Let s take a look at the central vacuum conveying control choices we have today.

Transcription

1 Let s take a look at the central vacuum conveying control choices we have today. First, a little background: Conveying controls for central vacuum systems have several jobs to do: 1. They connect and monitor all of the devices in a conveying system. These devices can be receivers, a vacuum pump (or pumps), material valves, dust collectors, vacuum valves and a collection of level sensors that help the system operate responsively and correctly. 2. They control the vacuum flow to each receiver in a system so that a central pump can be shared by multiple receivers. Most controls can manage multiple systems, meaning that multiple receivers and pumps are operating simultaneously, and independently. 3. In some cases, the control must provide a form of traffic control so that simultaneously operating vacuum systems will be organized in the way they call upon common components, like material source valves and back up pumps without confusion. 4. Recent advancements have used central conveying controls to also operate sophisticated material selection stations, further automating the material supply process. This is quite a task and we ll soon see that, depending upon the parameters of a given system, there are a number of controls that can accomplish these jobs; each with its own wiring method, capabilities and control approach. Let s use this basic diagram as an example of a vacuum system that requires a conveying control. Let s take a look at how each control system offered by Conair would be applied to this system. Like many plants, conveying components are located in various areas throughout the operation, filling blenders, dryers, storage bins and of course, processing machines and these components will be connected by material or vacuum tubing in addition to the wires we ll show in this presentation. Where these components are located could be mezzanines, above a row of drying hoppers or blenders, in a ResinWorks area, and of course, above or directly on processing machines that are organized according to the needs of the processor. First, lets take a look at how a basic, and some might say a traditional loading control would be installed into a system like this. The Conair model B-32 is a Basic, 32 receiver control system and a good example of a traditional approach to conveying control. To many customers, the B-32 s simplicity and low cost represents what their expectation of what a conveying control system should be. They may be unaware of the new features of our other control choices and unaware of the tradeoff they are making in installation complexity and cost. Let s show you what we mean , 8, 9, ,13, 14, 15 16, 17,18, 19, , First, this singular control panel would be mounted in a central location, convenient to operators and authorized personnel. Note that finding the right place for a single control might be a deal breaker for some operations who expect or need multiple control locations. The B-32 provides only one control panel. 1

2 Next, wires must be installed from the B-32 to all of the conveying components in the system. Connecting the control to each component often requires long runs of bundles of cables to reach each of the component groups we talked about. Each of these wires are multi-conductor usually between 8 and 12 wires, or conductors, inside each cable. And each conductor supports an input or output function. Inputs are typically sensors or some type of signal TO the control; like a demand switch, or fill sensor in a receiver, or an overload signal from a pump. Outputs are signals FROM the control that operate the component s functions; like a receiver s vacuum sequencing valve or a ratio valve or the starter or idle mode valve on a pump. Each of these conductors must be hand wired into the B-32 control and then hand wired to the component. Wiring at the component is often done twice: once at a terminal box located near the component, for convenience and future modifications and then again at the component itself. Although component wiring to Conair receivers is often aided by the use of Conair s unique Universal Terminal Boxes, or UTB s. UTB s are located on the flange of each receiver and come equipped with an umbilical cable that provides the connection from the nearby terminal box to a plug on the receiver s UTB. Very convenient! Once installed, the B-32 provides the user with 24 volt DC control of up to 32 receivers and 8, independently operating vacuum pumps, plus a single back-up pump that can be selected to backup any of the 8 system pumps. The single operator interface is a 3.2 inch LCD pushbutton mini-panel, surrounded by a helpful user-instruction label. The B-32 can selectively handle most conveying system options except the more sophisticated Automated Resin Manager or the Material Vision Proofing options. And the B-32 cannot juggle the challenges of valve stacking or valve sharing traffic control that is required when more than one independently operating pump system simultaneously call upon a single purge valve located on a shared material source. For instance, a purge valve on a centralized material supply bin. In these instances, multiple valves would have to be provided for B-32 operation. One for each pump system that might call upon that valve for material. Now let s take a look at another, much more sophisticated approach to this same system this time using an FLX control. The FLX, as the name implies, is a very flexible control platform for plants that may be growing in number of machines or material handling operations, or those who require sophistication in their conveying controls. The FLX starts with a single, central control panel very similar to the B-32. But that is where the similarity ends. The FLX goes on to provide additional control power with the addition of expansion panels. These expansion panels are all interconnected with a single wire carrying the versatile, industry-accepted Ethernet communications. Each panel is powered locally , , 29, 30 31,32, , 37, 38,39, , 43, 44, 45, 46, 47 48,

