Distributed Loader Control - Conair · 1-2 INTRODUCTION DLC48 Distributed Loader Control...

Distributed LoaderControl

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

DLC48 Model

UGC009/0902

Installation

Operation

Maintenance

Troubleshooting

It’s a good idea to record the model, serial and software version numbers of your equipment and the date you 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: UGC009/0902

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 2002 All rights reservedTHE CONAIR GROUP

UGC009/0902 DLC48 Distributed Loader Control

TABLE OFCONTENTS

INTRODUCTION .........................................1-1Purpose of the User Guide.....................................................1-2How the Guide is Organized .................................................1-2Your Responsibility as a User .............................................. 1-2ATTENTION: Read this so no one gets hurt ........................1-3

DESCRIPTION . . . . . . . . . . . . . . . . . . . .2-1What is the DLC48? . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2Typical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4How it Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

INSTALLATION . . . . . . . . . . . . . . . . . . . .3-1Unpacking the Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . .3-3Installing the DLC48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4Wiring Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4Mounting the Base Unit and Power Supply . . . . . . . . . . . .3-5Connecting a Keyboard (optional) . . . . . . . . . . . . . . . . . . .3-5Installing the Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6Installing the Bases and Cables . . . . . . . . . . . . . . . . . . . . .3-7Installing the Terminal Blocks . . . . . . . . . . . . . . . . . . . . . .3-8Attaching the Power Supply Units . . . . . . . . . . . . . . . . . . .3-9Installing the I/O Units . . . . . . . . . . . . . . . . . . . . . . . . . .3-10Wiring Pocket Conveying Valves . . . . . . . . . . . . . . . . . . .3-12Connecting Main Power . . . . . . . . . . . . . . . . . . . . . . . . . .3-12Starting Up the DLC48 . . . . . . . . . . . . . . . . . . . . . . . . . .3-13Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15Activating Nodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16Disabling Nodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18Configuring Loaders . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19Entering Pump and Loader Settings . . . . . . . . . . . . . . . . .3-22Identifying Loaders . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24Setting the Date and Time . . . . . . . . . . . . . . . . . . . . . . . .3-25Recording the Software Version . . . . . . . . . . . . . . . . . . . .3-26Setting Security Levels . . . . . . . . . . . . . . . . . . . . . . . . . .3-27Changing the Level 2 Password . . . . . . . . . . . . . . . . . . . .3-28

OPERATION . . . . . . . . . . . . . . . . . . . . . .4-1DLC48 Control Features . . . . . . . . . . . . . . . . . . . . . . . . . .4-2Operating the Conveying System . . . . . . . . . . . . . . . . . . . .4-4Enabling and Disabling Loaders . . . . . . . . . . . . . . . . . . . .4-5Changing Loader Settings . . . . . . . . . . . . . . . . . . . . . . . . .4-6Entering Loader Settings . . . . . . . . . . . . . . . . . . . . . . . . . .4-7Assigning a Backup Pump . . . . . . . . . . . . . . . . . . . . . . . . .4-8

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DLC48 Distributed Loader Control UGC009/0902

TABLE OFCONTENTS

MAINTENANCE . . . . . . . . . . . . . . . . . . . .5-1Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2Recalibrating the Touchscreen . . . . . . . . . . . . . . . . . . . . . .5-3

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 . . . . . . . . . . . . . . . . . . . . . .6-5Memory Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6Conveying System Alarms . . . . . . . . . . . . . . . . . . . . . . . . .6-8Power and Processor Problems . . . . . . . . . . . . . . . . . . . .6-10CPU Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12I/O Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15Loaders Fail to Operate . . . . . . . . . . . . . . . . . . . . . . . . . .6-19Network Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20ArmorBlock Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26

APPENDIXCustomer Service Information . . . . . . . . . . . . . . . . . . . . . .A-1Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

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1-1UGC009/0902 DLC48 Distributed Loader Control

l Purpose of the User Guide .........1-2l How the guide is organized ........1-2l Your responsibilities as a user ...1-2l ATTENTION: Read this so

no one gets hurt ..................... 1-3

INTRODUCTION

DLC48 Distributed Loader Control UGC009/09021-2 INTRODUCTION

This User Guide describes the Conair DLC48 DistributedLoader Control and explains step-by-step how to install, oper-ate, 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:

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

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

l Thorough review of instruction manuals for associatedequipment.

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

PURPOSE OFTHE USERGUIDE

HOW THEGUIDE ISORGANIZED

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YOURRESPONSIBILITYAS A USER

UGC009/0902 DLC48 Distributed 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: Improper installation,operation or servicing may result inequipment damage or personal injury.

This equipment should be installed, adjustedand serviced by qualified technical personnelwho are familiar with the construction, operationand potential hazards of this type of equipment.

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.

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 grounding canresult in personal injury and erratic machineoperation.

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.

UGC009/0902 DLC48 Distributed Loader Control 2-1

l What is the DLC48? . . . . . . . . . .2-2l Typical Applications . . . . . . . . . .2-4l How it Works . . . . . . . . . . . . . . .2-5l Specifications . . . . . . . . . . . . . .2-7

DESCRIPTION

The DLC48 is a flat-media, distributed input/output (I/O)loading control system. It provides I/O electronics near eachloader in the system, then connects all the I/O modules withsimple flat media cable. The DLC48 main control box con-tains only the operator interface station plus a control proces-sor and an interface to the I/O network. This control systemconfiguration greatly simplifies installation, reducing laborand wire costs and allows system expansion by simply addingmore I/O modules.

The DLC48 is designed to control up to 48 loaders and 8 vac-uum pumps with 1 standby pump. In its current configurationit has all the options of the DLC48 except proofing and aremote terminal (both of these options may be added in thefuture). Both 6” and 10” color touchscreens are available.

The DLC48 system uses Allen Bradley ArmorBlock I/O mod-ules for loaders and pumps. The modules are clamped ontoKwik-Link flat DeviceNet cable. The DeviceNet flat cables(one for solenoid power, one for electronics/communications)are typically run around the plant in one continuous routing.

WHAT IS THEDLC48?

DLC48 Distributed Loader Control UGC009/09022-2 DESCRIPTION

Variations to this standard routing are also possible, as needed.A Power Supply is connected to the DeviceNet cable to pro-vide power for solenoids and communications. There is no tra-ditional cutting, stripping, and terminating wire. The I/O mod-ules simply clamp on the DeviceNet cable. Connections withthe I/O modules are then made with “DIN” type screw-onconnectors that terminate at the loader with Conair’s uniqueplug-in UTB connector.

The controller and touchscreen panel automatically turn onwhen power is applied to the I/O station. After a bootupsequence, the Home Screen displays. From the Home screenyou can view the operating status of all vacuum receivers con-nected to the system.

Color-coded icons indicate receiver status:

l Disabled = Black l Demanding material = Blue

The DLC48 Home Screen lets the operator monitor the statusof all vacuum receivers at a glance. Color-coded icons indi-cate the 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.

l Disabled = Black l Demanding material = Bluel Enabled = White l Alarming = Redl Loading = Green

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

WHAT IS THEDLC48?

