOADERSTO THE SLC48

WIRE LOADERS CONNECTION RACKSensor power 1-20 and 41-44 Terminal #11 1

21-40 and 45-48 Terminal #14 2Sensor common 1-20 and 41-44 Terminal #10 1

(for 3-wire sensor) 21-40 and 45-48 Terminal #13 2Demand sensor input 1-10 slot 2, inputs 0-9 1

11-14 slot 3, inputs 4-7 115-20 slot 4, inputs 0-5 121-30 slot 15, inputs 0-9 231-34 slot 16, inputs 4-7 235-40 slot 17, inputs 0-5 241-42 slot 3, inputs 8-9 143-48 slot 16, inputs 8-10 2

Full sensor input 1-6 slot 2, inputs 10-15 17-10 slot 3, inputs 0-3 111-20 slot 4, inputs 6-15 121-26 slot 15, inputs 10-15 227-30 slot 16, inputs 0-3 231-40 slot 17, inputs 6-15 241-48 slot 25, inputs 0-7 2

24 VAC power 1-20 Terminal #7 121-48 Terminal #7 2

24 VAC power neutral 1-20 Terminal #8 121-48 Terminal #8 2

Ground 1-20 Ground terminal 121-48 Ground terminal 2

Vacuum solenoid (load) 1-16 slot 5, outputs 0-15 117-20 slot 1, outputs 0-3 121-36 slot 18, outputs 0-15 237-40 slot 14, outputs 0-3 241-48 slot 13, outputs 0-7 2

Ratio solenoid 1-16 slot 6, outputs 0-15 117-20 slot 7, outputs 0-3 121-36 slot 19, outputs 0-15 237-40 slot 20, outputs 0-3 241-46 slot 13, outputs 10-15 247-48 slot 14, outputs 4-5 2

Air discharge solenoid 1-10 slot 7, outputs 6-15 111-20 slot 8, outputs 0-9 121-30 slot 20, outputs 6-15 231-40 slot 21, outputs 0-9 241-44 slot 1, outputs 4-7 145-48 slot 23, outputs 10-13 2

The SLC48 can run eight vacuum pumps and one backuppump. There are two pump outputs for each 10 loaders.

Refer to the electrical prints included with this manual for allelectrical connections to the loader control. All pump outputsare 115 VAC and all overload inputs are 24 VDC. A generallist of pump electrical connections are as follows:

Wiring connections between pumps and dust collectors will bethe same for all pumps. Pump motor contactor connections tothe dust collectors are as follows:

If not already installed, connect the jumper wire between thenormally closed contact on the overload (Terminal 95) to themotor contactor coil (Terminal A2).

WIRING PUMPSTO THE SLC48


WIRE PUMPS CONNECTION RACK115 VAC neutral All pumps Terminal #22

Pump output and Pump 1 slot 1, output 10 1Dust Collector solenoid Pump 2 slot 1, output 11 1

Backup pump slot 1, output 12 1Pump 3 slot 1, output 13 1Pump 4 slot 1, output 14 1Pump 5 slot 14, output 10 2Pump 6 slot 14, output 11 2Pump 7 slot 14, output 13 2Pump 8 slot 14, output 14 2

Pump overload power Pumps 1-4 Terminal #11 1Backup pump Terminal #11 1Pumps 5-8 Terminal #14 2

Pump overload input Pump 1 slot 3, input 11 1Pump 2 slot 3, input 12 1Backup pump slot 3, input 13 1Pump 3 slot 3, input 14 1Pump 4 slot 3, input 15 1Pump 5 slot 16, input 11 2Pump 6 slot 16, input 12 2Pump 7 slot 16, input 14 2Pump 8 slot 16, input 15 2

WIRE CONNECTIONPump output / dust collector solenoid Terminal A1115 VAC neutral / dust collector solenoid neutral Terminal 96Pump overload power Terminal 97Pump overload input Terminal 98

IMPORTANT: Always referto the wiring diagrams thatcame with your controlsbefore making electricalconnections. The diagramsshow the most accurateelectrical component infor-mation.

WIRING PURGEVALVES TO THESLC48(OPTIONAL)


The SLC48 can operate up to 48 purge valves, which are usedto remove material from the lines at the end of a loadingcycle. Since purge valves are located at the material sourceinstead of at the loader, separate wiring connections to theSLC48 are required.

Each purge/material valve requires three wires to operate:

The SLC48 can operate up to 32 pocket conveying valves,which are used in central drying and distribution systems. Thepocket valve allows multiple loaders to draw dry material asneeded from a single drying hopper. Since the valves arelocated at the material source instead of the loader, separate,wiring connections to the SLC48 are required.

Each pocket conveying valve requires three wires to operate:

WIRE VALVES CONNECTION RACK24 VAC neutral 1-20 Terminal #8 1

21-48 Terminal #8 2Ground 1-20 Ground terminal 1

21-40 Ground terminal 2Purge solenoid* 1-16 slot 9, outputs 0-15 1

17-20 slot 8, outputs 12-15 121-36 slot 22, outputs 0-15 237-40 slot 21, outputs 11-15 241-48 slot 23, outputs 0-7 2

* NOTE: For loaders using a common purge valve, the purge solenoidalso must be connected to the purge output for each loader on that valve.

WIRING POCKETCONVEYINGVALVES TO THESLC48(OPTIONAL)

WIRE VALVES CONNECTION RACK24 VAC neutral 1-20 Terminal #8 1

21-32 Terminal #8 2Ground 1-20 Ground terminal 1

21-32 Ground terminal 2Pocket Conveying 1-16 slot 9, outputs 0-15 1Valve 17-20 slot 8, outputs 12-15 1

21-32 slot 22, outputs 0-15 2

NOTE: Purge valves and pocket conveying valves connect to the same outputs on the SLC48 control.Therefore, pocket conveying valves cannot be used withloaders that are connected to purge valves.

The SLC48 supports electronic proofing of material lines fromup to 16 material sources to as many as 48 loaders.

Electronic proofing ensures that the correct material reachesits destination when multiple materials are conveyed through acentral conveying manifold from multiple sources.

Material line couplers on the conveying manifold must beequipped with electrical plugs, which are wired to Input andOutput slots in SLC48 enclosure.

The SLC48 Input/Output enclosure is equipped with a three-prong plug and power cord. Each optional remote touchscreenpanel also has its own plug and power cord.

Plug the power cord(s) into a grounded 115VAC outlet rated for at least 15 Amp service.

Make sure the control enclosure is grounded.

WIRING FORMATERIAL LINEPROOFING(OPTIONAL)


CONNECTINGMAIN POWERTO THE SLC48

WIRE DEVICE CONNECTION RACKProofing receptacle Hoppers 1-16 slot 10, outputs 0-15 1Proofing plug Loaders 1-16 slot 11, inputs 0-15 1

Loaders 17-32 slot 12, inputs 0-15 1Loaders 33-48 slot 24, inputs 0-15 2


Failure to provide proper grounding can causecontrol malfunctions and could result in personalinjury from electrical shock.

The control must be connected to a groundedpower source. A properly sized conductive groundwire must be connected to the chassis groundterminal inside the Input/Output enclosure.

1

2

Before you can begin conveying, you must configure andidentify the loaders and conveying features you want to use.

Procedures on the following pages will explain how to:❒ Configure each loader in the system.❒ Assign loaders to pump systems.❒ Add details to further identify each loader.❒ Set the date and time that will appear in the alarm history.❒ Select or set security levels required by your operation.

To begin Initial Setup:

Turn on power to the SLC48. The Power ON/OFF switch is at the sideof the control enclosure.

Wait for the control to initialize. Do not touch the touchscreen panel until the control hascompleted the bootup and initialization process. Thisprocess takes a few seconds on 10-inch screen models andat least 3 minutes on models with 6-inch screens. Whenthe control has initialized, the Home Screen displays thenumber of available loading positions.

Proceed to CONFIGURING LOADERS.

INITIAL SETUP









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NOTE: The SLC48 contains the correct number of I/Omodules to support the number of loaders, conveyingoptions, material valves and pumps you specified inyour order. If you are adding receivers, pumps, valvesor other features to the original system, please seeAPPENDIX B: INSTALLING SLOTS AND LOADERS.

PowerON/OFF

Touchscreenpanel

NOTE: Loaders will appear as disabled (blackicons) until you have enabled them.

1

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3

TIP: You will need theLevel 3 or 4 security codeto perform most proce-dures in the initial setup.If you are not familiar withthe SLC48 security levels,please review SETTINGSECURITY LEVELS at theend of this Installation section before proceeding.

You configure each loading station in thesystem by enabling vacuum receivers andloading functions on theLoader Features screen.

The loader or featuremust be correctlyinstalled and wiredbefore it can be enabled.

CONFIGURINGLOADERS



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1Loader Features

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Enable Disabled

Ratio Valve

Loader Fill Alarm

Hopper Fill Alarm

Air Discharge Valve

Status

Proofing

Purge Valve

Pocket Convey Valve Enable Disabled

Enable Disabled

Enable Disabled

Enable Disabled

Enable Disabled

Enable Disabled

Enable Disabled

Continued on next page.

