hayssen training electrical

SCC ULTIMA CONTROL SYSTEM

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E-2.2 SCC HARNESS WIRING

1 Interface Board (EV221) 72 DC Power Supply g3 Main Control Board (EV203F) 94 EL Display 105 Touch Screen Control Board 116 Battery

Connector for PrinterReset ButtonMuster Stop ButtonSpeakerPrinter

SCC ULTIMA CONTROL SYSTEMSingle Tube: CPU Board

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SCC ULTIMA OUTPUT FAILURE ANALYSIS

A failure of a function will usually be accompanied by one of the following errormessages:

DEFECTIVE OUTPUT K/F XX: (XX is a value from 1 to 40)

1. Replace relay K XX with a known good relay (module).2. Replace the PICO-fuse F XX with a good fuse.

K1 K2 K3 K4 K5 K38 K39 K40

f\ F3 F4 F5

10 ID 10 ID ID ID IDF38 F39 F40

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I/O BOARD

PRE-MODULE FAULT:

Indicates a failure in the logic or buffer circuitry and a boardreplacement is necessary.

+24Vdc.

KXX FXX

LOGIC

BUFFER

PRE-MODULE FAULTSENSING LINE

ODC5S.S.R. PICO

FUSE

DEFECTIVE OUTPUT SENSING LINE

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VALVE

FEEDBACK LINES VERIFY CIRCUIT OPERATON

SCC ULTIMA CONTROL SYSTEMSCC ULTIMA Output Failure Analysis con't.

NO ERROR MESSAGE:

If a function fails to operate, and there is no error message, make sure that:

1. The function is turned on.2. Timing is correct.3. There is no mechanical problem. (Try MAC valve mechanical override).4. There are no loose or broken wires.

15-8 11/93


I/O Assignments for Single Tube and Twin Tube Application

K/F OUTPUT #

0102030405060708

0910111213141516

1718192021222324

25262728

293031323334

SINGLE TUBE / TWIN TUBE

JAW CLOSEPLATENKNIFESTRIPPERPRINTERS!QUALI-SEALHOLE PUNCHAUX#1

SHAKERSTAGER/SHAKER JAWSMEASURE ROLLS (INT)PULL BELTS (INT)AUX#2AUX#3PRINTER #2REG WINDOW (INT)

END SEAL AIRSEAM SEAL AIRBAG EJECTBAG DROPTUBE AIRPOKERPOKER AIRAUX TIMER 1

AUXTIMER2WATER VALVEPACERSHUTDOWN TIMER

FILL #1FILL #2SPARE 110 VAC OUTPUTDOUBLE LENGTH BAGAGITATORAUGER CLUTCH

15-9 11/93


I/O Assignments for Single Tube and Twin Tube Application con't.

K/F OUTPUT #

353637383940

SINGLE TUBE /TWIN TUBE

WEB GUIDE LEFTWEB GUIDE RIGHTREGISTRATION ROLL CLUTCHREGISTRATION ROLL BRAKEPULL BELT CLUTCHMETAL DETECT INDICATOR

INPUT #

201203205207209211213215

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SINGLE TUBE / TWIN TUBE

N/C SIDE (L/R)N/C LEFT SENSE WEB GUIDEN/C RIGHT SENSE WEB GUIDETEST BAG COUNTCC RESETEXTERNAL ENABLEHIGH WATERLOW OIL

MASTER RELAYAUX. STOP / DOOR GUARDMASTER STOP / METAL DETECTLOW AIR PRESSURE / AUX. STOPLEFT DOOR/LOW AIRRIGHT DOOR / MASTER STOPCC MASTER RELAY24 VDC SUPPLY

INTERRUPT INPUTS

INPUT #162164166168170172174

SINGLE TUBELOW FILMTRANSMISSION ENCODERAUGERCOUNTEXTERNAL GOTEST ENCODERREGISTRATION EYEJAWPROX

15-10 11/93


Registration Roller Clutch/Brake Problems

1. Using an oscilloscope, check the registration roller brake voltage while themachine is idling to generate a steady brake voltage signal at the circuit board.

Check the registration roller clutch voltage by having someone press "continuoustube" to generate a steady clutch voltage signal at the circuit board. To avoidwasting packaging material, do not thread the machine.

2. Connect the oscilloscope to the clutch and brake terminals on the circuit board.Set the oscilloscope sweep time to 2 ms/div. at 5 Vdc/div. (.5 Vdc with 10Xprobe).

3. Examine voltage trace. A single 40 ms overexcite pulse will occur and then thepulses should be as shown in figure 3.

The brake voltage should show 24 Vdc pulses, approximately 1.2 ms wide, at10 ms intervals.

The clutch voltage should show 24 Vdc pulses, approximately 1.5 ms wide at10 ms intervals.

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Registration Roller Clutch/Brake Problems

4. If the trace is different than this:

a. Turn all power OFF.

b. Disconnect the wires of the circuit under test.

c. Restore power.

5. Re-examine the voltage trace.

a. If the trace is correct, troubleshoot the coil circuit.

b. If the trace is incorrect, replace the circuit board.

