TSM integrated loading User Manual Operation Maintenance
Contents
1. MANUAL SWITCH LOADERS CONNECT TO THE VAC8 CARD S CONN 1 CONN 8 FIG A5 Page27 of 272. The Password are shown on page 2 of this manual From the System Menu you can e Set the time and date e Set and change the passwords e Update the software e Enable the diagnostic logs TELNET Page 17 of 27 Diagnostics Touch WA to open the Diagnostics menu This menu allows you to Update software Backup configuration Reload configuration ta Updating the firmware and backing up the configuration The SD card is in position o a The SD card is missing EK a gL gt EB config txt 33 4da El Configuration options i g p 23 S HE config bak 3 E 1 ys f Semi soe bb j La gt nue PaK 2 Save a backup of the configuration to the SD card A lso tt l l 3 Load the configuration from the SD card sy Sent tS bak 2 5 Load the backup from the SD card Save the configuration to the SD card Updating software See software update section 6 gw an suupoate sic l E o 6 Load the new software version from the SD card WARNING Before removing the SD card you must open the screen and touch the E En Saving to the SD card is suspended so it is safe to remove the SD card Do not remove the SD card the system may be saving information to the SD card System settings 1 12 05 2 LO T10 23709 Use this option to set the correct time day Y 3 OR 2010 10 23 00 and date gt gt A wW i A d A ES x Touch the appropriate box on the
3. y Line and enter the new value Touch the save icon to update the time A Passwords This screen can be used to change the operator and supervisor passwords e a Operator password This allows the operator access into the recipe section a A a Supervisor password This allows the supervisor into the recipe section and also the system settings d This password should be restricted to authorised personnel as it allows access to the settings Note it is important to make a note of new passwords Page 19 of 27 Vacuum receiver Vacuum line Compressed air Material line 9 Local on off switch Full empty reac sensor When replacing sections ensure the seal is in position There is a location tab on the cone and this fits into the slot on the loader body This is important as it lines up the magnetic read switch Page 20 of 27 To open the top of the loader use these 3 clips Filter VAC8 Module The VAC8 as the name suggests can connect up to 8 loaders to the vacuum control module with an 8 core shielded cable This cable connects to CONN14 on the VAC8 card In order to connect two loader cards in series wire the comms cable from the vacuum controller to CONN14 on the first VAC8 card and then link to the next VAC8 through CONN10 CONN11 i Using more than one VAC8 card Each VAC8 card uses up 8 modbus addresses If the VAC8 board s address sw
4. Loader No 01 gt at the top of the screen Loader ID This can be up to 4 characters and is entered using the Alphanumeric keyboard touch to the right of the loader ID to open the keyboard Vacuum Time This is the filling time for the loader in seconds Priority This is a very useful feature on a larger system where certain loaders need to fill more often than others 1 is the highest priority Post Fill Time If a high level sensor is used in the loader this is the filling time after the sensor is triggered Allowing the loader to fill completely Pump used If there is more than one pump used a loader can be assigned to what ever pump is needed Loader ID Gy posees Vacuum Time s Load Default Values J Default values Priority 1 7 Post Fill Time s Pump Used Copy this loader XX from X to X If you need to configure more than one loader and the others loaders will have a similar configuration you can copy the configuration from one loader to the other loaders to save some time setting them up Page 13 of 27 Configuring the Vacuum pump s PP1 Y Touch the cor and a popup will appear that that allows you to edit the Pump Pump ID configuration Start Time s Y Idle Time s To edit a pump setting you must unlock the Atm Valve Overlap s is i Dust Filter Type BH pump first To do this touch the icon enter Dust Peer BIASES tite Aa VAC8IO Used 1 Backup Pump No 5 8 0 None O t