UGC009/0902 DLC48 Distributed Loader Control DESCRIPTION 2-3

10-inch diagonal screen

6-inch diagonal screen

TYPICALAPPLICATIONS


The DLC48 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:l Single-material loading.l Ratio loading, with or without automatic material layering.l Positive (air-operated) receiver discharge.l Material line purging.l Material line proofing.l Pocket conveying from a drying hopper or other vessel.l Loader fill alarm to work with an optional fill sensor

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

in a drying hopper or other material vessel.

PumpSystem 1

PumpSystem 2

RatioLoading

PocketConveying

LinePurging

LoaderFill

HopperFill

Loader1

Loader2

Loader3

Loader7 Loader

8Loader

6

In this example, the DLC48 monitorsand controls conveying in a typicalCDS application.

Pump System 1 conveys material tothe drying hoppers from three differentmaterial sources.

Pump System 2 conveys material fromthe drying hoppers to three processing machines as it is needed.


HOW IT WORKSThe DLC48 communicates with each pump, vacuum receiverand material valve wired to ArmorBlock modules. The DLC48controls conveying operation based on settings the operatorenters on a touchscreen panel.

When receivers in a pump system demand material, theDLC48 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.

The DLC48 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.

3 The DLC48 will signal an alarm if:

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

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

Vacuum Flow

Material Flow

The DLC48 receives amaterial demand signal(input) from the fill sensor in Loader 1.

1The DLC48 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)

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HOW IT WORKS


The DLC48 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.

SPECIFICATIONS


MODELS DLC48Performance 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 DLC504Touchscreen 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 VDCSensor voltage to receivers 24 VDCOutput voltage to pumps 24 VDC

Dimensions inches {mm}Base unit cabinetA - Height 20 {508}B - Width 20 {508}C - Depth 8.6 {219}Power supply cabinetA - Height 20 {508}B - Width 20 {508}C- Depth 8.6 {219}

Weight lb {kg}Base unitInstalled 60 {27.2}Shipping 75 {34}Power supplyInstalled 60 {27.2}Shipping 75 {34}

Voltages Total amps115V/1 phase/60Hz (master control) 15115V/1 phase/60 Hz (remote control) 5

PowerSupply

Unit

DLC48 Base Unit and Touchscreen


l Unpacking the Boxes . . . . . . . . . . . . . . .3-2l Preparing for Installation . . . . . . . . . . . .3-3l Installing the DLC48 . . . . . . . . . . . . . . . .3-4l Wiring Considerations . . . . . . . . . . . . . .3-4l Mounting the Base Unit and

Power Supply . . . . . . . . . . . . . . . . . . . .3-5l Connecting a Keyboard . . . . . . . . . . . .3-5l Installing Brackets . . . . . . . . . . . . . . . . .3-6l Installing Bases and Cables . . . . . . . . .3-7l Installing the Terminal Blockes . . . . . . .3-8l Attaching the Power Supply Units . . . .3-9l Installing the I.O Units . . . . . . . . . . . . .3-10l Wiring Pocket Conveying Valves . . . . .3-12l Connecting Main Power . . . . . . . . . . . .3-12l Starting Up the DLC48 . . . . . . . . . . . . 3-13l Initial Setup . . . . . . . . . . . . . . . . . . . . . .3-15l Activating Nodes . . . . . . . . . . . . . . . . . .3-16l Disabling Nodes . . . . . . . . . . . . . . . . . .3-18l Configuring Loaders . . . . . . . . . . . . . . .3-19l Entering Pump and Loader Settings . .3-22l Identifying Loaders . . . . . . . . . . . . . . . .3-24l Setting the Date and Time . . . . . . . . . .3-25l Recording the Software Version . . . . .3-26l Setting Security Levels . . . . . . . . . . . . .3-27l Changing the Level 2 Password . . . . .3-28

INSTALLATION

The DLC48 distributed loading control comes in one or moreboxes, depending on the options ordered. The boxes shouldinclude:

r Base unit with touchscreen interface panel;r Power supply unit;r ArmorBlock I/O modules and bases;r DIN blocks and bases;r Termination blocks and bases;r Kwik-Link flat DeviceNet cable;r Cable installation brackets.

Carefully remove the DLC48 components from their shipping containers, and set upright.

Remove all packing material, protective paper,tape and plastic.

Carefully inspect all components to make sureno damage 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

DLC48 Distributed Loader Control UGC009/09023-2 INSTALLATION

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Master Control Unit with Touchscreen Interface Panel

Power Supply Unit

PREPARING FORINSTALLATION

UGC009/0902 DLC48 Distributed Loader Control INSTALLATION 3-3

You should plan the location of the DLC48 base unit 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 base unit. The base unit interface can be mounted on a wall or otherstable vertical surface. Select a location that:r Is central to loaders that the DLC48 will control.

Keep the DLC48 base unit as close as possible to theloading stations to minimize the amount of wire need-ed to connect the vacuum receivers to the control.

r Provides adequate clearance for safe operation andmaintenance. The base unit should be mounted at aheight that allows the operator to easily see and use thetouch screen. An external keyboard, if used, should belocated on a stable horizontal surface within sight ofthe touchscreen. Maintain at least 3 feet (1 m) clear-ance in front of the base unit for safe access to theInput/Output enclosure.

r 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 lifeof this equipment.

r Provides a grounded source of 115 VAC power. Thethree-prong power cords supplied with the DLC48base unit and power supply requires a grounded 115VAC outlet rated for at least 15 amp service.

Plan the power/communication cable routes.r Review all wiring guidelines and diagrams

provided in the manuals and electrical diagrams sup-plied with the DLC48 system and your conveyingequipment before beginning installation. See WIRINGCONSIDERATIONS.

r 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 amountsof static electricity when material is conveyed.

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

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WIRINGCONSIDERATIONS

Installation consists of:r Installing the Kwik-Link flat DeviceNet cables.r Installing the ArmorBlock bases and termination blocks.r Installing the ArmorBlock I/O units.r Mounting the base unit and power supply.r Installing the loader drop cables.r Wiring the purge and pocket valves included in the system.r Installing the drop cables between the pump ArmorBlocksand the pump starters.r Initial setup of the system control.

INSTALLINGTHE DLC48


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

l Disconnect and lock out the main power supply toequipment in the conveying system before attempting to wirepower and communication cables between the DLC48 con-trol, vacuum receivers, pumps, dust collectors and materialvalves.l Install all wiring, disconnects and fuses in accordancewith electrical codes in your region. All electrical installationsshould be done only by qualified electrical technicians.l Always refer to the wiring diagrams supplied with yourcontrol before making electrical connections. The diagramsshow the most accurate electrical component information. l Protect communication cables from sources of staticelectricity and electrical noise. r Use shielded cable or run wire through a contiguous

metal conduit or wireway. Failure to use a metal shieldcan expose the controls to static electricity, which candamage electronic components.

r Do not run communication cables near material lines andhoses, which produce large amounts of static electricitywhen conveying material.

r Keep communication cables at least 5 ft. (1.5 m) fromelectric motors, transformers, rectifiers, arc welders, gen-erators, induction furnaces and sources microwave radia-tion.

r 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 least 6inches (0.15 m) from AC power lines of less than 20 A; 1foot (0.30 m) from lines of 20A to 100 kVA; and 2 feet(0.60 m) from lines of 100 kVA or more.

l Always maintain a safe ground. Follow the safe grounding procedures in the wiring diagram package. Groundthe shielded cable inside the Input/Output enclosure only.l Do not operate the equipment at power levels other than those specified on the the equipment data plate.


