Conair Basic 32 Loader Control B32 User manual

Basic 32
Loader Control
Instant Access
Parts and Service
[phone]
[phone]
www.conairnet.com
The Conair Group, Inc.
One Conair Drive
Pittsburgh, PA 15202
Phone: [phone]
Fax: [phone]
B32 Model
UGC007/0702
Installation
Operation
Maintenance
Troubleshooting

It’s a good idea to record the model, serial and software
version numbers of your equipment and the date you received
it in the User Guide. Our service department uses this infor-
mation, along with the manual number, to provide help for the
specific equipment you installed.
Please keep this User Guide and all manuals, engineering
prints and parts lists together for documentation of your
equipment.
Date:
Manual Number: UGC007/0702
Model number:
Serial number(s):
Software version number(s):
DISCLAIMER: The Conair Group shall not be liable for errors con-
tained in this User Guide or for incidental, consequential damages
in connection with the furnishing, performance or use of this infor-
mation. Conair makes no warranty of any kind with regard to this
information, including, but not limited to the implied warranties of
merchantability and fitness for a particular purpose.
Please record your
equipment’s model and
serial number(s) and
the date you received it
in the spaces provided.
Copyright 2002 All rights reserved
THE CONAIR GROUP

UGC007/0702 Basic 32 Loader Control
TABLE OF
CONTENTS
INTRODUCTION .........................................1-1
Purpose of the User Guide.....................................................1-2
How the Guide is Organized .................................................1-2
Your Responsibility as a User .............................................. 1-2
ATTENTION: Read this so no one gets hurt........................1-3
DESCRIPTION . . . . . . . . . . . . . . . . . . . .2-1
What is the B32? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Typical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
How it Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
INSTALLATION . . . . . . . . . . . . . . . . . . . .3-1
Unpacking the Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Installing the B32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Wiring Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Mounting the Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Connecting to the B32 . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Wiring Loaders to the B32 . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Wiring Pumps to the B32 . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Wiring Purge Valves to the B32 . . . . . . . . . . . . . . . . . . . . .3-7
Connecting Main Power to the B32 . . . . . . . . . . . . . . . . . .3-8
Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Setting Loader Parameters . . . . . . . . . . . . . . . . . . . . . . . .3-10
Enabling Loaders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Enabling Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Selecting a Password . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
OPERATION . . . . . . . . . . . . . . . . . . . . . .4-1
B32 Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Viewing Loader Status . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Enabling and Disabling Loaders . . . . . . . . . . . . . . . . . . . .4-4
Enabling and Disabling Pumps . . . . . . . . . . . . . . . . . . . . .4-5
Configuring Loaders . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Assigning Pumps and Loaders . . . . . . . . . . . . . . . . . . . . . .4-7
Assigning a Backup Pump . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Configuring the Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Backing up the PLC Program . . . . . . . . . . . . . . . . . . . . . .4-10
MAINTENANCE . . . . . . . . . . . . . . . . . . . .5-1
Preventive maintenance checklist . . . . . . . . . . . . . . . . . . . .5-2
i

Basic 32 Loader Control UGC007/0702
TABLE OF
CONTENTS
TROUBLESHOOTING . . . . . . . . . . . . . . . .6-1
Before Beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
A Few Words of Caution . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Identifying the Cause of a Problem . . . . . . . . . . . . . . . . . .6-3
Clearing Interface Alarms . . . . . . . . . . . . . . . . . . . . . . . . .6-4
Clearing CPU and I/O alarms . . . . . . . . . . . . . . . . . . . . . .6-5
Conveying System Alarms . . . . . . . . . . . . . . . . . . . . . . . . .6-6
Operator Interface Problems . . . . . . . . . . . . . . . . . . . . . . .6-8
Processor and power problems . . . . . . . . . . . . . . . . . . . . . .6-8
CPU faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
I/O errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
APPENDIX
Customer service information . . . . . . . . . . . . . . . . . . . . . .A-1
Warranty information . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Restoring the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
PARTS/DIAGRAMS
Wiring Diagrams
Recommended Spare Parts
ii