5. Operation TSM integrated Maintenance loading Troubleshooting User Manual Instant Access Parts and Service 35342 9335560 35342 9334422 www tsmcontrols com info tsm controls com Table of Contents Please read before installing the SysteM ccoocccocnccnnccocnnocnonanonanonnnos 3 DISCLAIME astilla 4 Win oe A lalola 7 NMISUAl ISD CCUONE aii 7 Lader DIMENSION Sii iio 9 INE OF OPS Oia add 10 Accessing the VACUUM lOAdINO cooocccocccoccononoconcconnncanonanccnnnonanonaness 11 Switching on off the VACUUM lOaderS ooccccoccncccccncccccnconannnonannnnnnnnnos 11 Vacuum ICONS explained occcoccoccnoconccocnoncnononcnonnnnnnonanonannonnnonanenanoss 12 Configuring the Vacuum loaders cooocccccccccccccnncccnnncnnnnnonannnnnannnnnannnss 13 Configuring the VACUUM PUMPI S cccccoccnccccnnconcnnconcnnnnncnnonannnonacncnonenoss 14 DIAGNOSUC Sutra 15 Macul Us a 16 SAA o E E eee ne eee reseeeer ee 17 DIAGNO SUCS ic ccictsaate e o PO AEE 18 Updating software See software update Section cooocccocnco 18 OV SLSMT SONGS A N ANAE AAA EOE 19 Vacuum eco sana 20 VAGO MOGUC suraia o o en en 21 Frequently Asked QUESTIONS cccccoccncococcnnoconcnnoconnnnnnnnnnnonnannnnnnanonnnnnns 22 Vacuum Pump SYSTEM OVEIVIEW c ocooccccccccncncncnccnconncononncnnnonnnnnnnncnnnnnnnoss 23 VAGS CONNECHON CAG AN Sii cdta 24 VACUUM LOADER TERMINAL BOX WIRING DIAGRAM 27 Page 2 of 27 Pl
6. cations cables to material conveying lines or other conduit containing cables with high voltages or high currents If possible run the communications lines in armoured trunking that is properly earthed grounded at one end only All conveying lines MUST be made of flexible tubing and fitted with a ground wire Keep all communication lines well removed from vacuum loader and or material conveying pipes Cable shields must be properly connected at one end of the cable only Frequently Asked Questions Vacuum Pump system overview a r Solenoid valve Connected to the a L for dust filter pump via the Atmosphere Vacuum hose from loader manifold Dust collection container This will need to be emptied as required There is a viewing window to allow the operator to see when it is full Compressed air for AV Compressed air for filter clean FIG A1 Page 23 of 27 VAC8 connection diagrams Including extrusion control NBB CONSOLE i _ mn s n p O n eE A D E oy gt p z ERREKERI 12 gll3F 7 2 112 6 gl a o o 5 N E 7 I NE T ELCEMAN _ _ I I I niji EE E i 43 i E EL a n A EL E VO U N U N I HENSEN PAL aes EN TREE EEL E como BD Bra EPESEEET GERERE E e RA TT CONNS CONN CONN a ae eu a FILL 1 2 5 f s le 7 a connt4 dd 5 3 a Dd SOLENOID aie Ai VAC 8 ADDRESS SWITCH 3 a ASE 1 DER ADDRES BLK
7. der frame to each loader ONLY SHIELDED CABLES SHOULD BE USED Cable shields must be properly connected at ONE end of the cable only Failure to adhere to the above guidelines may void warranty Page 3 of 27 It is a good idea to record the model and serial number s of your equipment and the date you received it in the User Guide Our service department uses this information 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 SEd Panel DISCLAIMER TSM Control Systems Ltd shall not be liable for errors contained in this User Guide or for incidental consequential damages in connection with the furnishing performance or use of this information TSM 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 Copyright 2002 All rights reserved TSM Control Systems Page 4 of 27 Please record your equipment s model and serial number s software versions and the date you received it in the spaces provided Page 5 of 27 Page 6 of 27 Unpacking On opening cartons should be thoroughly searched to ensure that all components have been removed Before proceeding the packing note and this manual should be studied By referring to the Installation sectio
8. e 2 LOADER ADDRESS 916 Elle A WHT FLAP kell as ne aOR mu x VHT BRN APS ero N LINKS 1 8 FITTED 1 TO 2 AND 3 TO 4 ee ARE SHIELD LINKS 29 FITTED 1 TO 2 LINKS 30 FITTED 1 TO 2 ie i A i CONN 12 ajm CONN1 CONN2 CONN3 TY K E Edad pa 3 4 5 6 CREER LEEEEEFE LEREEEPE nn run a i oe N To o N TN E ef 2 g EE EY alel H a zE E l amp 0 mio 0 on lt 0 mio El 5 gt y XI Xi YA rara 5 Di Qs y PUMP mE 8 i 5 5 z 3 VACUUM RECEIVERS 6 STARTER BOX Ta o 2 BE La i LE an O SILES 2 Page 24 of 27 PUMP STARTER BOX 1 2 BLK BLK GRN YLW ISOLATOR 13 Ia 24V Local PSU 0 O El El oo Al 24V LOCAL VIOLET PSU 500VAC L1 L2 L3 E 380 460 AC 3 PHASE 50Hz MOTOR CONTACTOR 24VDC COIL CURRENT TRIP DIN RAIL PUMP STARTER BOX 32 VACUUM PUMP All wires 0 2amm2 unless otherwise stated Page 25 of 27 OV PUMP STARTER BOX 2 2 So o 24V LOCAL re Lu oO Al C al O z gt DIN RAIL PUMP STARTER BOX VAC8 GND S S X S 10 11 14 16 Field WIrinc Solenoid For Solenoid For Atmosphere Filter Clean Valve Valve All wires 0 595mm2 unless otherwise stated Beacon wired in box Page 26 of 27 VACUUM LOADER TERMINAL BOX WIRING DIAGRAM 24V SOLENOID VALVE PLUG TERMINAL BOX MOUNTED QN VACUUM LOADER REEL SWITCH CC EG VAC8 PIN 1 vACB PIN 2 VACB PIN 6 VACB PIN 7