The DLC48 base unit and power sup-ply should be mounted on a wall, orother secure vertical surface, at aheight providing easy access and aclear view of the touchscreen panel.

Bolt the base unit and power supply to the mountingsurface. Use the mounting brackets on the base unitenclosures.

Ground the base unit cabinet.Connect a ground wire to the base unit enclosure. Followprocedures outlined by your regional electrical codes andthe wiring diagrams 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 base unit enclosure.

Open the DLC48 base unit enclosure.

Plug the keyboardinto the available PS/2port.

MOUNTINGTHE BASE UNITAND POWERSUPPLY1

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CONNECTINGA KEYBOARD(OPTIONAL)

PS/2 port

Install the Kwik-Linkflat DeviceNet cable brack-ets provided or prepareyour chosen method ofcable support.

Install the two Kwik-Link flat DeviceNetcables. The gray cable pro-vides communications andinputs; the black cable pro-vides output power. Insurethat the cables are installedso that the tabbed edge ofthe cable may be installedinto the ArmorBlock basesand termination blocks cor-rectly.

Install the ArmorBlock base bracketsor prepare your chosenmethod of ArmorBlock sup-port wherever there is aloader or a pump.

INSTALLING THEBRACKETS


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.

It is important to keep the communication wiresaway from conveying lines, which can producelarge amounts of static electricity.

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Install the ArmorBlocks bases on thebase brackets.

Install the Kwik-Link flatDeviceNet cables in theArmorBlock bases.Insure that the cables areproperly installed in thebases and the piercingcaps are clamped evenly.If the cables are not flatin their slots, the contactswill not pierce the cablescorrectly. Remove thebases and discard. Installa new base 1/2 inch to 1inch from the rremovedbase. Refer to AllenBradley ArmorBlockMaXum I/O CablesBases Manual(Publication 1792D-5.9)included with the basesfor further details.

Initially install just twobases, one loader and onepump. The remainingbases can be installed oneat a time after the system is powered up.

INSTALLING THEBASES ANDCABLES


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Install the termination blocks on thetwo ends of the graycable. Install any linkcouplers if the system hasmultiple segments andmultiple power supplies.

Install the base unit anywhere along thelength of the flat cablerun within 25 feet of thecable. Install theDeviceNet Mini-DIN ter-mination tap on the grayflat cable. Connect thebase unit to theDeviceNet cable usingthe attached Mini-DINconnector.

INSTALLING THETERMINALBLOCKS


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Install the two power supply taps on the DeviceNet cable. The two power supply cables from thepower supply unit mustbe placed on the correctflat cable. The cablemarked “DeviceNetPower Supply” shouldbe attached to the grayDeviceNet cable and thecable marked “AuxiliaryPower” should beattached to the blackauxiliary power cable.

ATTACHINGPOWER SUPPLYUNITS


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Install the power supply units along the DeviceNet cable so that the power from the units will beevenly distributed along the cable. For example if thereare ten loaders evenly spaced along a 75 meter cable, thepower supply should be placed in the center of the cablewith five loaders on one side and five on the other. If nineof the loaders were onone end and the tenthloader on the other end,the power supply shouldprobably be placedsomewhere in the mid-dle of the nine loaderson the one end. Half ofthe current from thepower supply will flowone direction down the auxiliary power cable and half ofthe current will flow the other direction. If there are ques-tions refer to your Allen-Bradley DeviceNet CableSystem Planning and Installation Manual (Cat. No. DN-6.7.2), or contact your Conair Representative. Install thepower supply units within 25 feet of the DeviceNet cable.

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INSTALLING THEI/O UNITS


Install the ArmorBlock I/O units on the bases.Set the rotary switcheson the bottom of theblock to the desired nodenumber. Loaders shouldbe set to node 01 to 48(loader 1 to 48). PumpI/O blocks should be setto 51 to 58 (pump 1 to8). The standby pumpshould be set to node 59.Mark the white tag onthe block with the nodenumber for future refer-ence. Please refer toAllen BradleyArmorBlock MaXum 4Input/4 Output ModuleManual (Publication1792D-IN012B-EN-P)included with theArmorBlocks for furtherdetails.

Install the loader drop cables between the ArmorBlocks and the Universal Terminal Boxes (UTB).The connectors should be installed on the ArmorBlocks sothat the connector with four wires is installed on the upperleft ArmorBlock connectors. Install the connector withthree wires on the upper right ArmorBlock connectors.The final loader drop cable connector should be installedon the lower right hand ArmorBlock connector.

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Install the wiring for any purge and pocketvalves included with the system. The purge/pocket valveshould be wired from the junction box on the valve to thenearest Universal Terminal Box (UTB). The wiringshould be connected to the UTB using the supplied greenPhoenix connector. The pocket valve is given a numberbased on the loader it is connected to. For example thepocket valve that is connected to loader number 12’sUTB will be addressed as material source number 12 inthe settings screen.

Install the drop cables from the pumpArmorBlocks to the pump starters. Insure that the inputside of the ArmorBlockgoes to the input con-nection on the starterand that the output sideof the ArmorBlock goesto the output connectionon the starter.


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WIRING POCKETCONVEYINGVALVES(OPTIONAL)

The DLC48 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, separatewiring connections to the nearest loader universal terminalbox (UTB)DLC48 are required.

The DLC48 base unit and power supply are equipped with athree-prong plugs and power cords.

Plug the power cords into grounded 115 VACoutlets rated for at least 15 Amp service.

Make sure the base unit is grounded.

NOTE: Purge valves and pocket conveying valves connect to the same outputs on the DLC48 control.Therefore, pocket conveying valves cannot be usedwith loaders that are connected to purge valves.

CONNECTING TOMAIN POWER

WARNING: Electrical shock hazard

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 base unit enclosure.

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STARTING UPTHE DLC48


Once the system is completely assembledcheck that all connections are terminated correctly.

Turn on the power supply unit and test to make sure that power is correctly distributed. It is recom-mended that you remove the ArmorBlock that is locatedfarthest from the power supply and, using a voltmeter,check to insure that both the DeviceNet and Auxiliarypower is 24 VDC.

Once the power supply unit is turned on, check each ArmorBlock to insure that the AuxiliaryPower LED is on and glowing green. If not, theArmorBlock base is not clamped correctly and will needto be removed, discarded, and a new base installed. Installthe new base so that the piercing contacts enter the flatcable at a different location than the incorrectly mountedbase. It is also possible that the ArmorBlock may be bad.In this case, a known good ArmorBlock should be tem-porarily fitted to the base to check if the ArmorBlockmodule may be bad.