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

Basic 32 Loader Control UGC007/0702
1-2 INTRODUCTION
This User Guide describes the Conair Basic 32 Loader
Control and explains step-by-step how to install, operate,
maintain and repair this equipment.
Before installing this product, please take a few moments to
read the User Guide and review the diagrams and safety infor-
mation in the instruction packet. You also should review man-
uals covering associated equipment in your system. This
review 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 and
call your attention to important information regarding safe
installation and operation.
Symbols within triangles warn of conditions that could
be hazardous to users or could damage equipment.
Read and take precautions before proceeding.
Numbers within shaded squares indicate tasks or steps
to be performed by the user.
A diamond indicates the equipment’s response to an
action 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 concerning
installation, operation and maintenance of this equipment.
Responsible safety procedures include:
lThorough review of this User Guide, paying particular
attention to hazard warnings, appendices and related dia-
grams.
lThorough review of the equipment itself, with careful
attention to voltage sources, intended use and warning
labels.
lThorough review of instruction manuals for associated
equipment.
lStep-by-step adherence to instructions outlined in this
User Guide.
PURPOSE OF
THE USER
GUIDE
HOW THE
GUIDE IS
ORGANIZED
1
u
r
l
YOUR
RESPONSIBILITY
ASAUSER

UGC007/0702 Basic 32 Loader Control INTRODUCTION 1-3
We design equipment with the user’s safety in mind. You can
avoid the potential hazards identified on this machine by fol-
lowing the procedures outlined below and elsewhere in the
User Guide.
ATTENTION:
READ THIS SO NO
ONE GETS HURT
WARNING: Improper installation, oper-
ation or servicing may result in equip-
ment damage or personal injury.
This equipment should be installed, adjusted,
and serviced by qualified technical personnel
who are familiar with the construction, operation
and potential hazards of this type of equipment.
All wiring, disconnects and fuses should be
installed by qualified electrical technicians in
accordance with electrical codes in your region.
Always maintain a safe ground. Do not operate
the equipment at power levels other than what
is specified on the the equipment serial tag and
data plate.
WARNING: Electrical shock hazard
This equipment is powered by electrical voltage
as specified on the machine serial tag and data
plate.
A properly sized conductive ground wire from
the incoming power supply must be connected
to the chassis ground terminal inside the
Input/Output enclosure. Improper grounding can
result in personal injury and erratic machine
operation.
Always disconnect and lock out the incoming
main power source before opening the electrical
enclosure or performing non-standard operating
procedures such as troubleshooting or routine
maintenance. Only qualified personnel should
perform troubleshooting procedures requiring
access to the electrical enclosure while power
is on.

2-1
UGC007/0702 Basic 32 Loader Control
lWhat is the B32? . . . . . . . . . . . .2-2
lTypical Applications . . . . . . . . . .2-2
lHow it Works . . . . . . . . . . . . . . .2-3
lSpecifications . . . . . . . . . . . . . .2-4
DESCRIPTION

The control is mounted on the front of the I/O station. Inside
is a processor with base, containing up to 8 input/output mod-
ules. The number of input and output modules will vary with
the number of vacuum receivers and conveying options.
WHAT IS THE
B32?
Basic 32 Loader Control UGC007/0702
2-2 DESCRIPTION
TYPICAL
APPLICATIONS
Backup
Pump
Pump
System 1
Pump
System 2
Pump
System 4
Pump
System 3
Pump
System 5
Pump
System 6
Pump
System 8
Pump
System 7
B32
The Basic 32 has been designed for basic conveying applica-
tions.
Loader-pump assignments are completely flexible. Individual
vacuum receivers can be assigned to any one of the eight
loading systems. Each receiver can be configured for one of
the following:
lSingle-material loading.
lRatio loading, with or without automatic material layering.
lPositive (air-operated) receiver discharge.
lMaterial line purging.
lLoader fill alarm to work with an optional fill sensor
mounted in the receiver body or direct feed chamber.
lHopper fill alarm to work with an optional demand sensor
mounted in a drying hopper or other material vessel.
lNo alarm.
The controller and control automatically turn on when power
is applied to the I/O station. After a bootup sequence the home
screen displays. From the home screen the operator can scroll
to all monitoring and control functions.