CAUTION: Incorrect configurations willcause the SLC48 control to stop.Before enabling loaders and loading functions,make sure the loader, valve or option has beeninstalled in the system. Each loader and featuremust be wired to a correctly installed and enabledInput or Output Slot. The SLC will fault and theloading control will stop if the required I/O modulehas not been installed for the feature you enabled.

LOADER FEATURES:Loader Fill Alarm Activates a No Material Alarm if the loader

does not fill before the load time is reached.Requires an optional fill sensor in the receiver.

Hopper Fill Alarm Activates a No Material Alarm if the receiveror hopper is not filled by the loader within thenumber of tries set by the user. Requiresa demand sensor in the vessel.

Air Discharge Controls an air-activated discharge on the Valve loader. Requires an optional positive discharge.

Ratio Valve Controls loading of more than one material into one vacuum receiver. Requires an optional ratiovalve at the material inlet of the receiver.

Purge Valve* Purges material from the conveying line at theend of a loading cycle. Requires an optionalpurge valve on the material line.

Pocket Conveying Releases material from the source into the Valve* conveying line. Requires installing the valve at

the base of the drying hopper or other vessel.

Proofing Indicates that a material line is connected tothe correct material source. Requires materialline couplings equipped with electrical plugs.

* NOTE: You can enable either a purge or a pocket conveying valve, but not both forthe same loader.

TIP: Touch the “Help” keyon any screen to findinstructions and definitionsabout the functions available on that screen.

To enable conveying features,you must open the LoaderFeatures screen. You must enterthe Level 3 access code to complete this procedure. SeeSETTING SECURITY LEVELS at theend of the installation section.

Touch “Setup” on the Home Screen.� The Security Screen

is displayed

Enter the Level 3 access code.Touch “Key Pad” to open thekeypad. Enter the numbersfor Level 3 access and thentouch “Enter”.� The Security Screen

displays four choices.

Touch “LoaderFeatures Screen.”� The Loader Features for

Loader 1 is displayed.

Touch “Enable” foreach feature installedon that loading station.You also can enable theloader, but you should leavethe loader disabled (off) untilyou have assigned it to apump system.� The feature is on when

“Enabled” is highlighted.

Touch “Next” to accessfeatures for the next loader inthe system.

Repeat the procedurefor each loader.

Proceed to ENTERING PUMP

AND LOADER SETTINGS.

CONFIGURINGLOADERS



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Security ScreenHome

*] KeyPad

Enter Security Code


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Security ScreenHome

****] KeyPad

SetDate and

Time

Enter Security Code

Back-upPump

Selection



ChangeUser

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1Loader Features

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Enable Disabled

Ratio Valve

Loader Fill Alarm

Hopper Fill Alarm

Air Discharge Valve

Status

Proofing

Purge Valve


Enable Disabled

Enable Disabled

Enable Disabled

Enable Disabled

Enable Disabled

Enable Disabled

IMPORTANT: Verify instal-lation of vacuum receivers,valves and options beforeenabling them in theSLC48.

Loader positions areinstalled in the SLC48 inbanks of 16 — Loaders 1 to16, 17 to 32 and 33 to 48.This allows easier expan-sion of the system. But italso means the control maydisplay a Loader Featuresscreen for a loader positionwhere no vacuum receiverexists. (Example: Loader 36in a 35-loader system.)Disabled Enabled Demand Loading Alarm

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1Loader Features

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Enable Disabled

Ratio Valve

Loader Fill Alarm

Hopper Fill Alarm

Air Discharge Valve

Status

Proofing

Purge Valve


Enabled Disable

Enabled Disable

Enabled Disable

Enabled Disable

Enabled Disable

Enabled Disable

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You assign loaders to pump systems, enable loaders, set loadtimes, and enter other loading parameters on the LoaderSettings screen.

Below are the loader functions that can appear on the screen.

ENTERINGPUMP ANDLOADERSETTINGS








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Enable Disabled

Regrind Time (secs.)

Load Time (secs.)

Pump Number

Purge Time (secs.)

Status

Material Source

Dump Time (secs.)

Alarm CheckSet

Ratio Cycle

2 Set

3 Set

Set Set

Set Set


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1 Set

LOADER SETTINGS:Load Time The number of seconds (1-300) that the

receiver loads material.

Dump Time The number of seconds (1-300) that thereceiver will discharge material into a vesselbefore the next load cycle begins.

Pump Number Assigns the loader to a pump system (1-8).

Alarm Check The number of times (0-20) that the SLC48 will try to load a receiver before sounding an alarm when demand has not been satisfied.

Purge Time* The number of seconds (0-300) that vacuum continues to pull material through the line aftera purge or pocket conveying valve closes to thematerial source. This clears the line of material.

Material Source* The number (1-32) that identifies a material source equipped with a pocket conveying valve.This setting also is used for material line proofing.

Regrind Time* The number of seconds (1-300) that regrind or asecond material should be loaded with virginmaterial when a ratio valve is used.

Ratio Cycle* The number of times (1-3) that a ratio valveswitches between virgin and regrind during theload cycle to produce layers of material.

* NOTE: These settings will be displayed only if the corresponding feature has beeninstalled and enabled for the specific loader.

NOTE: Loaders may beassigned to any pump in theconveying system. Eachpump system can handle upto 24 loaders.

The SLC48 initially assignsloaders sequentially, ingroups of six loaders to onepump. (Example: Loaders 1-6 to Pump 1, Loaders.7-12to Pump 2, etc.)



To get to the Loader Settings screen and enter the settings:

Touch “Setup” to openthe Security Screen.

Enter the Level 3 access code.Touch “Key Pad” to open thekeypad. Enter the numbers for Level 3 access and thentouch “Enter”.� The Security Screen


Touch “Loader Settings Screen.”� The settings screen for


Enter the settings.Touch the “Set” key for eachloader function you want toset or change. A keypadopens on the screen. Touchthe number keys correspond-ing to the setting, then touch“Enter” on the keypad.

Enable the loader.Touch “enable” to make theloader available to vacuumconveying.

Repeat the procedurefor all loaders.Touch “Next” or “Prev” toscroll to the Loader Settings Screen for each loader.

Proceed to IDENTIFYING LOADERS.

ENTERINGPUMP ANDLOADERSETTINGS


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Security ScreenHome

*] KeyPad

Enter Security Code


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Security ScreenHome

****] KeyPad

SetDate and

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Enter Security Code

Back-upPump

Selection



ChangeUser

Password


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1Loader Settings

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Enabled Disable

Regrind Time (sec.)

Load Time (secs.)

Pump Number

Purge Time (secs.)

Status

Material Source

Dump Time (secs.)

Alarm CheckSet

Ratio Cycle

Set

Set

10 Set Set

50 Set Set


20

1 Set


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1Loader Settings

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Enabled Disable


Load Time (secs.)

Pump Number

Purge Time (secs.)

Status

Material Source

Dump Time (secs.)

Alarm CheckSet

Ratio Cycle

Set

Set

Set Set

Set Set


20

1

10

3Set

10 12

20 2

1

2

3

4

5

6

NOTE: Optimum settings vary according to equipmentand application. Refer to the manuals for each compo-nent of your conveying system for information about thebest settings for your application.

TIP: The overall vacuum-ontime (cycle time) for aloader equals the LoadTime unless a purge orpocket conveying valve isused. With purge and pocket conveying options,the cycle time equals Load Time + Purge Time.

The SLC48 identifies each loader in the system by a number.

On the Loader Statusscreen you can addmore information tohelp identify the loader.

You may want to addtext that describes thematerial source, thedestination or the materials being loaded.

Touch “Status” to go to the Loader Status screen. Thisscreen does not require a security code for access.

Touch “Edit,” then the white text block.This will activate the keyboard. On 6-inch screen models,you must use an external keyboard to enter the text. The10-inch screen models display an on-screen keyboard.

Enter the text using the keyboard.When you have finished entering text, press the “Enter”key on the keyboard.

Save the text.If you are using an external keyboard, touch the “SendText” key on the touchscreen. If you are using the on-screen keyboard, touch “Save Text.”

Repeat the procedure for each loader.Touch “Next” to go to the next loader in the system or“Prev” to go to the previous loader.

Proceed to SETTING THE DATE AND TIME.

IDENTIFYINGLOADERS



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1Loader 1 Status

Next

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Enabled Disable

Edit

AlarmSummary

Loader assigned to:

Connected to Pump 1

Pump Currently Idle

Drying Hopper 1 - PET


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1Loader 1 Status

Next

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Enabled Disable

Edit

AlarmSummary

Loader assigned to:

Connected to Pump 1

Pump Currently Idle


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3

Connected to Pump 1

Pump Currently Idle


10-inch touchscreen6-inch touchscreen

4

5TIP: Touch the “Help” keyon any screen to findinstructions and definitionsabout the functions available on that screen.

You can set the date andtime that the controluses to record alarmhistories.

The SLC48 will auto-matically update thetime for DaylightSavings Time.

To set or change thedate and time:

Touch “Setup” fromany screen.� The Security Screen

is displayed

Enter the Level 3 access code.Touch “Key Pad” to open thekeypad. Enter the numbersfor Level 3 access and thentouch “Enter”.� The Security Screen


Touch “Set Date and Time.”� The Date and Time screen

is displayed.