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Auxiliary Power LED

Net / Mod Status LED


Once the first two ArmorBlocks display a green Auxiliary Power LED, turn on the power switch onthe base unit to start the controller and touchscreen. Withthe processor in run mode, check all the ArmorBlocks forthe condition of the Net/Mod Status LED. For loader 1(node address 01) and pump 1 (node address 51), theLEDs display as solid green indicating that the loader andpump are enabled (factory default). On all otherArmorBlocks, the Net/Mod status LED show as blinkingred or blinking green. If any block shows a solid redNet/Mod status light, either the address is incorrect on therotary switches for one or more blocks may be defective.Check all switch positions and correct/replace theblock(s) as necessary.

When the ArmorBlocks show solid green,blinking red, and the Net/Mod status LEDs blinkinggreen, the enable the nodes via the operator interface. SeeINSTALLING THE I/O UNITS in the Installation section ofthis manual. When a node is enabled, the blinking redlight changes to solid green (this may take a few sec-onds).

Install remaining ArmorBlock base andArmorBlocks, one at a time. Enable the blocks as they areinstalled and check the status LEDs for he correct status.

After ArmorBlocks are enabled and show asolid green Auxiliary Power LED and a solid greenNet/Mod Status light, the system is ready to run.

STARTING UPTHE DLC48

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NOTE: ArmorBlocksand bases can beadded or removed fromthe system while thesystem is powered on.

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Before you begin conveying, you must configure and identifythe loaders and conveying features you want to use.

For initial setup you need to:r Configure each loader in the system.r Assign loaders to pump systems.r Add details to further identify each loader.r Set the date and time that will appear in the alarm histo-ry.r Select or set security levels required by your operation.

To begin Initial Setup:

Turn on power to the DLC48. The Power ON/OFF switch is on theside of the base unit.

Wait for the control to initialize. Do not touch the touchscreen paneluntil the control has completed thebootup and initialization process. Thisprocess takes 20 to 30 seconds. When the control has ini-tialized, the Home screen displays the number of avail-able loading positions.

INITIAL SETUP


PowerON/OFF

Touchscreenpanel

NOTE: All loaders display as disabled (blackicons) at initial setup until they are enabled.

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TIP: You will need theLevel 3 or 4 security codeto perform most proce-dures in the initial setup. Ifyou are not familiar withthe DLC48 security levels,please review SETTINGSECURITY LEVELS in theInstallation section beforeproceeding.

Each loader and each pump is considered a node on theDeviceNet system. The system is sent from the factory withone loader node and one pump node active. Before more load-ers or pumps can be used, the nodes must be activated via thetouchscreen. The loaders must be set at nodes 1 to 48 (loader1 to 48). The pumps must be set at nodes 51 to 58 (pump 1 to8).

When a node (either a loader or a pump) isadded to the loading system, the associated hardware (I/Obase and ArmorBlock I/O) must first be mounted on theDeviceNet trunk cables and the rotary switches on thebottom of the ArmorBlock I/O module must be set to thecorrect node number.

Once the hardware is mounted, the ModuleStatus indicating light on the module blinks red or greenindicating that the new node is not recognized. Mountingthe I/O base and ArmorBlock module may be done whilethe loading system is running. Once the hardware is inplace, stop the loading system and disable all loaders.

Go to the settings screen and place the system

in the highest level of password access (54647). A “rackand slot status” button displays in the lower left corner ofthe screen. Press this button; the rack and slot statusscreen displays.

Press the Nodes button.The Nodes screen displays.


ACTIVATINGNODES

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WARNING:Turning nodes active or inactive will cause abrief stop (approximately two seconds) to theoperation of the loading system. It is recom-mended that all loaders be disabled and thesystem stopped when making nodes active orinactive.

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To enable a node, press the INC or DEC button until the correct node number (1 to 48 are loaders,51 to 58 are pumps) displays on the screen. The Enableand Disable buttons highlight, showing the current statusof the node. Press the Enable button to enable the node.After a few seconds the indication on the touchscreenshould go from “Disabled” to “Enabled”. Also theModule Status indicating light on the ArmorBlock I/Omodule should go from blinking red or green to a solidgreen color. The node is now active and available for use.

ACTIVATINGNODESCONT’D


NOTE: Any action takenon this screen requiresmultiple communicationmessages on theDeviceNet. This will makethe response time seemsluggish compared to theother screens. After press-ing the INC, DEC, Enable,or Disable buttons, it maytake 5 to 10 secondsbefore a response isseen.

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DISABLINGNODES


WARNING:Prior to disabling a node, remove all wiring fromthe ArmorBlock I/O to ensure that all inputs are inthe off state. If a node is disabled while an inputis on, this input will be retained in memory afterthe node is disabled. This will cause incorrectoperation of the loading control. If this situationoccur, the node must be reinstalled and enabled.Remove the input wiring and disable the node inthe correct sequence.

To disable a node from the Nodes screen. Press the Disablebutton to disable the node. The indication on the touchscreenchanges from Enabled to Disabled. The Module status indi-cating light on the ArmorBlock I/O module changes fromsolid green to blinking green or blinking red.


CONFIGURINGLOADERS

Configure each loadingstation in the system byenabling vacuumreceivers and loadingfunctions on the LoaderFeatures screen.

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

CAUTION: Incorrect configurationscause the DLC48 control to stop.Before enabling loaders and loading functions,make sure the loader, valve and option have beeninstalled in the system. Each loader and featuremust be wired to a correctly installed and enabledArmorBlock. The DLC will fault and the loadingcontrol will stop if the required ArmorBlock hasnot 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.

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

To enable conveying features,you must open the LoaderFeatures screen and enter theLevel 3 access code to complete this procedure. SeeSETTING SECURITY LEVELS in theInstallation section.

Press Setup button on the Home Screen. TheSecurity Screen displays.

Enter the Level 3 access code. Press Key Padto open the keypad. Enter thenumbers for Level 3 accessand press Enter. The SecurityScreen displays four choices.

Press Loader FeaturesScreen button. The LoaderFeatures for Loader 1 dis-plays.


CONFIGURINGLOADERS

LOADER FEATURES:Closed/Open Allows the pump systems to operate either in a Loop Control closed loop or open loop mode. In a closed loop

system, dry air that is pulled from the loaders dur-ing a load cycle is routed back into the drying hopper lines. In an open loop system, this air is released into the ambient atmosphere. The system consists of an additional valve that is added at each pump to switch between closed or open loop loading. This function can be selected on a loader by loader basis by using the "Loader Features Scrn II" button located on the security screen. On this screen, closed loop control can be either enabled or disabled for each loader.

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

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Press Enable for eachfeature installed on thatloading station. You alsocan enable the loader, butyou should leave the loaderdisabled (off) until you haveassigned it to a pump sys-tem. The feature is on whenEnabled is lit.

Press Next to accessfeatures for the next loaderin the system.

Repeat the procedurefor each loader.