UGC007/0702 Basic 32 Loader Control DESCRIPTION 2-3
HOW IT WORKS
The B32 communicates with each pump, vacuum receiver and
material valve wired to Input/Output modules within the con-
trol enclosure. The B32 controls conveying operation based on
settings the operator enters on the HMI.
When receivers in a pump system demand material, the B32
turns on the vacuum pump and dust collector in the appropri-
ate pump system. It then opens the correct vacuum and mater-
ial valves to convey material to satisfy the demand.
The overview screen lets the operator monitor the status of all
vacuum receivers at a glance. Icons indicate the real-time sta-
tus of each receiver.
Other screens allow you to change system settings or to view
pump systems, loader details, alarm histories.

SPECIFICATIONS
Basic 32 Loader Control UGC007/0702
2-4 DESCRIPTION
MODEL B32
Performance characteristics
Maximum number of vacuum receivers 32
Maximum number of vacuum pumps 8 (plus back-up)
Programmable logic controller Allen Bradley Micrologix 1500
Touchscreen operator interface Allen Bradley PV300 Micro
Communications with master control DH485
Screen size, inches {mm} 2.87 X 1.67 {73 X 42}
User interface method Keypad
Output voltage to receivers/valves 24 VDC
Sensor voltage to receivers 24 VDC
Output voltage to pumps 24 VDC
Dimensions inches {mm}
Master control cabinet
A - Height 31.4 {998}
B - Width 23.8 {606}
C - Depth 12.5 {318}
Weight lb {kg}
Installed 70 {32}
Shipping 85 {39}
Voltages Total amps
115V/1 phase/60Hz (master control) 10
CALCULATING CABLE LENGTH:
Total the distances from the Input/output Station(s) location to each vacu-
um receiver on the system. Be sure to account for reasonable slack at
each loading station for connections, cable routing, etc.
APPLICATION NOTES:
Conair vacuum receivers come equipped with a quick-disconnect connec-
tor set that includes 10 feet of cable. Junction boxes must be provided to
connect the system cable and each vacuum receiver’s connector set.
SPECIFICATION NOTES:
B32 loader control cable: 18 gauge shielded, 8-conductor may be used
for standard vacuum receivers with up to one optional output and input,
otherwise 10-conductor cable is required.
Specifications can change without notice. Check with your Conair
representative for the most current information.
A
B
C
5.5 inch screen
(optional)
3 inch screen
standard

3-1
UGC007/0702 Basic 32 Loader Control
lUnpacking the Boxes . . . . . . . . . . .3-2
lPreparing for Installation . . . . . . . .3-3
lInstalling the B32 . . . . . . . . . . . . . .3-4
lWiring Considerations . . . . . . . . . .3-4
lMounting the Control . . . . . . . . . .3-5
lConnecting to the B32 . . . . . . . . . .3-6
lWiring Loaders to the B32 . . . . . . .3-7
lWiring Pumps to the B32 . . . . . . . .3-7
lWiring Purge Valves to the B32 . . .3-7
lConnecting Main Power . . . . . . . . .3-8
lInitial setup . . . . . . . . . . . . . . . . . . .3-9
lSetting Loader Parameters . . . . .3-10
lEnabling Loaders . . . . . . . . . . . . .3-11
lEnabling Pumps . . . . . . . . . . . . . .3-11
lSelecting a Password . . . . . . . . . .3-12
INSTALLATION