Enter the date and the time. Touch the button next to thefield you want to change(Example: “Mon” forMonth). On the keypad,touch the numbers corre-sponding to the date or time,then press “Enter” to closethe keypad.

Repeat this process for all fields, then touch “PUSH toUpdate Date/Time” to save the changes.

Touch “Back” to return to the Security Screen.

Proceed to RECORDING THE SOFTWARE VERSION.

SETTING THEDATE AND TIME



Touch Screen

Date and TimeBack

Date

3/15/01

15

01

Mon

Day

Year

3

Time

03:22:55

22

55

Hour

Min

Sec

03

PUSH to update Date/Time


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Security ScreenHome

*] KeyPad

Enter Security Code


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Security ScreenHome

****] KeyPad

SetDate and

Time

Enter Security Code

Back-upPump

Selection



ChangeUser

Password


Touch Screen

Date and TimeBack

Date

3/15/01

15

01

Mon

Day

Year

3

Time

03:22:55

22

55

Hour

Min

Sec

03

PUSH to update Date/Time

IMPORTANT: For changes totake effect, you must enter a set-ting in every field — even fieldsthat do not require a change —before you touch “PUSH toUpdate Date/Time.”

Time and Date must be set atthe touchscreen interface on theInput/Output enclosure. It cannotbe set at a remote touchscreen.

Enter time as 24-hour time inHours/Minutes/Seconds.(Example: 14:30:00 for 2:30 PM)

Enter dates as numbers representing Month/Day/Year.

Touch < or > to move the keypadto the left or right of the screen.

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3

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5


Before starting operation, you should record the version of theSLC48 software in the front of this manual. The Conair service department will need this information, along with theserial number, to provide help for the specific equipment youinstalled.

To determine the software version number:

Touch “Setup” to display the SecurityScreen.

Enter the Level 4security code.Touch “Key Pad” to open thekeypad. Enter the numbersfor Level 4 access and thentouch “Enter”. (See SETTINGSECURITY LEVELS)

Touch “Rack & SlotStatus.”This opens the Rack & SlotStatus screen.

Touch the “Ver” key. This will open a screen thatdisplays the software versionnumber and access to thepowerstation shell.

Record the softwareversion number.In this example, the versionnumber is P108_01.

Touch “Setup” toreturn to the SecurityScreen.

Proceed to SETTING SECURITY LEVELS.

RECORDING THESOFTWAREVERSION


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Enter Security Code


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Security ScreenHome

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SetDate and

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Enter Security Code

Back-upPump

Selection



ChangeUser

Password

Rack &Slot

Status

LoaderBank

Status


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Rack & Slot Status

Ver

Home

ClearMajorFaults

Rack 1 Slots

Enabled DisabledSlot 0 Slot 1 Slot 2

Enabled EnabledSlot 3

Rack 2 Slots

Enabled EnabledSlot 4 Slot 5 Slot 6




DisabledSlot 12 Major

FaultClearMinorFaults

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The SLC48 provides four levels of security to prevent unauthorized changes to loader or system settings. You shouldset the most appropriate level for your operating procedures.

�� Level 1 Access (no security code required)This is the most restrictivelevel, allowing no changes toloader or system settings. Theoperator can view the statusof loaders and pump systems;acknowledge an alarm; ordisable or enable a loader.

�� Level 2 Access (user-selectable code)The operator has access toLoader Settings, in addition toLevel 1 monitoring screens.The Level 2 operator cannotassign the loader to a pump,but can change load time,dump time, alarm check andsettings for optional loaderfunctions. The default code of 0000. See CHANGING THELEVEL 2 PASSWORD.

�� Level 3 Access (factory-set code 7373)This is a supervisory level.The Level 3 user can changethe Level 2 security code, aswell as set system time anddate; assign loaders to pumps;assign the backup pump; andconfigure loader features.

�� Level 4 Access (factory-set code 54647)This provides factory-levelaccess to all functions andsystem parameters. It shouldbe used only when expandingthe original system or trouble-shooting SLC processor errorcodes. For more information,see APPENDIX B: INSTALLINGSLOTS AND LOADERS.

SETTINGSECURITYLEVELS


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Security ScreenHome

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Enter Security Code


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Security ScreenHome

****] KeyPad

Enter Security Code



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SetDate and

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Enter Security Code

Back-upPump

Selection



ChangeUser

Password


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Security ScreenHome

*****] KeyPad

SetDate and

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Enter Security Code

Back-upPump

Selection



ChangeUser

Password

Rack &Slot

Status

LoaderBank

Status

IMPORTANT: The securitylevel remains at whatever levelwas most recently used unlessyou enter the code for a different security level.

If you have made changes to system settings using a securitycode for Level 2, 3 or 4, makesure you return to the SecurityScreen and enter the code forthe access level you want touse for operation.

TIP: To control access to theSLC48 security level codes,you may want to removepages 3-19 and 3-20 from thismanual and store them in asafe place.


Security codes for accessLevels 3 and 4 are set at the factory and cannot be changed.

Users with Level 3access can set or changethe Level 2 securitycode, which is set by thefactory at 0000.

To set or change theLevel 2 security code:

Touch “Setup” to display the SecurityScreen.

Enter the Level 3security code.Touch “Key Pad” on theSecurity Screen to open anumeric keypad. Touch 7, 3, 7, 3, and then Enter.

Touch “Change UserPassword.”� The User Password Entry

screen is displayed.

Enter a new code.Touch “Key Pad” to open thenumeric keypad. The newcode can be any 1- to 5-digitnumber between 0 and 64000.Enter the new code on thekeypad, then touch “Enter” tosave the change and close thekeypad.

Touch “Prev” to returnto the Security Screen.

Set the appropriate security level.Touch “Key Pad” to open the keypad. Enter the securitycode for the access level you want your operators to use.

You may want to record the new Level 2 security code on thesecurity pages of this manual.

CHANGING THELEVEL 2PASSWORD


Touch Screen

Pumps

Status

Help

Security ScreenHome

*] KeyPad

Enter Security Code


Touch Screen

Pumps

Status

Help

Security ScreenHome

****] KeyPad

SetDate and

Time

Enter Security Code

Back-upPump

Selection



ChangeUser

Password


Touch Screen

Pumps

Status

Help

User Password EntryScreen

Home

*] KeyPad

Enter User Password(0-64000)

1

2

3

4

5 Disabled Enabled Demand Loading Alarm

Touch Screen

Pumps

Status

Help

User Password EntryScreen

Home

*] KeyPad

Enter User Password(0-64000)

6

IMPORTANT: The securitylevel remains at whatever levelwas most recently used unlessyou enter the code for a different security level.

If you have made changes to system settings using a securitycode for Level 2, 3 or 4, makesure you return to the SecurityScreen and enter the code forthe access level you want touse for operation.


�� SLC48 control features . . . . . . . . .4-2�� Operating the conveying system .4-4�� Enabling and disabling loaders . . .4-5�� Changing loader settings . . . . . . .4-6�� Assigning a backup pump . . . . . . .4-8

OPERATION

SLC48 Sentral Loader Control UGC003/02014-2 OPERATION

SLC48CONTROLFEATURES








Go to nextdevice


Touch Screen

Pumps

Status

Setup

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1

17

25

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2 3 4 5 6 7 8

10 11 12 13 1514 16

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1 2 3 4 5 6

7 8

Pump 1 System

Next

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1


Pumps

Setup

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6Loader 6 Status

Next

Home

Enabled Disable

Edit

AlarmSummary

Loader assigned to:

Demanding Material

Connected to Pump 1


Machine 1 - PET


Pumps

Status

Help

Security ScreenHome

*] KeyPad

Enter Security Code

The SLC48 operator interface allows you to view the status of everyvacuum receiver in your conveying system at a glance. It also provides touchscreen access to additional screens used to monitorpump groups, enter settings for each loading station, view alarms andchange system parameters.

Home ScreenColor-coded loader iconsdisplay the status of eachvacuum receiver in thesystem. Colors change asthe operating status of thereceivers change:

Black = Loader disabledWhite = Loader enabledBlue = Loader demand-

ing materialGreen = Loader loadingRed = Loader alarm

Touch an icon to view additional details about thestatus of a specific loader.

Loader Status ScreensTouch STATUS or a specificloader icon to view details abouta vacuum receiver and theassigned pump. You can enableor disable the loader or view asummary of alarms. Touch NEXTor PREV to scroll through allloaders in the system

Security ScreenTouching SETUP displays thesecurity screen. To prevent acci-dental or unauthorized changesto system settings, securitycodes are required to access any screen that allow changes to loader settings or systemparameters.

Pump System ScreensTouch PUMPS to view the statusof all vacuum receivers assignedto a specific pump system.

Touch NEXT or PREV to scrollthrough all pump groups.

Alarm Summary Touch to acknowledgean alarm or view asummary of alarms.

Help Touch HELP to viewinstructions about thatspecific screen.

UGC003/0201 SLC48 Sentral Loader Control OPERATION 4-3

Security codes are required to access any screens that allowchanges to loader, pump or conveying system settings. TouchSETUP on any screen to reach the Security Screen, where thesecurity code can be entered using the on-screen keypad.