CONFIGURINGLOADERS


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IMPORTANT: Verify instal-lation of vacuum receivers,valves and options beforeenabling them in theDLC48.

Loader positions areinstalled in the DLC48 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.)

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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

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 DLC48 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 DLC48 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 “KeyPad” to open the keypad.Enter the numbers for Level 3 access and thentouch “Enter”.u The Security Screen

displays four choices.

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

Loader 1 is displayed.

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” to scroll to theLoader Settings Screen foreach loader.

Proceed to IDENTIFYING LOADERS.

ENTERINGPUMP ANDLOADERSETTINGS

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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.

DLC48 Distributed Loader Control UGC009/0902

The DLC48 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.

Press Status to go to the Loader Status screen.This screen does not require a security code for access.

Press Edit, then the white text block.This activates 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.Press the Enter button on the keyboard to 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 Prevto go to the previous loader.

IDENTIFYINGLOADERS

3-24 INSTALLATION

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Connected to Pump 1

Pump Currently Idle

Drying Hopper 1 - PET

10-inch touchscreen6-inch touchscreen

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

Set the date and timethat the control uses torecord alarm histories.

The DLC48 automati-cally updates the timefor Daylight SavingsTime. To set or changethe date and time:

Press Setupfrom any screen.The Security screendisplays.

Enter the Level 3 access code. Touch Key Padto open the keypad. Enterthe numbers for Level 3access and press Enter. TheSecurity screen displays fourchoices.

Press Set Date andTime. The Date and Timescreen displays.

Enter the date and the time. Touch the buttonnext to the field you want tochange (Example: “Mon”for Month). On the keypad,touch the numbers corre-sponding to the date or time,then press Enter to close thekeypad.

Repeat this process for allfields, then touch PUSH toUpdate Date/Time to savethe changes.

Press Back to return to the Security screen.

SETTING THEDATE AND 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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Before starting operation, record the version of the DLC48software in the front of this manual. The Conair servicedepartment will need this information, along with the serialnumber, to provide help for the specific equipment youinstalled.

To determine the software version number:

Press Setup to display the Security Screen.

Enter the Level 4security code. Press KeyPad button to open the key-pad. Enter the numbers forLevel 4 access and thenpress Enter. (See SETTING

SECURITY LEVELS)

Press Rack & SlotStatus. This opens the Rack& Slot Status screen.

Press the Ver button. This open the software ver-sion screen displaying theversion number and accessto the powerstation shell.

Record the softwareversion number. In thisexample, the version numberis P108_01.

Press Setup to return to the Security screen.

RECORDING THESOFTWAREVERSION

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The DLC48 provides four levels of security to prevent unauthorized changes to loader or system settings. You shouldset the most appropriate level for your operating procedures.

l 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, anddisable or enable a loader.

l 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.

l 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.

l Level 4 Access (factory-set code 54647)This provides factory-levelaccess to all functions andsystem parameters. Use onlywhen expanding the originalsystem or troubleshootingDLC processor error codes.

SETTINGSECURITYLEVELS

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 theDLC48 security level codes,you may want to removepages 3-27 and 3-28 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:

Press Setup to display the Security screen.

Enter the Level 3security code. Press Key Padon the Security screen toopen the numeric keypad.Touch 7, 3, 7, 3, and pressEnter.

Press Change UserPassword. The UserPassword Entry screen dis-plays.

Enter a new code.Press Key Pad button to openthe numeric keypad. The newcode can be any 1- to 5-digitnumber between 0 and64000. Enter the new code onthe keypad, and press Enterto save the change and closethe keypad.

Press Prev to return tothe Security screen.

Set the appropriate security level.Press Key Pad button to open the keypad. Enter the secu-rity code for the access level you want your operators touse.

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

CHANGING THELEVEL 2PASSWORD

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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.


l DLC48 Control Features . . . . . . . .4-2l Operating the Conveying System .4-4l Enabling and Disabling Loaders . .4-5l Changing Loader Settings . . . . . . .4-6l Entering Loader Settings . . . . . . . .4-7l Assigning a Backup Pump . . . . . .4-8

OPERATION

DLC48 Distributed Loader Control UGC009/09024-2 OPERATION

DLC48CONTROLFEATURES

The DLC48 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 ScreensPress Status or a specific loadericon to view details about a vacu-um receiver and the assignedpump. You can enable or disablethe loader or view a summary ofalarms. Press Next or Prev toscroll through all loaders in thesystem

Security ScreenPress Setup to display the secu-rity screen. To prevent accidentalor unauthorized changes to sys-tem settings, security codes arerequired to access any screenthat allow changes to loader set-tings or system parameters.

Pump System ScreensPress Pumps to view the status of all vacuum receiversassigned to a specific pump system.

Press Next or Prev to scrollthrough all pump groups.

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

Help Use to view instruc-tions about the specif-ic screen you are cur-rently viewing.

UGC009/0902 DLC48 Distributed Loader Control OPERATION 4-3

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

DLC48CONTROLFEATURES

Back-Up Pump Selection(Requires Level 3 Security Code)Assign a backup pump to anypump system by enabling thepump next to the appropriatesystem number.

Press Home, Pumps, Status orSetup 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.

Press Next or Prev to scrollthrough all loaders.

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

Once power is applied to the system, the DLC48 automatical-ly operates vacuum pumps, loaders and material valvesaccording to the conveying functions and loader settingsentered during the initial setup.

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

To view loaders in a specific pump system:

Press Pumps to view the Pump System screen.

Press Next or Prev to view each pump system.

To view details about a specific loader:

Press Status or the loader icon to view Loader Status.

Press Next or Prev to view each loader.

To acknowledge an alarm:

Press the specific loader icon to view Loader Status.

Press Silence Alarm to display the Alarm Summary screen. The cause of the alarm must be fixedbefore the pump or loading station will resume operation.See the TROUBLESHOOTING section of this manual.

OPERATING THECONVEYINGSYSTEM


The Home Screen displaysthe status of all loaders.

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TIP: Press the Help key onany screen to find instruc-tions and definitions aboutthe functions available onthat screen.

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

To disable or enable a loader from the Loader Status screen:

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

ENABLINGAND DISABLINGLOADERS


WARNING: Develop and follow proceduresfor safe operation of the system from the cen-tral control panel to avoid possible injury orequipment damage.

The DLC48 allows operators and maintenance personnel to disable and enable conveying systemcomponents. Unexpected energization of thesecomponents could result in equipment damage orinjury.

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

from main power and/or compressed airsources before servicing. Ensure that all energysources for the device are locked out andtagged.

r Before removing lockout devices or enablingpumps, loaders or material valves, make surethat all personnel are clear of the machine,tools have been removed and any safetyguards have been reinstalled.

Press Enable toenable the loader.

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orPress Disable todisable the loaderThe loader icon changes to black when the loader is disabled. When the loader is enabled, the icon colorchanges to the color indicating the loader’s operating status.

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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

TIP: Press the Help buttonon any screen to findinstructions and definitionsabout the functions available on that screen.