Carefully remove the B32 components from
their shipping containers, and set upright.
Remove all packing material, protective paper,
tape and plastic.
Carefully inspect all components to make sure
no damage occurred during shipping. Notify the shipper
immediately if damage is found.
Take a moment to record serial numbers,
the software version number and electrical power specifi-
cations in the blanks provided on the back of the the User
Guide’s title page. The information will be helpful if you
ever need service or parts.
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.
The B32 central loading control comes in one box. The box
should include:
UNPACKING
THE BOXES
Basic 32 Loader Control UGC007/0702
3-2 INSTALLATION
1
2
3
4
5

PREPARING FOR
INSTALLATION
UGC007/0702 Basic 32 Loader Control INSTALLATION 3-3
You should plan the location of the B32 control to ensure easy
access and minimal wiring.
Select a mounting location for the control.
The interface and Input/Output enclosure can be mounted
on a wall or other stable vertical surface.
Select a location that:
rIs central to loaders that the B32 will control. Keep
the B32 Input/Output station as close as possible to the
loading stations to minimize the amount of wire needed to
connect the vacuum receivers to the control.
rProvides adequate clearance for safe operation and
maintenance. The control should be mounted at a height
that allows the operator to easily see and touch the screen.
Maintain at least 3 feet (1m) clearance in front of the con-
trol for safe access to the Input/Output enclosure.
rProvides a clean, dry, vibration-free environment.
Exposure to wide temperature variations, high ambient
temperature, power line fluctuations, caustic fumes or
excessive amounts of dust, dirt, vibration, shock and
moisture could harm performance and reduce the life of
this equipment.
rProvides a grounded source of 115 VAC power.
The three-prong power cord supplied with the B32 con-
trol requires a grounded 115 VAC outlet rated for at least
15 amp service.
Plan the power/communication cable routes.
rReview all wiring guidelines and diagrams provided
in the manuals and electrical diagrams supplied with the
B32 control and your conveying equipment before begin-
ning installation. See WIRING CONSIDERATIONS.
rKeep communication wires away from sources of
static electricity. Static electricity can damage the con-
trols.Communication cables should not be run near the
material lines and hoses, which produce large amounts of
static electricity when material is conveyed. You should
use shielded cable unless you run wires through metal
conduit.
rAvoid running communication cables across power
feed lines. If you must run the cable across power feed
lines, run the cable at right angles to the lines.
1
2

WIRING
CONSIDERATIONS
Installation of the B32 control consists of:
rMounting the enclosure.
rWiring loaders to the control.
rWiring pumps to the control.
rWiring material valves to the control.
rConnecting the control to a main power source.
rInitial setup of the system control.
INSTALLING
THE B32
Basic 32 Loader Control UGC007/0702
3-4 INSTALLATION
WARNING: Improper installation may
result in equipment damage or personal
injury.
● Disconnect and lock out the main power supply to
equipment in the conveying system before wiring
power and communication cables between the
B32 control, vacuum receivers, pumps, dust col-
lectors and material valves.
● Install all wiring, disconnects and fuses in accor-
dance with electrical codes in your region. All
electrical installations should be done only by
qualified electrical technicians.
● Always refer to the wiring diagrams supplied with
your control before making electrical connections.
The diagrams show the most accurate electrical
component information.
● Protect communication cables from sources of
static electricity and electrical noise.
● Use shielded cable or run wire through a contigu-
ous metal conduit or wireway. Failure to use a
metal shield can expose the controls to static
electricity, which can damage electronic compo-
nents.
● Do not run communication cables near material
lines and hoses, which produce large amounts of
static electricity when conveying material.
● Keep communication cables at least 5 ft. (1.5 m)
from electric motors, transformers, rectifiers, arc
welders, generators, induction furnaces and
sources microwave radiation.
● Avoid running communication cable across power
feed lines. If you must run cable across power
lines, run the cable at right angles to the line.
Keep the cable at least 6 inches (0.15 m) from AC
power lines of less than 20 A; 1 foot (0.30 m) from
lines of 20A to 100 kVA; and 2 feet (0.60 m) from
lines of 100 kVA or more.