SLC48CONTROLFEATURES








Go to nextdevice


Touch Screen

Pumps

Status

Help

Security ScreenHome

****] KeyPad

SetDate and

Time

Enter Security Code

Back-upPump

Selection



ChangeUser

Password


Pumps

Setup

Prev

Help

1Loader Features

Next

Home

Enable Disabled

Ratio Valve

Loader Fill Alarm

Hopper Fill Alarm

Air Discharge Valve

Status

Proofing

Purge Valve


Enabled Disable

Enabled Disable

Enabled Disable

Enabled Disable

Enabled Disable

Enabled Disable


Pumps

Status

Setup

Prev

Help

Back-Up Pump Selection Home

Pump System 1

Pump System 2

Pump System 3

Enable Disabled

Enabled Disable

Enable Disabled

Enable Disabled

Enable Disabled

Enable Disabled

Enable Disabled

Enable Disabled

Pump System 4

Pump System 6

Pump System 7

Pump System 8

Pump System 5


Pumps

Setup

Prev

Help

1Loader Settings

Next

Home

Enabled Disable


Load Time (secs.)

Pump Number

Purge Time (secs.)

Status

Material Source

Dump Time (secs.)

Alarm CheckSet

Ratio Cycle

Set

Set

Set Set

Set Set


Back-Up Pump Selection(Requires Level 3 Security Code)You can assign a backup pumpto any pump system by enablingthe pump next to the appropriatesystem number.

Touch HOME, PUMPS, STATUSor SETUP to view those screens.

Loader Settings(Requires Level 2 Security Code)For each loader, enter the loadtime, discharge time, and thenumber of times the loader willtry to load before activating analarm. Enter settings for anyoptions, such as ratio or purgevalves, that are installed.

Loader Features(Requires Level 3 Security Code)You can enable or disable fea-tures for each loader.

Touch NEXT or PREV to scrollthrough all loaders.

NOTE: Enabling a feature that isnot installed will stop the control.

Once power has been applied to the system, the SLC48 automatically operates vacuum pumps, loaders and materialvalves according to the conveying functions and loader settings that were entered during the initial setup.

You can monitor all aspects ofthe conveying system from thetouchscreen panel on theInput/Output enclosure or fromremote touchscreen panels.

To view loaders in a specific pump system:Touch “Pumps” to view the Pump System screen.

Touch “Next” or “Prev” to view each pump system.

To view details about a specific loader:Touch “Status” or the loader icon to view Loader Status.

Touch “Next” or “Prev” to view each loader.

To acknowledge an alarm:Touch the specific loader icon to view Loader Status.

Touch “Silence Alarm” to display the Alarm Summaryscreen. The cause of the alarm must be fixed before thepump or loading station will resume operation. See theTROUBLESHOOTING section of this manual.

Instructions on the following pages explain procedures youmay need to perform during operation:

� Enable or disable a loader.� Change loader settings, such as load and dump times.� Assign a backup pump to one of the pump systems.

OPERATING THECONVEYINGSYSTEM



Pumps

Status

Setup

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17

25

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41

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10 11 12 13 1514 16

18 19

26 27

20 21

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31 32

34 35 36 37

42 43 44 45

38

46

39

47

40

48

9

The Home Screen displaysthe status of all loaders.


Status

Setup

Prev

Help

1 2 3 4 5 6

7 8

Pump 1 System

Next

Home

1


Pumps

Setup

Prev

Help

6Loader 6 Status

Next

Home

Enabled Disable

Edit

AlarmSummary

Loader assigned to:

Demanding Material

Connected to Pump 1


Machine 1 - PET

12

12

12


During operation, you may need to disable a loader for maintenance or enable a loader that was taken out of service.

You can disable or enable a loader from the Loader Statusscreen:

Touch the loader icon or “Status” on anyscreen. Touch “Prev” or “Next” to view loaders in the system.

Touch “Disable” todisable the loader.

The loader icon changes to black when the loader is disabled. When the loader is enabled the icon color, willchange to the color indicating the loader’s operating status.

ENABLINGAND DISABLINGLOADERS


WARNING: Develop and follow procedures forsafe operation of the system from central andremote control panels to avoid possible injuryor equipment damage.

The SLC48 allows operators and maintenance personnel to disable and enable conveying systemcomponents from remote locations. Unexpectedenergization of these components could result inequipment damage or injury.

Safe operating procedures should include:❒ Disconnect any loader, pump or material valve

from main power and/or compressed air sourcesbefore servicing. Ensure that all energy sourcesfor the device are locked out and tagged.

❒ Before removing lockout devices or enablingpumps, loaders or material valves, make surethat all personnel are clear of the machine, toolshave been removed and any safety guards havebeen reinstalled.


Pumps

Setup

Prev

Help

1Loader 1 Status

Next

Home

Enable Disabled

Edit

AlarmSummary

Loader assigned to:

Connected to Pump 1

Pump Currently Idle



Pumps

Setup

Prev

Help

1Loader 1 Status

Next

Home

Enabled Disable

Edit

AlarmSummary

Loader assigned to:

Connected to Pump 1

Pump Currently Idle


Touch “Enable” toenable the loader.

1

2 or


You may need to change loader settings whenever you changematerials or to obtain the best conveying performance.

You must enter a security code to access the Loader Settingsscreen and change the following settings.

CHANGINGLOADERSETTINGS








Go to nextdevice


Touch Screen

Pumps

Setup

Prev

Help

1Loader Settings

Next

Home

Enabled Disable


Load Time (secs.)

Pump Number

Purge Time (secs.)

Status

Material Source

Dump Time (secs.)

Alarm CheckSet

Ratio Cycle

Set

Set

Set Set

Set Set




LOADER SETTINGS:Load Time The number of seconds (1-300) that the

receiver loads material.

Dump Time The number of seconds (1-300) that thereceiver will discharge material into a vesselbefore the next load cycle begins.

Pump Number Assigns the loader to a pump system (1-8).

Alarm Check The number of times (0-20) that the SLC48 will try to load a receiver before sounding an alarm when demand has not been satisfied.

Purge Time* The number of seconds (0-300) that vacuum continues to pull material through the line aftera purge or pocket conveying valve closes to thematerial source. This clears the line of material.

Material Source* The number (1-32) that identifies a material source equipped with a pocket conveying valve.This setting also is used for material line proofing.

Regrind Time* The number of seconds (1-300) that regrind or asecond material should be loaded with virginmaterial when a ratio valve is used.

Ratio Cycle* The number of times (1-3) that a ratio valveswitches between virgin and regrind during theload cycle to produce layers of material.

* NOTE: These settings will be displayed only if the corresponding feature has beeninstalled and enabled for the specific loader.


To get to the Loader Settings Screen and enter new settings:

Touch “Setup” to go tothe Security Screen.

Enter the Level 2 security code.Touch “Key Pad” on theSecurity Screen to open anumeric keypad. Touch thenumbers corresponding tothe code for Level 2 access,then touch “Enter”.

Touch “Loader Settings Screen.”� The settings screen for


Touch the “Set” keynext to the setting youwant to change. � The keypad is displayed.

Enter the new settingon the keypad andtouch “Enter.”

Repeat the procedurefor each setting andloader you want tochange.Touch “Next” or “Prev” toscroll to the Loader Settings screen for other loaders.

Set the correct securitylevel for operators.If necessary, return to the Security Screen and enter thepassword for Level 1 access.

ENTERINGLOADERSETTINGS

NOTE: Optimum settings vary according to application.Refer to the manuals for each component of your conveying system for information about the best settingsto use for your application.


Touch Screen

Pumps

Status

Help

Security ScreenHome

*] KeyPad

Enter Security Code


Touch Screen

Pumps

Status

Help

Security ScreenHome

****] KeyPad

Enter Security Code



Touch Screen

Pumps

Setup

Prev

Help

1Loader Settings

Next

Home

Enabled Disable


Load Time (secs.)

Pump Number

Purge Time (secs.)

Status

Material Source

Dump Time (secs.)

Alarm CheckSet

Ratio Cycle

Set

Set

Set Set

Set Set



Touch Screen

Pumps

Setup

Prev

Help

1Loader Settings

Next

Home

Enabled Disable


Load Time (secs.)

Pump Number

Purge Time (secs.)

Status

Material Source

Dump Time (secs.)

Alarm CheckSet

Ratio Cycle

Set

Set

10 Set Set

50 Set Set


20

1

1

2

3

4

5

6

6

A backup pump can be assigned to replace any of the eightpump systems during operation.

To assign a backup pump:

Touch “Setup” to go tothe Security Screen.

Enter the Level 3 security code.Touch “Key Pad” on theSecurity Screen to open anumeric keypad. Touch thenumbers corresponding tothe code for Level 3 access,then touch “Enter”.

Touch “Back-up PumpSelection.”� The Back-Up Pump

Selection screen is displayed.

Touch “Enabled” nextto the pump systemthat will have thebackup pump.

Set the correct securitylevel for operators.If necessary, touch “Setup”and return to the SecurityScreen. Enter the passwordfor the operator access level (Level 1 or Level 2) that you assigned during initial setup.