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 DLC48 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 view the Loader Settings screen and enter new settings:

Press Setup to go to theSecurity screen.

Enter the Level 2 security code. Press Key Padon the Security screen toopen the numeric keypad.Enter the code for Level 2access and press Enter tosave.

Press Loader SettingsScreen button. The settingsscreen for Loader 1 displays.

Press the Set buttonnext to the setting you wantto change. The keypad dis-plays.

Enter the new settingon the keypad and pressEnter to save.

Repeat the procedurefor each setting and loaderyou want to change. Use theNext and Prev buttons toscroll to the Loader Settingsscreen for other loaders.

Set the correct securitylevel for operators. If neces-sary, return to the SecurityScreen and enter the pass-word 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.

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

To assign a backup pump:

Press Setup to go to the Security Screen.

Enter the Level 3 security code. Press the KeyPad button to open thenumeric keypad. Enter thecode for Level 3 access,then press Enter to save.

Press Back-up PumpSelection. The Back-UpPump Selection screen dis-plays.

Press Enabled next tothe pump system that willhave the backup pump.

Set the correct securi-ty level for operators. Ifnecessary, press Setup toreturn to the Securityscreen. Enter the passwordfor the operator access level (Level 1 or Level 2) thatyou assigned during initialsetup.

ASSIGNING ABACKUP PUMP


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l Maintenance Checklist . . . . . . . .5-2l 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 DLC48 requires the following maintenance checks:

l Whenever you change materialsr Verify the loader settings for pump systems or

loaders effected by the material change. Pay particularattention to load times, dump times and material sourceidentification if you have pocket conveying valves andmaterial line proofing. See CHANGING LOADERSETTINGS in the Operation section.

l Quarterlyr Check power and cable connections and wires.

Over time, the power and cable connections betweenthe DLC48 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.

l After loading new software, or as neededr 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 DLC48 software.See RECALIBRATING A TOUCHSCREEN.

MAINTENANCECHECKLIST

DLC48 Distributed Loader Control UGC009/09025-2 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.

Press Setup and enterthe Level 4 security code.Press Key Pad on theSecurity screen to open thekeypad. Enter the code forLevel 4 access and pressEnter to save the code.

Press the Rack & Slot Status button. The Rackand Slot Status screen dis-plays.

Press Ver to view theversion information.

Press Exit toPowerstation Shell. TheDLC48 reboots into theCTC powerstation shell.

Press Settings, andthen Pwrsta. This displaysthe Calibrate Touchscreenscreen.

Press Calibrate Touchscreen and follow theonscreen instructions. Use the keyboard to complete theprocedures.

Press Back after the calibration routine is complete. This returns you to the powerstation shell.

Press Run and then Interact. This restarts theDLC48 program. Wait until the DLC48 finishes initializ-ing before continuing operation.

RECALIBRATINGTHETOUCHSCREEN

UGC009/0902 DLC48 Distributed Loader Control MAINTENANCE 5-3

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8


l Before Beginning . . . . . . . . . . . .6-2l A Few Words of Caution . . . . . .6-2l Identifying the Cause

of a Problem . . . . . . . . . . . . . . .6-3l Clearing Conveying Alarms . . . .6-4l Clearing CPU and I/O Alarms . .6-5l Memory Errors . . . . . . . . . . . . . .6-6l Conveying System Alarms . . . .6-8l Power and Processor

Problems. . . . . . . . . . . . . . . . .6-10l CPU Faults . . . . . . . . . . . . . . . .6-12l I/O Errors . . . . . . . . . . . . . . . . .6-15l Loaders Fail to Operate . . . . . .6-19l Network Errors . . . . . . . . . . . . .6-20l ArmorBlock Errors . . . . . . . . . .6-26

TROUBLESHOOTING

Before you begin troubleshooting:o 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

DLC48 Distributed Loader Control UGC009/09026-2 TROUBLESHOOTING

WARNING: Improper installation, operationor servicing may result in equipment damageor personal injury.

The DLC48 should be installed, adjusted, andserviced only by qualified technical personnelwho are trained in the operation and trou-bleshooting of this type of equipment.

DANGER: Electrical shock hazard

Diagnosing the cause of electrical system andCPU problems in this equipment may require theuse of precision electronic measuring equipment,as well as access to the electrical enclosurewhile power is on. Only qualified electrical techni-cians, trained in the use of the equipment and inavoiding exposure to voltage hazards, shouldperform procedures that require access to theenclosure while power is on.

WARNING: Develop and follow proceduresfor safe operation and maintenance of thesystem.

The DLC48 allows operators and maintenance personnel to disable and enable conveying sys-tem components. Unexpected energization ofthese components could result in equipmentdamage or injury.

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

from main power and/or compressed airsources before servicing. Ensure that all ener-gy sources for the device are locked out andtagged.

r Before removing lockout devices and enablingsystem components, verify that all personnelare clear of the machine, tools have beenremoved, and any safety guards have beenreinstalled.

A FEW WORDSOF CAUTION

The TROUBLESHOOTING section explains how to clear analarm, and provides diagnostic tables to help determine thecause of the alarm.

Diagnostic tables have been divided into:

r Conveying System Alarms. These tables focus on the “NoMaterial” and “Pump Overload”alarms that the DLC48 displayson the Alarm Summary screen.The DLC48 continues to controlthe system, but the alarmingloading station do not load untilthe alarm is acknowledge and thecause of the problem is fixed.

r Power and Processor Problems.These tables focus on power supply, processor or rack prob-lems indicated by LEDs locatedon the power supply and SLC5/04 processor module (Slot 0)located inside the base unit.These problems cause theDLC48 control to stop.

r CPU Faults.These tables focus on Hex errorcodes that apply to the SLC 5/04processor module (Slot 0) andare displayed as faults on theRack & Slot screen. These prob-lems cause the DLC48 control tostop.

r Input/Output Errors.These tables focus on Hex errorcodes that apply to Input/Outputmodules (Slots 1-48) and aredisplayed as faults on the Rack& Slot screen. The first two dig-its of the code refer to the Slotnumber that caused the error. Ifthe Slot cannot be determined,the first two digits are 1F. Theseproblems cause the DLC48 control to stop.

IDENTIFYING THECAUSE OF APROBLEM

UGC009/0902 DLC48 Distributed Loader Control TROUBLESHOOTING 6-3

IMPORTANT: Refer to themanuals supplied by themanufacturers of loaders,pumps and material valvesin your system for additionaldiagnostic and repair infor-mation. Contact Conair Service foradditional details on theSLC 5/04 processor orRack & Slot components.

When a conveying problem occurs, the icon for the affectedloader or pump flashes red and the control turns on the audi-ble alarm.

The DLC48 reports thetime and type of alarmon the Alarm Summaryscreen. Up to 100 NoMaterial, 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:

Press Status or the loader icon. This displays theLoader Status screen.

Press Silence Alarm.When the audible alarm is notactive, the control displaysthe See Alarms button.

Press See Alarms to view the Alarm Summary.Note the type and time of thealarm. Use the up and downarrows to scroll through thealarm history and view otheralarms that may involve thisdevice.