9. ease read before installing the system Moving plastic granules can produce extreme static charges All flexible tubing conveying lines MUST contain a ground wire When connecting the flexible hose you can strip back a length of ground wire and bend it inside the hose When this is pushed onto a metal tube the earth connection is made lf this type of piping is not used then extra care must be taken to ensure the vacuum loaders are properly earthed If pipes carrying the granules are not properly earthed then the electrical energy will be discharged down through the system electronics causing possible malfunction and damage Generally static symptoms include the resetting of the Remote Display or granules sticking to the sides of the hopper or the mixing chamber Therefore do not attach communications cables to material conveying lines or other conduit containing cables with high voltages or high currents We recommend using shielded cable with twisted pairs inside E G cat 5 cable multi strand If possible run the communications lines in armoured trunking that is properly earthed grounded at one end only Keep all communication lines well removed from vacuum loader and or material conveying pipes All flexible conveying lines MUST contain a ground wire that is earthed at least on one end Earth continuity should be checked between the vacuum loaders and the blender body If necessary run an earth strap from a point on the blen
10. ere are 3 VAC8 enabled on the system gt O To add another VAC8 to the system touch the Set Loader Defaults Enable All Loaders Disable All Loaders icon and enter the password 9335 to a 8 EE E unlock the system Touch enable for the 4 vac pd 8 as shown Confirm the action The loader ool 0 i Ez a ose number f will change from 0 to 8 0 a is lf you want to setup the default ID s touch the Ei LY Discharge Time s Vacuum Loading 1Ds ui icon and the loaders will be given the default ID s for VAC8 5 L33 L40 will be assigned or you can setup the loaders individually as described in page 11 JIGIIIDI lf you want to setup the loader defaults then touching Defaults_ will setup the loader defaults for all loaders assigned to that VAC8 Pump ID Start Time s Idle Time s Default values Atm Valve Overlap s Dust Filter Type VAC8IO Used 1 1 Dust Filter Blasts 2 1 Backup Pump No s s o uone O Page 16 of 27 System menu e Touch amp The system menu contains all of the options primarily used during initial setup and before normal operation As all system parameters can be changed from this menu a password is required for access from the Main Menu IMPORTANT We recommend that you restrict access to the supervisor password to supervisor management personnel and the Engineering password to technical personnel
11. he password 9335 ma The icon will then change to e allowing the pump s to be edited Pump ID This can be up to 4 characters and is entered using the Alphanumeric keyboard touch to the right of the loader ID to open the keyboard Pump Start Time When a loader calls for a fill the system will allow the pump this number of seconds to start up before commencing a loader fill Pump Idle Time This is the length of time in seconds that the pump will continue running after all of the loaders are full This is normally set to 30 seconds to avoid unnecessary stopping starting of the pump A Valve Overlap Time atmosphere relief valve If this time is set then when a loader is finished filling the AV will open for this number of seconds to lower the vacuum in order for another loader to open its fill valve Dust Filter Type None no dust filter is installed TSM A TSM dust filter is installed BH dust filter output remains on continuously The Dust Filter blasts then becomes the no of seconds which the filter output is activated for Dust Filter Blasts This is the number of filter cleans the dust filter will perform VAC8IO used This option assigns the pump control to a particular VAC8 card Backup Pump If a pump develops a problem then a backup pump can be automatically switched in as a replacement as long as it has been configured to do so Pump ID Start Time s oa Idle Time s ett nee Presta Default values Atm Val