ASSIGNING ABACKUP PUMP



Touch Screen

Pumps

Status

Help

Security ScreenHome

*] KeyPad

Enter Security Code


Touch Screen

Pumps

Status

Help

Security ScreenHome

****] KeyPad

SetDate and

Time

Enter Security Code

Back-upPump

Selection



ChangeUser

Password


Touch Screen

Pumps

Status

Setup

Prev

Help

Back-Up Pump Selection Home

Pump System 1

Pump System 2

Pump System 3

Enable Disabled

Enabled Disable

Enable Disabled

Enable Disabled

Enable Disabled

Enable Disabled

Enable Disabled

Enable Disabled

Pump System 4

Pump System 6

Pump System 7

Pump System 8

Pump System 5

1

2

3

4

5


�� Maintenance checklist . . . . . . . .5-2�� Recalibrating the touchscreen .5-3

MAINTENANCE

You should develop a preventive maintenance schedule for all components in the conveying system to ensure optimum operation and performance.

The SLC48 may require the following maintenance checks:

�� Whenever you change materials❒❒ Verify the loader settings for pump systems or loaders

effected by the material change. Pay particular attentionto load times, dump times and material source identifi-cation if you have pocket conveying valves and materialline proofing. See CHANGING LOADER SETTINGS in theOperation section.

� Quarterly❒❒ Check power and cable connections and wires.

Over time, the power and cable connections betweenthe SLC48 and conveying system components maybecome loose or wires may become worn. Tighten anyloose connections and replace any wire or cable that hasbecome worn or damaged.

� After loading new software, or as needed❒❒ Recalibrate the touchscreen. If the operator panel

becomes unresponsive to a touch on the screen, youmay need to recalibrate the touchscreen. This couldhappen after reloading or updating the SLC48 software.See RECALIBRATING A TOUCHSCREEN.

PREVENTIVEMAINTENANCECHECKLIST

SLC48 Sentral Loader Control UGC003/02015-2 MAINTENANCE

If the operator panel becomes unresponsive to a touch on thescreen, you may need to recalibrate the touchscreen. Beforebeginning, make sure that a standard PS/2 keyboard has beenconnected to the control. See CONNECTING A KEYBOARD inthe Installation section.

Touch “Setup” andenter the Level 4 security code.Touch “Key Pad” on theSecurity Screen to open anumeric keypad. Touch thenumbers corresponding tothe code for Level 4 access,then touch “Enter”.

Touch “Rack & Slot Status.”

Touch “Ver” on theRack & Slot Statusscreen.

Touch “Exit toPowerstation Shell.”The SLC48 will reboot intothe CTC powerstation shell.You will see several labeledtouch keys on the left-handside of the screen.

Touch “Settings,” andthen “Pwrsta.”This brings you to a screen displaying a key labeled“Calibrate Touchscreen.”

Touch “Calibrate Touchscreen” and carefullyfollow the on-screen instructions. You will use thekeyboard to complete the procedures.

Touch “Back” after the calibration routine iscomplete. This returns you to the powerstation shell.

Touch “Run” and then “Interact.” This willrestart the SLC48 program. Wait until the SLC48 finishesinitializing before continuing operation.

RECALIBRATINGA TOUCHSCREEN

UGC003/0201 SLC48 Sentral Loader Control MAINTENANCE 5-3


Touch Screen

Pumps

Status

Help

Security ScreenHome

*****] KeyPad

SetDate and

Time

Enter Security Code

Back-upPump

Selection



ChangeUser

Password

Rack &Slot

Status

LoaderBank

Status


Touch Screen

Pumps

Status

Setup

Prev

Help

Rack & Slot Status

Ver

Home

ClearMajorFaults

Rack 1 Slots



Rack 2 Slots







1

2

3

4

5Disabled Enabled Demand Loading Alarm

Touch Screen

Pumps

Status

Setup

Home

6

7

8


�� Before beginning . . . . . . . . . . . .6-2�� A few words of caution . . . . . . .6-2�� Identifying the cause

of a problem . . . . . . . . . . . . . . .6-3�� Clearing conveying alarms . . . .6-4�� Clearing CPU and I/O alarms . . .6-5

Diagnostics�� Conveying system alarms . . . . .6-6�� Power and processor problems. 6-8�� CPU faults . . . . . . . . . . . . . . . .6-10�� I/O errors . . . . . . . . . . . . . . . . .6-12

TROUBLESHOOTING

Before you begin troubleshooting:❏ Find the manuals and wiring diagrams thatwere shipped with your equipment.These materials contain details you will need to diagnose andrepair problems in specific components, including customwiring, features or I/O options not covered in this User Guide.

BEFOREBEGINNING

SLC48 Sentral Loader Control UGC003/02016-2 TROUBLESHOOTING

DANGER: Electrical shock hazard

Diagnosing the cause of electrical system and CPUproblems in this equipment may require the use ofprecision electronic measuring equipment, as wellas access to the electrical enclosure while power ison. Only qualified electrical technicians, trained inthe use of thie equipment and in avoiding exposureto voltage hazards, should perform procedures thatrequire access to the enclosure while power is on.

WARNING: Improper installation, operation orservicing may result in equipment damage orpersonal injury.

The SLC48 should be installed, adjusted, and ser-viced only by qualified technical personnel who aretrained in the operation and troubleshooting of thistype of equipment.

A FEW WORDSOF CAUTION

WARNING: Develop and follow procedures forsafe operation and maintenance of the system.

The SLC48 allows operators and maintenance personnel to disable and enable conveying systemcomponents from remote locations. Unexpectedenergization of these components could result inequipment damage or injury.

Safe maintenance procedures should include:❒ Disconnect any loader, pump or material valve

from main power and/or compressed air sourcesbefore servicing. Ensure that all energy sourcesfor the device are locked out and tagged.

❒ Before removing lockout devices and enablingsystem components, verify that all personnel areclear of the machine, tools have been removed,and any safety guards have been reinstalled.

The TROUBLESHOOTING section explains how to clear analarm, and provides diagnostic tables to help you determinethe cause of the alarm.

Diagnostic tables have been divided into:

❒❒ Conveying System Alarms. These tables focus on the “NoMaterial” and “Pump Overload”alarms that the SLC48 displayson the Alarm Summary screen.The SLC48 continues to controlthe system, but the alarmingloading station will not load untilthe alarm is acknowledge and thecause of the problem is fixed.

❒❒ Power and Processor Problems.These tables focus on power supply, processor or rack prob-lems indicated by LEDs locatedon the power supply and SLC5/03 processor module (Slot 0)located inside the I/0 enclosure.These problems cause the SLC48control to stop.

❒❒ CPU Faults.These tables focus on Hex errorcodes that apply to the SLC 5/03processor module (Slot 0) andare displayed as faults on theRack & Slot screen.

These problems cause theSLC48 control to stop.

❒❒ Input/Output Errors.These tables focus on Hex errorcodes that apply to Input/Outputmodules (Slots 1-25) and aredisplayed as faults on the Rack& Slot screen. The first two dig-its of the code refer to the Slotnumber that cuased the error. Ifthe Slot cannot be determined,the first two digits are 1F

These problems cause the SLC48 control to stop.

IDENTIFYING THECAUSE OF APROBLEM

UGC003/0201 SLC48 Sentral Loader Control SECTION HEAD 6-3


Touch Screen

Pumps

Status

Setup

Prev

Help








AcknowledgeAlarm

ClearAlarm

SLC 5/03 CPU

RUN

RS232

FLT DH485

FORCE

BATT

RUN PROGREM

POWER


Touch Screen

Pumps

Status

Setup

Prev

Help

Rack & Slot Status

Ver

Home

ClearMajorFaults

Rack 1 Slots



Rack 2 Slots





DisabledSlot 12

0010

MajorFault

ClearMinorFaults

IMPORTANT: Refer to themanuals supplied by themanufacturers of loaders,pumps and material valvesin your system for additionaldiagnostic and repair infor-mation.Contact Conair service ifyou need additional detailson the SLC 5/03 processoror Rack & Slot components.


Touch Screen

Pumps

Status

Setup

Prev

Help

Rack & Slot Status

Ver

Home

ClearMajorFaults

Rack 1 Slots



Rack 2 Slots





DisabledSlot 25

1F52

MajorFault

ClearMinorFaults

When a conveying problem occurs, the icon for the affectedloader or pump will begin flashing red and the control willturn on the audible alarm.

The SCL48 reports thetime and type of thealarm on the AlarmSummary screen. Up to100 No Material, PumpOverload and SourcingError alarms can bestored in the alarm his-tory. To scroll throughthe history, touch the upor down arrows.

To silence the alarm and fix the problem:

Touch “Status” or theloader icon.This will display the LoaderStatus screen.

Touch “Silence Alarm.”When the audible alarm is notactive, the control displays the“See Alarms” button.

Touch “See Alarms” tosee the Alarm Summary.Note the type and time of thealarm. Touch the up and downarrows to scroll through thealarm history and view otheralarms that may have involvedthis device.