To resume operation,press Acknowledge Alarmand fix the problem. Refer tothe diagnostic tables in theTroubleshooting section todetermine the cause of theproblem. Also refer to thetroubleshooting and repair information contained inmanuals supplied with the alarming device.

CLEARINGCONVEYINGALARMS


1

2

3

4NOTE: To remove all alarmsfrom the Alarm Summaryhistory, press 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 Clearalarm buttons are displayedonly to users with access toSecurity Levels 2, 3 or 4.

CPU and Input/Output alarms will stop the DLC48 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 5/04CPU and power supplymodules.

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

Press Setup to displaythe Security screen.

Enter the Level 4 security code.

Press Rack & Slot Status to display the Rack &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 theerror code. Refer to the error code table below to identifythe affected slot, then see the diagnostic tables in this sec-tion. The error code is reported in hexidecimal format,with the first two digits identifying a specific I/O moduleslot. If the digits are 1F, an exact slot cannot be deter-mined.

Press Clear Major Fault or Clear Minor Faultafter the fault is corrected.

CLEARING CPUAND I/O ALARMS


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

Under certain conditions, such as low backplane power or lowbattery conditions, the Allen Bradley SLC line of controllersare designed to dump their main memory. This is to preventthe controller from operating with corrupted memory. Thelogic behind this is that it is better to dump the program andnot operate at all then to operate with corrupted memory thatmay cycle outputs in an erratic and possibly unsafe manner.Although this may protect equipment and personnel, it willleave you with a non-functioning control.

To make the control functional as soon as possible, Conair hasadded a flash memory module to the control. This modulecontains the original program as loaded at the factory. When amemory fault occurs, this program is loaded from the flashmemory module into the SLC controller’s memory. Thisenables you to get back up and running without requiringConair service personnel to reload the program. However, theflash memory only loads the factory default configuration. Allitems that are field tuned such as feature selection, load times,dump times, pump assignments, etc., must be re-entered forall of the loaders. If a memory error does occur, a warningdisplays:

If this screen displays, a qualified technician should check theloading control system to be certain there are no electricalproblems. Press Acknowledge Memory Error to return to theconfiguration/operation screens. The factory default programhas been loaded so all configuration parameters need to be re-entered before the loaders are enabled.

MEMORYERRORS


The real time clock in the programmable controller is alsostopped if a memory loss occurs. The clock needs to berestarted by entering the correct time and date. See SETTINGDATE AND TIME in the Installation section for this procedure.

It is also possible to store a copy of the program with all para-meters (load times, dump times, etc.) on an optional externaldevice to enable recovery from a memory error withoutreloading all parameters manually. Please contact ConairService if this option is desired.

MEMORYERRORS


CONVEYINGSYSTEMALARMS


Alarm

No Material alarm

Possible causeThere is no material atthe source.

The loader settings areincorrect.

There is a leak in the vacuum system.

Solution

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

r 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. r Verify that the Load Time,

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

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

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

r 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:l The Alarm Check signaled an alarm after the operator-set

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

l 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:l The Alarm Check signaled an alarm after the operator-set

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

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

Alarm

No Material alarm(continued)

Pump Overload

Possible causeIs the vacuum pumpworking correctly?

The fill/demand sensor ordemand switch are notworking properly.

Compressed air lines con-nected incorrectly.

The vacuum pump overload has tripped.

SolutionVerify that the vacuum pumpis on, connected to the DLC48and working correctly. Referto the pump manual.

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

r Verify that fill and demandsensors are set at the cor-rect height and adjustedproperly. Refer to manualssupplied with the fill ordemand signaling device.

If a compressed air line is notconnected to vacuum or mate-rial valves, the valves cannotopen to allow the pump todraw material into the receiv-er. 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.

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

r Verify power line voltageand connections on thepower terminals.

r Verify proper 120/240Vpower supply jumper selection.

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

r 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.r Disconnect power to the

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

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

r Recheck other probablecauses.

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

r 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 DLC48 base unit whilepower is on.

Power LEDwill be off.

PROCESSORAND POWERPROBLEMS


Fault

Processor Not inRun Mode

Possible causeImproper mode selectedor user program logicerror.

Line power out of operating range.

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

Defective processor,power supply or rack.

Solution

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

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

for suspend instructions ifcontrol is in suspend mode.

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

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

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

r Reinstall the power supplyand processor, then applypower.

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

r Try Run mode selections ofprocessor in existing rack.

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

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


CPU FAULTS


Error Code

0001 - NVRAMerror

0002 - Unexpectedhardware watchdogtime-out

0003 - Memorymodule memoryerror

0004 - Memoryerror occurred dur-ing the Run mode

Possible causel Noisel Lightningl Improper groundingl No surge suppression

on inductive loadsl Poor power sourcel Loss of battery or

capacitor backup

l Noisel Lightningl Improper groundingl No surge suppression

on inductive loadsl 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 amemory error

0013 - Internal fileerror

0014 -Configuration fileerror

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:l Noisel Lightningl Improper groundingl No surge suppression


Solution

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

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

The problem is detected as theDLC 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 theDLC 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 minorerror bit is set atthe end of the scan.

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

Possible causel A math or FRD

instruction overflowhas occurred.

l Sequencer or shift reg-ister instruction errorwas detected.

l A major error wasdetected whileexecuting a user faultroutine.

l 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.


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 hasbeen detected asmissing.

xx53 - The DLCdetected an I/Omodule in a slotthat the user pro-gram defines asunused.

Possible causel Noisel Lightningl Improper groundingl 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.

l The I/O module hasreset itself.

l 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.

If you suspect the module hasreset itself, clear the majorfault and run. Otherwise: r Disable the slot, remove

the module, clear the fault,and run.

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


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 theuser program isdetected as thewrong type.

xx55 - The DLCdetected 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.

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

l 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

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

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

r 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.

r 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.

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 - ProcessorI/O driver 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.

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

l 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.

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

r 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 mod-ule interrupt sub-routine (ISR) file.

xx93 - UnsupportedI/O module specificmajor error.

xx94 - The DLCdetected that amodule was insert-ed under power inthe run or testmode.

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.

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

l 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:.

r Remove the module, clearthe fault, and run.

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



If one or more loaders fail to operate, start troubleshooting atthe loader and work your way backward to the controls untilthe problem is found.

The first place to check is at the ArmorBlock itself. Are theAuxiliary Power and Net/Mod Status lights solid green?Check to see if the orange LED’s that display the input andoutput states are turning on at the correct times. If so, theproblem is probably a mechanical or electrical problem at theloader itself.

If the orange LED’s are not coming on, check back at theoperator interface to be sure the loader is configured andenabled correctly. If so, check the DeviceNet scanner cardlocated inside the base unit to see if any error codes are dis-played (see chart following for explanations of error codes).

LOADER(S) FAILTO OPERATE


OutputInput

AuxiliaryPower LED

Net / Mod Status LED

The ArmorBlock Interface Module is supplied with two LEDdiagnostic indicators and a numeric address/error display. Thissection identifies the the information and messages suppliedby the LEDs and display.