12. itch rotary hexadecimal switch is set to 1 then this particular card corresponds to loader addresses 1 8 If the board address 2 then it corresponds to loader addresses 9 16 E T C ii Connection of flap loaders to VAC8 card Fig A2 shows the connections to the VAC8 loader card Each flap loader has 4 wires connecting it to the VAC8 card 2 for the flap switch full empty signal and 2 for the pneumatic valve in the lid See the end of this manual for the schematics on how to wire up the loaders to the VAC8 iii Connection of VAC8 card to pump starter box Each Vac8 card has the possibility of controlling 1 pump Page 21 of 27 Some of the most common alarms encountered Wiring Considerations Why is the screen showing full when the receiver is empty Why am receiving Communications errors It is easier to run high voltage power lines and low voltage communications lines in the same conduit will this cause any problems Why is it necessary to keep communications cables and material conveying lines separate Page 22 of 27 e ls the local on off switch on the loader connection box in the 1 position e ls the magnet located on the back of the flap lining up with the sensor on the outside of the loader e Can the flap on the bottom of the loader move freely If communications to devices are showing a lot of timeouts TSM diagnostic displays e Has the communication cable been shielded
13. ll display vacuum loaders on the blender icon To access the loader screen simply touch the loader icon A Switching on off the vacuum loaders The loaders are arranged in banks of 16 loaders To access a loader touch the bank that it belongs to and that bank will open Once a loader bank Is selected Loaders can be Enabled Disabled by touching the top of each individual loader E Any loader alarms can be cleared by touching this icon This icon allows you to return to the home screen Page 11 of 27 Vacuum icons explained Loader conditions Pump station Loader off 562 Grey Loaderon Empty Green Loader on full Green green Fill time Full Empty gt Be Oh k TE i F a bs AS F ide Be hy E Ma Pump on AV open Filter cleaning Loader alarm Page 12 of 27 Configuring the Vacuum loaders don Touching the centre of the loader opens the loader setup screen gt 241 onde a y Loader No 01 E Touch the loader icon and a popup will appear Prority 1 7 To edit a loader setting you must unlock Post Fill Time s the loader first To do this touch the Pump Used A A Load Default Values y 5 icon enter h wor Copy this Loader 01 from Oto 0 2 con enter the password e OE AOE The icon will then change to ET allowing the loaders to be edited You can scroll through the loaders by using the side arrows 4
14. make sure it is shielded on one end only e Check that the communication cables are not routed along side high voltage cables Also check that cables shields are terminated properly See below for further information e Check that the communication cables are not touching the material conveying lines If these lines are not earthed properly the electronics could be damaged by static e The communications driver chips on the Vac8 card may have been damaged and need to be replaced The chips are U5 and U6 They are MAX3442E chips The wires connecting the various elements of a TSM system are normally communications data lines and are low voltage As such care should be taken to keep them well removed from high voltage lines DO NOT RUN HIGH AND LOW VOLTAGE LINES TOGETHER WITHIN THE SAME CONDUIT Shielded cable must be used for communications lines We suggest Cat 5E cable Although it is not strictly necessary to run communications wires from TSM equipment in conduit it is advisable from a safety and aesthetic point of view Moving plastic granules can produce extreme static charges If pipes carrying the granules are not properly earthed then the electrical energy will be discharged down through the system electronics causing possible malfunction and damage Generally static symptoms include the resetting of the Remote Display or granules sticking to the sides of the hopper or the mixing chamber Therefore do not attach communi