To resume operation,touch “AcknowledgeAlarm” and fix theproblem.Refer to the diagnostic tablesin this section to help deter-mine the cause of the problem.To repair a problem, refer totroubleshooting and repair information contained in manuals supplied with the alarming device.

CLEARINGCONVEYINGALARMS



Pumps

Setup

Prev

Help

6Loader 6 Status

Next

Home

Enabled Disable

Edit

SilenceAlarm

Loader assigned to:

Demanding Material

Connected to Pump 1


Machine 1 - PET


Touch Screen

Pumps

Status

Setup

Prev

Help








AcknowledgeAlarm

ClearAlarm


Pumps

Status

Setup

Prev

Help








AcknowledgeAlarm

ClearAlarm

1

2

3

4


Pumps

Setup

Prev

Help

6Loader 6 Status

Next

Home

Enabled Disable

Edit

SeeAlarms

Loader assigned to:

Demanding Material

Connected to Pump 1


Machine 1 - PET

NOTE: To remove all alarmsfrom the Alarm Summaryhistory, touch “Clear Alarms.”Alarms are removed fromthe alarm history only afterthe alarm has been acknowl-edged and the alarm condi-tion is no longer present.The “Acknowledge” and“Clear” alarm buttons aredisplayed only to users withaccess to Security Levels 2,3 or 4.

CPU and Iinput/Output alarms will stop the SLC48 control.

These alarms may becaused by problems withthe power supply,processor, power racksor Input/Output mod-ules. The alarm will beindicated by error codeson the Rack & SlotStatus screen or byLEDs on the SLC 5/03CPU and power supplymodules.

To clear and fix a CPU or I/O error:

Touch “Setup” to dis-play the security screen.

Enter the Level 4 security code.

Touch “Rack & SlotStatus” to display theRack & Slot screen.

Look for the error code under Major Fault. Review screens for both Rack 1 and Rack 2 slots bytouching the appropriate keys on the screen. Note the errorcode. Refer to the error code table below to identify theaffected slot, then see the diagnostic tables in this section.

The error code is reported in hexidecimal format, with thefirst two digits identifying a specific I/O module slot. Ifthe digits are 1F, an exact slot cannot be determined.

Fix the problem, then touch “Clear MajorFault” or “Clear Minor Fault.”

CLEARING CPUAND I/O ALARMS

UGC003/0201 SLC48 Sentral Loader Control TROUBLESHOOTING 6-5


Touch Screen

Pumps

Status

Setup

Prev

Help

Rack & Slot Status

Ver

Home

ClearMajorFaults

Rack 1 Slots



Rack 2 Slots





DisabledSlot 12

0010

MajorFault

ClearMinorFaults


Touch Screen

Pumps

Status

Help

Security ScreenHome

*****] KeyPad

SetDate and

Time

Enter Security Code

Back-upPump

Selection



ChangeUser

Password

Rack &Slot

Status

LoaderBank

Status

SLOTS AND HEX CODE EQUIVALENTS (xx represents first two digits of the error code)

Slot xx Slot xx Slot xx Slot xx Slot xx

0 00 7 07 14 0E 21 15 28 1C1 01 8 08 15 0F 22 16 29 1D2 02 9 09 16 10 23 17 30 1E3 03 10 0A 17 11 24 184 04 11 0B 18 12 25 195 05 12 0C 19 13 26 1A6 06 13 0D 20 14 27 1B

1

2

3

4

5

CONVEYINGSYSTEMALARMS


Alarm

No Material Alarm

Possible causeIs there material at thesource?

Are the Loader Settingscorrect?

Is there a leak in the vacuum system?

Solution

❒ Verify that there is enoughmaterial at the source,including regrind sources ifa ratio valve is used.

❒ Verify that the material lineis connected to the correctsource of material.

If the parameters set on theLoader Settings screen areincorrect, material demandmay not be satisfied. ❒ Verify that the Load Time,

or Load Time plus PurgeTime, is sufficient to fill thereceiver. Adjust as needed.

❒ Verify that the AlarmCheck allows a sufficientnumber of loading cycles tofill the receiver. Adjust asneeded.

❒ Verify that the MaterialSource is correctly identi-fied when using pocket con-veying or material proofing.

❒ Verify that the loader isassigned to the correctpump system.

If there are leaks in the system,the pump cannot pull a goodvacuum and the receiver mayhave no or little material flow-ing into it. Check the vacuumpump gauge. If the reading islow, check all hoses, gaskets,receiver lids, and valves forsigns of damage or wear.Replace as needed.

The No Material Alarm can be triggered in two ways:� The Alarm Check signaled an alarm after the operator-set

number of consecutive loading attempts failed to satisfy thereceiver’s demand for material.

� The optional fill sensor in the receiver or hopper was notsatisfied after one loading cycle.

CONVEYINGSYSTEMALARMS


The No Material Alarm can be triggered in two ways:� The Alarm Check signaled an alarm after the operator-set

number of consecutive loading attempts failed to satisfy thereceiver’s demand for material.

� The optional fill sensor in the receiver or hopper was notsatisfied after one loading cycle.

Alarm

No Material Alarm(continued)

Pump Overload

Sourcing Error

Possible causeIs the vacuum pumpworking correctly?

Is the fill/demand sensoror demand switch work-ing properly?

Are compressed air linesconnected correctly?

The vacuum pump overload has tripped.

The system could not loadmaterial from the sourceidentified in the LoaderSettings screen.

SolutionVerify that the vacuum pumpis on, connected to the SLC48and working correctly. Refer tothe pump manual.

❒ Verify that sensors andswitches are connected correctly at the loader orhopper and at the control.

❒ Verify that fill and demandsensors are set at the correctheight and adjusted proper-ly. Refer to manuals sup-plied with the fill or demandsignaling device.

If a compressed air line is notconnected to vacuum or mater-ial valves, the valves cannotopen to allow the pump todraw material into the receiver.Verify that compressed airlines supplying the correctpressure have been connectedto the vacuum sequencingvalve, ratio valve, pocket con-veying or purge valve.

This alarm will prevent thepump from being energizeduntil the overload is corrected.Refer to the pump manual tocorrect the problem.

Verify that the material line isconnected to the correctsource, or that the correctsource has been identified inthe Loader Settings screen.

PROCESSORAND POWERPROBLEMS


Fault

Inadequate SystemPower

Possible causeNo line power or improper line power voltage selection.

Power supply fuse blown.

Power supply overloaded.

Defective power supply.

Solution

❒ Verify power line voltageand connections on thepower terminals.

❒ Verify proper 120/240Vpower supply jumper selection.

❒ Check the incoming powerfuse and verify that incom-ing power connections arecorrect. Replace fuse.

❒ If fuse blows again, replacethe power supply.

This problem can occur inter-mittently if the power supply isoverloaded when output load-ing and temperature varies.❒ Disconnect power to the

power supply. Remove sev-eral output modules fromthe rack. Wait five minutes.Reapply power.

❒ If the condition recurs,recalculate the powerrequired by the module con-figuration and verify properpower supply selection.

❒ Recheck other probablecauses.

❒ Check power to the rackpower supply for possibletransient or shorting.

❒ Replace the power supply.

WARNING: Electrical shock hazardDiagnosing electrical and processor problemsrequire access to the electrical enclosure whilepower is on. Only qualified electrical technicians,who are trained in how to avoid voltage hazards,should perform troubleshooting procedures thatrequire access to the SLC48 Input/Output enclo-sure while power is on.

POWER

Power LEDwill be off.

PROCESSORAND POWERPROBLEMS


Fault

Processor Not inRun Mode

Possible causeImproper mode selectedor user progam logicerror.

Line power out of operating range.

Power supply and/or procesor is seatedimproperly in the rack.

Defective processor,power supply or rack.

Solution

❒ Verify processor mode.❒ Try Run mode entry if con-

trol is in program/test mode.❒ Check user program logic

for suspend instructions ifcontrol is in suspend mode.

❒ Check for proper 120/240Vpower supply jumper selec-tion and incoming powerconnections.

❒ Check for proper line volt-age at the incoming powerconnections.

❒ Disconnect power andremove the power supplyand processor from the rack.Check connections.

❒ Reinstall the power supplyand processor, then applypower.

IMPORTANT: The processor onlyoperates in Slot 0 of Rack 1.

❒ Try Run mode selections ofprocessor in existing rack.

❒ Place the processor in a testrack. Apply power, recon-figure and try Run modeselection. If unsuccessful,replace the processor.

❒ Place the power supply in atest rack. If unsuccessful,replace power supply. If youcan enter Run mode,replace the existing rack.

SLC 5/03 CPU

RUN

RS232

FLT DH485

FORCE

BATT

RUN PROGREM


CPU FAULTS


Error Code

0001 - NVRAMerror

0002 - Unexpectedhardware watchdogtime-out

0003 - Memorymodule memoryerror

0004 - Memory erroroccurred during theRun mode

Possible cause�� Noise�� Lightning�� Improper grounding�� No surge suppression

on inductive loads�� Poor power source�� Loss of battery or

capacitor backup

�� Noise�� Lightning�� Improper grounding�� No surge suppression

on inductive loads�� Poor power source

Memory in the memorymodule is corrupted.