3 Ethernet communications can be provided by conventional copper wiring, referred to as copper media or via fiber optics, which provide the ability to run longer distances without the need for the signal amplification required for copper media. The main advantage of using Ethernet communications to span the distances within a plant are probably becoming clear to you: instead of running individual cables to all components from one control location, the FLX s use of Ethernet allows these distances to be covered by one cable rather than many. Along the Ethernet cable, near the conveying components, expansion panels can be installed and from there the point-to-point wiring we talked about with the B-32 can take place. Expansion panels can be added as part of the initial installation, or later, as things change or equipment is added. 56, ,61 62 The following panels are available for FLX systems: First: The main control panel equipped with a very easy to use color touch screen interface, employing attractive, universal symbols and enough power to operate 32 receivers, 10 pumps, and 64 source valves. This is a great start to an expandable control system and the only control many facilities will need! But with a single Ethernet cable connection we can add: A remote I/O panel: This panel is nearly identical to the main control and can include a second operator interface, identical to the first or not. This panel provides the same I/O as the main control, doubling the system s capabilities. Next, FLX expansion panels can be added. These panels can include yet another color touch screen operator interface panel the FLX can support up to a total of 6 operator interfaces; where any change to any setting in the system can be made. Additional Ethernet-connected expansion panels include: A Receiver expansion panel: up to 8 receivers can be added to the system with each receiver expansion panel. A Pump Expansion panel: for adding up to 4 pumps. A Source Valve expansion panel: for adding up to 16 purge valves. And lastly, a Combination expansion panel that adds up to 8 receivers and up to 16 source valves to the system. So, an FLX system, with a full complement of expansion panels, can accommodate 24 VDC control of up to 128 receivers, 40 pumps, 256 source valves and 6 touch screen control panels. In addition, the FLX, with its Ethernet communication capability can communicate directly with ARM Automated Resin Manager robotic valve material valve selectors and Resin Selection Stations equipped with MVP Material Vision Proofing systems. In addition, the FLX includes specific icons and control functions for UNloading as well, so it can be readily used to keep granulator bins emptied. Quite a capability! The FLX operates with versatile Wago brand PLC s and includes 8 full color touch screen operator interfaces , 65 66, , 74 75,

4 Now, let s take a step towards simplicity and take a look at a system with significantly reduced needs and a control system suited to those needs. Conair s model ELC-16, Easy Loading Control, provides users with control of up to 16 receivers and 1 pump. In addition, it allows users to operate receivers from compact controls located on each receiver, instead of a centrally-mounted control panel. This is quite a change from the central control panels we have been talking about. But the ELC-16 provides the perfect control system for small operations and for plants that have recently made the switch from self-contained motor loaders and are used to making changes to loaders that are right in front of them. The ELC-16 control does have some similarities with its bigger brothers like the FLX in that it uses network wiring to connect all controls in the system back to the central vacuum pump. Its not Ethernet but CAN Bus, a powerful, practical format for a system like this. Unlike Ethernet, The ELC-16 s CAN bus wiring carries power with it, so there is only one plug-in for the system at the pump. All controls are connected together with one combination CAN bus communication and power cable that starts at the pump. The controls all talk to one another too, so that more sophisticated loading functions, like first in first out demand sequences are coordinated between controls. Wiring an ELC-16 consists of running the single Can bus cable from the pump control to junction boxes located near each receiver. Conair provides special junction boxes for this use and they provide all the necessary termination hardware for a quick and easy installation. Special drop cables are included with each control that connect to this junction box and then drop down to the ELC control. ELC controls connect to the receiver itself based on whether the control is added, or purchased with the receiver. The ELC replaces the UTB. The flange mounted ELC control provides basic receiver functions but can be enhanced with a plug-in, hand-held module that provides enhanced function control and remote control convenience. So here s how the ELC would look on a compact system: Note that the ELC-16 is only a single pump system, capable of controlling 16 receivers and one pump. So source valves, if used, must be connected to each control one to one style, so valve sharing is not possible. And like the B-32, operation of ARM s or MVP s is not possible. But the range of operation with each ELC control is extensive, including functions for ratio loading, line purging, extended unload times, load and hold, alarm programming and other useful, vacuum loading tools , , , ,

5 Now, last on our list of conveying controls, let s take a look at a control system built specifically on the latest Allen Bradley / Rockwell Automation line of PLC s, Armor Blocks and touch screens: The ELS Ethernet Loading System includes one wire communication features similar to the FLX control line, but uses all AB components, to help shops that understand and have standardized on AB. And the ELS is the largest conveying control system available, with the ability to control up to 500 receivers, 96 pumps and 1024 source valves. The ELS includes stand alone, 10 touch screen control panels, up to 6 of them, and then uses Ethernet to communicate with selected, Conair configured ArmorBlocks and larger capacity ArmorPoint modules to provide the I/O capabilities necessary to operate the system s receivers, pumps, etc. With these industrial, installation-friendly modules, the ELS system nearly eliminates ALL point-to-point wiring by using modular plugs for nearly every connection making installation, troubleshooting and system changes very fast and very simple. The ELS system also includes localized power supplies for the Ethernet connected I/O drops, providing power AT the device, not from a central panel. Multiple I/O modules may be powered by a single power supply. Allen Bradley I/O modules, configured by Conair for conveying devices include: A four-receiver ArmorBlock, and a 16 receiver Armorpoint, A three-pump ArmorBlock, and a 16 pump ArmorPoint, An 8 source valve ArmorBlock and a 32 source valve ArmorPoint. The ELS offering is further enhanced by a family of connection options for all conveying system components, including circular I/O plugs with Phoenix connectors for existing Conair receivers and even valves and sensors equipped circular connectors to ensure that ANY connection in the system can be made with no tools and no hand wiring expertise. ELS is the essence of plug and play flexibility. And, as a member of Conair s advanced control series, the ELS supports the operation of the ARM, Automated Resin Manager and the MVP, Material Vision proofing systems, all with single wire Ethernet simplicity. From small to large, simple to sophisticated, Conair conveying controls continue to provide conveying system ease of operation, reliability and features that makes them the choice of processors throughout the world. Thanks for watching this presentation on Conair Conveying System Controls. 106, , , , , , 119, , , , , , , ,