15. n the following items should be found and identified a A Ri N A SS OS Ia PY A Om Cm Cm Om A A on TS a LA LJ VAC8 Module MN Vacuum Recelvers LJ Vacuum pump LL Flexible Hose y Vacuum manifolds E Suction Lance The packing note will indicate the presence of any additional special order items Visual Inspection Visually inspect all components to ensure that no damage occurred during transit The visual check should include any connectors for evidence of broken or bent pins Any missing items or damaged parts should be immediately notified to TSM Control Systems Page 7 of 27 Installation 4 Commissioning e Cable from Blender control module console to VAC8 Module These cables provide power 24V and serial communications to each vacuum loader control card Please Note In order to ensure system accuracy the system cables should not run parallel to heavy power line cables or cables supplying inductive loads The cables should not run through areas where high electrostatic fields exist If either of the above conditions exist then it may be necessary to run the cables through electrically screened trunking cables should not run parallel to material conveying lines Power should not be applied to any part of the system until authorised personnel have checked it i e the TSM commissioning engineer or a project electrician who is competent to assemble the system A Fle
16. ve Overlap s Load Default Values J Dust Filter Type Dust Filter Blasts VAC8IO Used Backup Pump NO s s o none Page 14 of 27 Diagnostics 4 i244 _ Gil oe SIGIDIIGIIIIIIGS From the home screen you can access the y IIGIIII Diagnostics Vacuum Setting and the Setup menu Diagnostics To access the diagnostics touch amp f icon When the communications are working the TX and the RX counters should be the same value If you have more that 10 Err or timeouts then there is a problem with the communications see F A Q section for trouble shooting help lf a VAC8 card stops communicating the controller will stop polling it continuously and will retry once every minute Therefore if communications to a VAC8 board fail that board wont slow the comms to the other boards lf the communications have been running for a long period of time there may be some Err s or lt 9 O Y 00 0 x lt ooooo os i OOOOOSOS s ocooocooooo 0 Y dd UAuyNnN Aa GD SO0050O0 5S oo timeouts occurring over time so you should reset the counters using the ES icon and then allow the counters to run to approximately 100 counts VAC8 y si The 4 shows which VAC8 card is controlling the pump This cannot be 1 81H changed here you must assign the VAC8 lO on the pump configuration page Page 15 of 27 Vacuum Setup Touch This screen shows that th
17. xible antistatic hose Flexible antistatic hose with an earth wire should only be used for connecting the vacuum loaders to the manifold All other piping should be stainless steel or another suitable alternative When connecting the flexible hose to either the loader or the manifold strip back 3 4 cm of the wire and bend it inside the hose When the hose is pushed onto the loader manifold the wire will make contact with the metal surface and therefore earth the hose through the loader manifold Page 8 of 27 Loader Dimensions TFR IS FACOG ide e e ae 026 oasio osns 1235 enne ero at e E O Eo 2 2 5 3 2 2 5 3 2 2 5 3 2 2 5 3 4 Page 9 of 27 Principle of Operation The Blender serves as a vacuum loading control system lt operates as a master controller communicating serially with a number of vacuum receiver control cards as required Each vacuum receiver control card has a unique address that the Blender identifies when communicating with that vacuum loader The vacuum loading screen gives the operator access to all of the information required to setup monitor and operate all the loaders connected to the blender A password protected menu system allows supervisor access to configuration and diagnostics information Page 10 of 27 Accessing the vacuum loading gt 00 00 00 lf a blender is configured with integrated loading the home screen wi
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