Solution

The problem is detected duringpower up. See WIRINGCONSIDERATIONS in theInstallation section to correctthe problem. Reload the pro-gram and enter Run mode. Youcan use the autoload featurewith a memory module toreload the program and enterRun mode automatically.


Reprogram the memory mod-ule. If the error persists,replace the memory module.



CPU FAULTS


Alarm

0010 - Processordoes not meetrequired revisionlevel

0011 - Executableprogram file #2 isabsent

0012 - The ladderprogram has a mem-ory error

0013 - Internal fileerror

0014 - Configurationfile error

Possible causeThe program was devel-oped for a processor witha revision level differentthan the revision of theinstalled processor.

Incompatible or corruptprogram is present.



Both of these faults maybe caused by:�� Noise�� Lightning�� Improper grounding�� No surge suppression


Solution

The problem is detected as theSLC tries to enter Run mode.Contact Conair service.

The problem is detected as theSLC tries to enter Run mode.Reload the program or repro-gram with RS Logix 500 soft-ware.

The problem is detected as theSLC tries to enter Run mode.See WIRING CONSIDERATIONSin the Installation section tocorrect the problem. Reloadthe program and enter Runmode. You can use the auto-load feature with a memorymodule to reload the programand enter Run mode automati-cally.

The problem is detected as theSLC tries to enter Run mode.See WIRING CONSIDERATIONSin the Installation section tocorrect the problem. Reloadthe program and enter Runmode. You can use the auto-load feature with a memorymodule to reload the programand enter Run mode automati-cally.



CPU FAULTS

Error Code

0020 - A minor errorbit is set at the endof the scan.

0021 - A remotepower failure of anexpansion I/O rackhas occurred.

Possible cause�� A math or FRD

instruction overflowhas occurred.

�� Sequencer or shift reg-ister instruction errorwas detected.

�� A major error wasdetected whileexecuting a user faultroutine.

�� M0-M1 file addresseswere referenced in theuser program for a disabled slot.

Power was removed, orpower dipped below specifications, for anexpansion rack.

Solution

The problem is detected duringthe software run time. Correctthe programming problem,reload the program and enterthe Run mode.

Reapply power to the expan-sion rack.

NOTE: Voltage or currentthat is over specifications inany of the power suppliesalso can produce any of theI/O error codes listed on thefollowing pages. The over-voltage or over-current con-dition also will be indicatedby the power supply LEDbeing off.

WARNING: Electrical shock hazardDiagnosing electrical and processor problemsrequire access to the electrical enclosure whilepower is on. Only qualified electrical technicians,who are trained in how to avoid voltage hazards,should perform troubleshooting procedures thatrequire access to the SLC48 Input/Output enclosure while power is on.

I/O ERRORS


Error Code

xx50 - A rack dataerror is detected.

xx51 - A “stuck”runtime error isdetected on an I/Omodule.

xx52 - A requiredI/O module has beendetected as missing.

xx53 - As the SLCtried to run, it detect-ed an I/O module ina slot that the userprogram defines asunused.

Possible cause�� Noise�� Lightning�� Improper grounding�� No surge suppression


If this is a discrete I/Omodule, this is a noiseproblem. If this is a specialty I/O module,refer to the appropriateuser manual for the probable cause.

An I/O module that wasconfigured and enabledfor a particular slot ismissing or has beenremoved.

�� The I/O module hasreset itself.

�� The I/O slot is not configured for a module that is present.

Solution

See WIRING CONSIDERATIONSin the Installation section tocorrect the problem. Clear thefault on the Rack & Slotscreen and re-enter Run mode.

Cycle power to the system. Ifthis does not correct the prob-lem, replace the module.

Disable the slot and insert therequired module. SeeAPPENDIX B: INSTALLINGSLOTS AND LOADERS.

If you suspect the module hasreset itself, clear the majorfault and run. Otherwise:

❒ Disable the slot, removethe module, clear the fault,and run.

❒ Modify the I/O configura-tion to include the module,then reload the program andrun.

See APPENDIX B: INSTALLINGSLOTS AND LOADERS.


NOTE: The “xx” in the following codes represent the I/O slot number.If the first two digits of the code are 1F, the exact slot cannot be determined.

I/O ERRORS


Error Code

xx54 - A modulerequired by the userprogram is detectedas the wrong type.

xx55 - The SLCdetected the wrongI/O count for a discrete I/O moduleor the wrong driverfor a specialty I/Omodule.

xx56 - The rackconfiguration isincorrect.

xx57 - A specialtyI/O module has notresponded to theLock SharedMemory command.

Possible causeThe I/O module in thespecific slot is differentthan the type configuredby the user for that slot.

�� If this is a discrete I/Omodule, the I/O countis different than whatwas selected in the I/Oconfiguratoin.

�� If this is a specialty I/Omodule, the card driver is incorrect.

The rack configurationspecified by the user doesnot match the hardware.

The specialty I/O moduleis not responding to theprocessor within therequired time limit.

Solution

❒ Replace the module withthe correct module, clear thefault, and run.

❒ Change the I/O configura-tion for the slot, reload theprogram, and run.


❒ Discrete I/O module: Replace it with a modulehaving the I/O count select-ed in the I/O configuration.Clear the fault, then run.

❒ Specialty I/O module:Refer to the user manual forthat module.


Check the I/O modules in therack against the enabled anddisabled slots in the Rack &Slot screen. Correct the rackconfiguration, reload the program and run. SeeAPPENDIX B: INSTALLINGSLOTS AND LOADERS.

Cycle rack power. If this doesnot correct the problem, referto the user manual for the spe-cialty I/O module. You mayhave to replace the module.



I/O ERRORS



Error Code

xx58 - A specialtyI/O module generat-ed a generic fault.

xx59 - A specialtyI/O module has notsignaled completionof a command with-in the time limit.

xx5A - Hardwareinterrupt problem.

xx5E - Processor I/Odriver error

xx60 through xx6F

xx70 through xx7F

xx90 - Interruptproblem on a disabled slot

Possible causeThe card fault bit is set(1) in the module’s statusbyte.

The specialty I/O modulecomplete a commandfrom the processor withinthe time allowed.

�� If this is a discrete I/Omodule, this is a noiseproblem

�� If this is a specialty I/Omodule, refer to theuser manual for themodule.

The processor I/O driversoftware is corrupt.

Identifies an I/O modulespecific recoverable error.

Identifies an I/O modulespecific recoverable error.

A specialty I/O modulerequested service while aslot was disabled.

Solution

Cycle power to the rack. If thisdoes not correct the problem,refer to the user manual for thespecialty I/O module. you mayhave to replace the module.

Refer to the user manual forthe specialty I/O module. Youmay have to replace the mod-ule.

❒ Discrete I/O module: Cyclerack power. Check for anoise problem and be sureproper grounding practicesare used.

❒ Specialty I/O module: Youmay have to replace themodule. Refer to the usermanual for this module.

Reload the program.

Refer to the user manual forthe specialty I/O module.


Refer to the specialty I/O module user manual. You mayhave to replace the module.



I/O ERRORS

Error Code

xx91 - A disabledslot has faulted.

xx92 - Invalid ornon-existent moduleinterrupt subroutine(ISR) file.

xx93 - UnsupportedI/O module specificmajor error.

xx94 - The SLCdetected that a mod-ule was insertedunder power in therun or test mode.

Possible causeA specialty I/O module ina disabled slot has fault-ed.

The I/O configurationand ISR file informationfor the specialty I/O module is incorrect.

The processor does notrecognize the error codefrom a specialty I/O module.

�� The module was insert-ed in the rack underpower.

�� The module has resetitself.

Solution

Cycle rack power. If this doesnot correct the problem, referto the user manual for the spe-cialty I/O module. You mayhave to replace the module.

Refer to the user manual forthe specialty I/O module forthe correct ISR file informa-tion. Correct the I/O configura-tion/ISR file information,reload the program and run.


Modules should never beinserted in a rack under power.If this occurs and the moduleis not damaged:.

❒ Remove the module, clearthe fault, and run.

❒ Add the module to the I/Oconfiguration, reference themodule in the user programwhere required, reload theprogram, and run.




IMS0002/0296 SERVICE INFORMATION APPENDIX A-1

Conair has made the largest investment in customer support inthe plastics industry. Our service experts are available to helpwith any problem you might have installing and operatingyour equipment. Your Conair sales representative also can helpanalyze the nature of your problem, assuring that it did notresult from misapplication or improper use.

To contact Customer Service personnel, call:

From outside the United States, call: 814-437-6861

You can commission Conair service personnel to provide on-site service by contacting the Customer Service Department.Standard rates include an on-site hourly rate, with a one-dayminimum plus expenses.

If you do have a problem, please complete thefollowing checklist before calling Conair:

❒ Make sure you have all model, serial and parts listnumbers for your particular equipment. Servicepersonnel will need this information to assist you.

❒ Make sure power is supplied to the equipment.

❒ Make sure that all connectors and wires withinand between control systems and related components have been installed correctly.

❒ Check the troubleshooting guide of this manualfor a solution.

❒ Thoroughly examine the instruction manual(s)for associated equipment, especially controls.Each manual may have its own troubleshootingguide to help you.