UGC007/0702 Basic 32 Loader Control INSTALLATION 3-5
The B32 Input/Output enclosure should be
mounted on a wall, or other secure vertical
surface, at a height providing easy access
and a clear view of the touchscreen panel.
Bolt the control to the
mounting surface. Use the mounting
brackets on the I/O enclosure.
Ground the control enclosure.
Connect a ground wire to the control. Follow procedures
outlined by your regional electrical codes and the wiring
diagrams included with this manual.
MOUNTING
THE CONTROL
1
2
WARNING: Improper installation may
result in equipment damage or personal
injury.
● Always maintain a safe ground. Follow the safe
grounding procedures in the wiring diagram pack-
age. Ground the shielded cable inside the
Input/Output enclosure only.
● Do not operate the equipment at power levels other
than those specified on the the equipment data
plate.

Each vacuum receiver, pump and
material valve in the system must be
wired to power or common/ground
terminals and Input/Output modules
inside the B32 control enclosure.
Each loader requires at least six
wire connections to the
Input/Output enclosure.
One additional wire is required for
each option or for a three-wire sensor used for either demand
or loader full inputs. Connect the loader cable wires to the I/O
station according to the color codes:
CONNECTING TO
THE B32
Basic 32 Loader Control UGC007/0702
3-6 INSTALLATION
WARNING: Improper installation
may result in equipment damage or
personal injury.
Always refer to the wiring diagrams that came
with your controls before making electrical con-
nections. The diagrams show the most accurate
electrical component information.
Use shielded cable unless you run wires in
metal conduit. Failure to use a metal shield will
expose the controls to static electricity, which
can damage electronic components.
When using shielded cable, make sure the
shield is grounded inside the I/O stations only.
It is also important to keep the communication
wires away from conveying lines, which can
produce large amounts of static electricity.
Input/Output modules

The loader wires connect to power terminals or terminals on
the I/O modules inside the control enclosure. The number of
loaders and options in the conveying system will determine
the number of connections that are required.
Refer to the electrical prints included with this manual for all
electrical connections to the loader control. All loader outputs
are 24 VDC and all demand and fill sensor inputs are 24
VDC.
A general list of loader electrical connections is included in
the appendix.
UGC007/0702 Basic 32 Loader Control INSTALLATION 3-7
WIRING LOADERS
TO THE B32
IMPORTANT: Always refer
to the wiring diagrams that
came with your controls
before making electrical
connections. The diagrams
show the most accurate
electrical component infor-
mation.
WIRING PUMPS
TO THE B32
The B32 can run eight vacuum pumps and one backup pump.
Refer to the electrical prints included with this manual for all
electrical connections to the loader control. All pump outputs
are 24 VDC and all overload inputs are 24 VDC.
The B32 can operate up to 32 purge valves, which are used to
remove material from the lines at the end of a loading cycle.
Since purge valves are located at the material source instead
of at the loader, separate wiring connections to the B32 are
required.
WIRING PURGE
VALVES TO THE
B32
(OPTIONAL)

Basic 32 Loader Control UGC007/0702
3-8 INSTALLATION
CONNECTING
MAIN POWER
TO THE B32
The B32 Input/Output enclosure is equipped with a three-
prong plug and power cord. Each optional remote touchscreen
panel also has its own plug and power cord.
Plug the power cord(s) into a grounded 115
VAC outlet rated for at least 15 Amp service.
Make sure the control enclosure is grounded.
WARNING: Electrical shock hazard
Failure to provide proper grounding can cause
control malfunctions and could result in personal
injury from electrical shock.
The control must be connected to a grounded
power source. A properly sized conductive
ground wire must be connected to the chassis
ground terminal inside the Input/Output enclo-
sure.
1
2