Module Status Indicator

The bi-color (green/red) module indicator confirms that poweris presently at the module and if the module is functioningcorrectly.

NETWORKERRORS


LED Status

Off

Green

Flashing green

Flashing red

Red

Solution

Check the power connectionsand apply power to the mod-ule.

No action required.

Configure the module.

Correctly reconfigure the mod-ule.

Replace the module.

NOTE: Information for this Network Errors section wasderived from the Trouibleshooting chapter in Allen Bradleypublication # 1747-6.5.5 - August 2000.

Possible causeNo power at the module.

The module is operatingproperly.

The module is not config-ured.

The module is not config-ured correctly.

The module has an unre-coverable fault.

NETWORKERRORS


Network Status Indicator

The bi-color (green/red) network indicator supplies trou-bleshooting information about the DeviceNet channel commu-nication link.

LED Status

Off

Green

Flashing green

Cause/IndicationThe device has no poweror the channel is disabledfor communication due tobus off condition, loss ofnetwork power, or hasbeen intentionally disabled.

Indicates normal opera-tion. All slave devices inthe scan list table are com-municating normally withthe module.

The two-digit numeric dis-play for the channel indi-cates an error code thatprovides more informationabout the condition of thechannel. The channel isenabled but no communi-cation is occurring.

Solution

Power up the module, providenetwork power to the channel,and insure the channel isenabled in both the moduleconfiguration table and themodule command word.

No action required.

Configure the scan list tablefor the channel to add devices.

Network Status Indicator (Continued)

Numeric Display Code Summary

The ArmorBlock Interface Module uses numeric codes to dis-play diagnostic information. The display flashes at one secondintervals.

The following table summarizes the meanings of the numericcodes.

NETWORKERRORS


LED Status

Flashing red

Red

Cause/IndicationThe two-digit numeric dis-play for the channel indi-cates an error code thatprovides more informationabout the condition of thechannel. At least one of theslave devices in the mod-ule’s scan list table hasfailed to communicate withthe module.

The communication chan-nel has failed. The two-digit numeric display forthe channel displays anerror code that providesmore information aboutthe condition of the chan-nel. The module may bedefective.

SolutionExamine the failed device(s)and the scan list table for accu-racy.

Reset the module. If failurescontinue, replace the module.

Numeric code

0 - 63

DescriptionNormal operation. Thenumeric display indicatesthe interface’s nodeaddress on the DeviceNetnetwork.

SolutionNone.

Numeric Display Code Summary (Continued) NETWORKERRORS


Numeric code

70

71

72

73

74

75

76

77

78

DescriptionModule failed “DuplicateNode Address” check.

Illegal data in scan listtable (node number alter-nately flashes).

Slave device stopped com-municating (node numberalternately flashes).

Device key parameters donot match scan list tableentry (node number alter-nately flashes).

Data overrun on portdetected.

No scan list is active inthe module.

No direct network trafficfor module detected.

Data size returned doesnot match scan lists entry(node number alternatelyflashes).

Slave device in scan listtable does not exist (nodenumber alternately flash-es).

SolutionChange the module channeladdress to another availableaddress. The node addressselected is already in use onthat channel.

Reconfigure the scan list tableand remove any illegal data.

Inspect the field devices andverify connections.

Enter a matching scan listdevice ID. Make sure that thedevice at the flashing nodeaddress matches the desiredkey parameters (vendor, prod-uct code, product type).

Modify your configuration andcheck for invalid data.

Enter a scan list.

None. The module hears othernetwork communication.

Reconfigure your module andchange the addressing.

Add the device to the network,or delete the scan list entry forthat device.

Numeric Display Code Summary (Continued)NETWORKERRORS


Numeric code

79

80

81

82

83

84

85

86

DescriptionModule has failed totransmit a message.

Module is in IDLE mode.

Module is in FAULTmode.

Error detected insequence of fragmentedI/O messages from device(node number alternatelyflashes).

Slave device is returningerror responses whenmodule attempts to com-municate with it (nodenumber alternately flash-es).

Module is initializing theDeviceNet channel.

Run time data sizereturned from slavedevice is not the sizeexpected.

Device is producing idlestate data while the scan-ner is in Run Mode.

SolutionMake sure that your module isconnected to a valid network.Check for disconnected cables.Verify baud rate.

None.

None.

Check scan list table entry forslave device to make sure thatinput and output data lengthsare correct. Check slave deviceconfiguration.

Check accuracy of scan listtable entry. Check slave deviceconfiguration.

None. This code clears itselfonce module attempts to ini-tialize all slave devices on thechannel.

Check slave device installationand configuration.

Check deviceconfiguration/slave node sta-tus.

Numeric Display Code Summary (Continued) NETWORKERRORS


Numeric code

87

88

89

90

91

92

DescriptionAvailable for allocation.Scanner has not yet beendetected by allocated mas-ter, or slave mode isenabled but scanner is notallocated to a master.

This is not an error. Atpower-up and reset, themodule displays all 14segments of the nodeaddress and status displayLEDs.

Auto Device Replacement(ADR) error. Slave deviceresponded with an errorto the initialization datasent to it by the scanner;or the configuration tablein the scanner's flashmemory is not valid for aslave node.

User has disabled commu-nication port

Bus-off condition detectedon comm. port. Module isdetecting communicationerrors.

No network power detect-ed on comm. port.

SolutionMonitor scanner to determineif error code clears when mas-ter detects scanner. If errorremains, check scanner slavemode configuration.

None.

Try the ADR download again.If it still fails, try clearing theADR flash by downloading anempty ADR configuration tothe scanner and then try theADR configuration again.

Reconfigure your module.Check the disable bit in theModule Command Register.

Check DeviceNet connectionsand physical media integrity.Check system for failed slavedevices or other possiblesources of network interfer-ence.

Provide network power. Makesure that module drop cable isproviding network power tomodule comm port.

ARMORBLOCKERRORS

Numeric Display Code Summary (Continued)NETWORKERRORS


Numeric code

95

97

98

99

E9

For detailed information on errors encountered with theArmorBlocks, refer the the Troubleshooting section of theAlan Bradley ArmorBlock User’s Manual supplied with theunits.

DescriptionApplication FLASHupdate in progress.

Module halted by usercommand.

Unrecoverable firmwarefailure.

Unrecoverable hardwarefailure.

Non-volatile configurationcorrupt

SolutionNone. Do not disconnect themodule while applicationFLASH is in progress. Youwill lose any existing data inthe module's memory.

None.

Service or replace your mod-ule.

Service or replace your mod-ule.

Cycle power to module.Download configuration tomodule.

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 canhelp analyze the nature of your problem, assuring that it didnot result 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:

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

r Make sure power is supplied to the equipment.

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

r Check the troubleshooting guide of this manualfor a solution.

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

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

r 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:

l 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.)

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

l 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.

Distributed Loader Control - Conair · 1-2 INTRODUCTION DLC48 Distributed Loader Control...

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