❒ Check that the equipment has been operated asdescribed in this manual.

❒ Check accompanying schematic drawings for information on special considerations.

BEFORE YOU

CALL ...

HOW TO CONTACT

CUSTOMER

SERVICE

Additional manuals andprints for your Conairequipment may beordered through theCustomer Service orParts Departments for anominal fee.

WE’RE HERETO HELP

WARRANTY INFORMATION IMS0003/0796APPENDIX A-2

EQUIPMENTGUARANTEE

PERFORMANCEWARRANTY

WARRANTY

LIMITATIONS

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 normaluse and service for which it was recommended (except forparts that are typically replaced after normal usage, such asfilters, liner plates, etc.). Conair’s guarantee is limited toreplacing, at our option, the part or parts determined by us tobe defective after examination. The customer assumes the costof transportation of the part or parts to and from the factory.

Conair warrants that this equipment will perform at or abovethe ratings stated in specific quotations covering the equip-ment or as detailed in engineering specifications, provided theequipment is applied, installed, operated and maintained in therecommended manner as outlined in our quotation or specifi-cations.

Should performance not meet warranted levels, Conair at itsdiscretion will exercise one of the following options:

� Inspect the equipment and perform alterations or adjust-ments to satisfy performance claims. (Charges for suchinspections and corrections will be waived unless failureto meet warranty is due to misapplication, improperinstallation, poor maintenance practices or improper oper-ation.)

� Replace the original equipment with other Conair equip-ment that will meet original performance claims at noextra cost to the customer.

� Refund the invoiced cost to the customer. Credit is sub-ject to prior notice by the customer at which time aReturn Goods Authorization Number (RGA) will beissued by Conair’s Service Department. Returned equip-ment must be well crated and in proper operating condi-tion, including all parts. Returns must be prepaid.

Purchaser must notify Conair in writing of any claim and pro-vide a customer receipt and other evidence that a claim isbeing made.

Except for the Equipment Guarantee and PerformanceWarranty stated above, Conair disclaims all other warrantieswith respect to the equipment, express or implied, arisingby operation of law, course of dealing, usage of trade or oth-erwise, including but not limited to the implied warranties ofmerchantability and fitness for a particular purpose.

The SLC48 Sentral Loader Control has been designed for easyexpansion of the conveying system as your processing needschange.

The SLC48 communicates with each pump, vacuum receiver,material valve and material proofing device that is wired toInput and Output modules inside the control enclosure. Beforea loading station, pump, valve or proofing device can be used,the appropriate module must be installed in the correct cardSlot built into the two Racks inside the control enclosure.

To expand the conveying system or add features, you will:

❒ Install the additional vacuum receivers, pumps, valvesand/or proofing hardware in the conveying system. Refer toinstallation instructions supplied with your equipment.

❒ Install the appropriate I/O modules in the correct racks andslots inside the SLC48 control enclosure.

❒ Wire the additional equipment to the I/O modules.❒ Enable the additional slots using the SLC48 Rack & Slots

screens. ❒ Install the additional loading stations in the SLC48 control.

Loading stations are installed in banks of 16 loaders at atime using the SLC48 Loader Banks screens.

❒ Enable the new loading features, assign loaders to pumpsystems, and enter loader settings for each loading station.

INSTALLINGSLOTS ANDLOADERS

UGC002/0301 INSTALLING SLOTS AND LOADERS APPENDIX B-1

Rack 1

Rack 2

Slot

1Slot

12Slot

11Slot

10Slot

4Slot

3Slot

2Slot

7Slot

6Slot

5PowerSupply

Slot

9Slot

8

Slot

13Slot

24Slot

23Slot

22Slot

16Slot

15Slot

14Slot

19Slot

18Slot

17Slot

21Slot

20

Slot

0

Slot

25

SLC 5/03 CPU

Input modules

Output modules

I/O module

Card slot

Rack

Before beginning, make sure you havethe wiring diagrams that were suppliedwith your SLC48 control and the correct number of Allen Bradley SLCInput and Output modules to add theloading stations, pumps or valves toyour system.

Each module consists of a micro-processor card attached to a terminalblock with 16 terminals numbered 0-15.

Disconnect power to the SLC48 control.

Open the SLC48 control enclosure.

Insert each Input or Output module into thecorrect rack and card slot.For the correct rack and slot location, refer to the wiringdiagrams that were supplied with your SLC48 control.Push the module into the rack until the card is seatedsecurely in the I/O port in the card slot.

Wire receivers, pumps and valves to the correct terminals on the I/O modules. See WIRING CONSIDERATIONS and the wiring proceduresin the INSTALLATION section of the SLC48 User Guide.

INSTALLINGI/O MODULES

INSTALLING SLOTS AND LOADERS UGC003/0201APPENDIX B-2


Always disconnect and lock out the main power tothe SLC48 before opening the control enclosure.Failure to disconnect and lock out the main powerbefore installing I/O modules could result insevere personal injury and damage to the control.

123

I/O module

Card slot port

Rack

4

NOTE: To remove an I/Omodule, push in on theplastic tabs at the top and bottom of the module,then pull the module outof the slot.

UGC003/0201 INSTALLING SLOTS AND LOADERS APPENDIX B-3

Before you can use your additional receivers, valves or pumps,you must enable each installed I/O slot for the new devices.

Turn on power to the SLC48 control. Wait for the initialization and bootup sequence to end.


is displayed

Enter the Level 4 access code.See SETTING SECURITY LEVELS

in the SLC48 User GuideInstallation section.

Touch “Rack & SlotStatus.”� The Rack & Slot screen

is displayed.

Enable the newlyinstalled slot(s).Touch “Rack 1 Slots” or“Rack 2 Slots” to view theslots in each rack. Touch a“Disabled” slot to enable it.Touch an “Enabled” slot todisable it.

NOTE: Do not enable a slotunless an I/O module hasbeen installed in that slot onthe rack. The SLC48 willfault and stop if the I/O module has not been installed in an enabled slot.

Proceed to INSTALLING LOADER BANKS.

ENABLING ANDDISABLINGSLOTS


Touch Screen

Pumps

Status

Setup

Prev

Help

1

17

25

2 3 4 5 6 7 8

10 11 12 13 1514 16

18 19

26 27

20 21

28 29

22

30

23 24

31 32

9


Touch Screen

Pumps

Status

Help

Security ScreenHome

*****] KeyPad

SetDate and

Time

Enter Security Code

Back-upPump

Selection



ChangeUser

Password

Rack &Slot

Status

LoaderBank

Status

1

2

3

4

CAUTION: Incorrect configurations willcause the SLC48 control to stop.Each loader, pump and valve must be wired to acorrectly installed and enabled Input or OutputSlot. The SLC will fault and the loading control willstop if the required I/O module has not beeninstalled and enabled for the device.


Touch Screen

Pumps

Status

Setup

Prev

Help

Rack & Slot Status

Ver

Home

ClearMajorFaults

Rack 1 Slots



Rack 2 Slots







5

INSTALLINGLOADER BANKS

INSTALLING SLOTS AND LOADERS UGC002/0301APPENDIX B-4

Loaders are installed in the SLC48 control in banks of 16.When you expand the conveying system from 16 or 32 loading stations to a total of 48 loading stations, you mustinstall the additional “banks” of loaders before the control willdisplay them.

Turn on power to the SLC48 control. Wait for the initialization and bootup sequence to end.


is displayed

Enter the Level 4 access code.See SETTING SECURITY LEVELS

in the SLC48 User GuideInstallation section.

Touch “Loader BankStatus.”� The Loader Bank Status

screen is displayed.

Touch “Install” toinstall the new bankof loaders.A highlighted “Installed”appears next to each of bankloaders that has beeninstalled on the control.

The Home screen will nowdisplay the newly installedbank of loaders.

Enable loader featuresand loaders.The new loaders will appear disabled (black) until they areconfigured and enabled.

Proceed to the INITIAL SETUP

procedures in the Installationsection of the SLC48 UserGuide to enable features andenter loader settings.


Touch Screen

Pumps

Status

Setup

Prev

Help

1

17

25

2 3 4 5 6 7 8

10 11 12 13 1514 16

18 19

26 27

20 21

28 29

22

30

23 24

31 32

9


Touch Screen

Pumps

Status

Help

Security ScreenHome

*****] KeyPad

SetDate and

Time

Enter Security Code

Back-upPump

Selection



ChangeUser

Password

Rack &Slot

Status

LoaderBank

Status

1

2

3

4


Touch Screen

Pumps

Status

Setup

Prev

Help

Loader Bank Status Home

InstalledLoaders 1-16

InstalledLoaders 17-32

InstallLoaders 33-48

5


Touch Screen

Pumps

Status

Setup

Prev

Help

1

17

25

2 3 4 5 6 7 8

10 11 12 13 1514 16

18 19

26 27

20 21

28 29

22

30

23 24

31 32

9

33

41

34 35 36 37

42 43 44 45

38

46

39

47

40

48

6

Documents

SLC48 Sentral Loader Control - Conair Group · 2001. 3. 15. · 7Loader 6 8 In this example, the SLC48 monitors and controls conveying in a typical CDS application. Pump System 1