15-12 11/93


Error Message Definitions

The following error messages will appear on the SCC ULTIMA Display at differenttimes during the operation of the system.

There are three types of error messages involved for each piece of equipment con-nected to the display.

Information messages Shutdown errors Safety errors

In most cases the error message will have an arrow following the message whichindicates right (*) or left (*) side. Error messages from either side will report to thescreen selected.

INFORMATION MESSAGES

These messages are normal and can occur in all modes. They do not cause a shut-down. Examples of these messages are:

"BAG IN POSITION" - is displayed after completion of the film setup function andan eyespot was detected.

"EYESPOT NOT DETECTED" - is displayed after completion of the film setup func-tion and an eyespot was not detected.

"OUT OF REGISTRATION" - is displayed while running in the filled bags modeand an eyespot was not detected within the registration window. In the empty bagmode, this message will appear without any shutdown. If in the filled bags mode,the message may prompt a shutdown if registration cannot be restored by the bag-maker without operator intervention.

15-13 11/93


Error Message Definitions con't.

"REGISTRATION RESTORED" - is displayed while running in the filled bagsmode. The eyespot was detected in the window following an out of registration con-dition.

NOTE: When a filled cycle goes out of registration, the bagmaker will cancel theendseal operation display "OUT OF REGISTRATION" and go immediately into afilm setup. If an eyespot is detected, the film will be pulled into position, a backsealmade, the error message cancelled, and operations will continue normally. A bag ofabout 2-1/2 times normal length with a double charge will be produced in theprocess.

If registration cannot be restored, the scale will be disabled, bagmaker stopped, andthe "OUT OF REGISTRATION" error will remain displayed.

"JAM DETECTED - ULTIMA" - is displayed when the jaws are jammed, (the jawsdid not close in the time allotted). This message is only displayed for the first jam. ^~"second consecutive jam would shut the system down."UNDEFINED COMMAND -CC" - means the ULTIMA received a command fromthe display that was not defined in the Protocol.

"DEFECTIVE OUTPUT K/F **-ULTIMA"- means output did not turn OFF or ON ascommanded by processor. The possible causes for this error include:

defective output module K** defective fuse broken wire to the load or loose terminal defective load

** = the I/O board number of the output with the error.

"DEFECTIVE HTR OUTPUT Z*- ULTIMA" - means one of the heaters did not turnOFF or ON as commanded by the processor.

Possible causes for the problem include:

defective output module Z* circuit breaker tripped in zone Z* .^ broken wire to the load or loose terminal defective load

* = the heat zone with the error.15-14 11/93



"PREMODULE FAULT P*:B*MJLTIMA" - an output did not turn either OFF or ONas commanded by the processor and the error occurred before the output module.

P* = the output port with the errorB** = the bit number within that port

The cause of this type message is usually a defective board mounted device such as adriver, latch/ etc., and will generally not be field reparable.

"DEFECTIVE INPUT **-ULTIMA" - an input used in the safety string is reportingit's down, but the MASTER RELAY is still up.

This message would appear if the wiring to the external switch were defective goingto the processor.

"******** TEMP IS TOO LOW -ULTIMA" - means the actual temperature is below theset value (from 5 to 20) for that temperature zone.

******** = the specific zone.

This message will appear on startup in a continuous bags mode. It notifies you thatbagmaker will not cycle because one or more heating zones are not at the properoperation temperature.

*********'TEMP IS TOO HIGH-ULTIMA" - means the actual temperature is abovethe set value (from 5 to 20 degrees) for that temperature zone.

******** = the specific zone.

NOTE: The above temperature messages are only displayed for the single cycle andany continuous cycle in progress. (The +/- 5 to 20 degrees depends on the setup ofthe proportioning band).

"********'11 = represents JAW FRONT / JAW REAR / PLATEN / AUX. zones.

15-15 11/93



CONTROLLED SHUTDOWN ERRORS

These errors cause a controlled shutdown. Your system will stop upon completingthe present function. Examples of these errors are:

"TERMINAL COUNT - ULTIMA" - is displayed in filled bags mode when the termi-nal count (bag stop) = 0."FEED RATE EXCEEDS ULTIMA SPEED" - is displayed in filled bags mode whenthe feed system dumps the product faster than the ULTIMA is making bags.

"LOW FILM - ULTIMA" - means the low film switch was activated (only displayedwhile running filled bags). The shutdown will occur to keep the film from beingpulled through the bagmaker which would make it much more difficult to changerolls of film.

-

"EXTERNAL ENABLE - ULTIMA" -is displayed in filled bags mode when the exttnal enable input is activated.

"START DELAY TOO LONG - ULTIMA" - means the next product dump wasreceived and the current start delay had not timed out yet (the current bag cycle hadnot started). This requires the adjustment of the start delay function to be no longerthan the time required for the bagmaking cycle.

"SHORTED RTD: ******** - ULTIMA" - means an RTD is shorted.

"OPEN RTD: ********. ULTIMA" - means an RTD is open or not connected.

"ILLEGAL ******** TEMP - ULTIMA" - means the temperature was set above a rea-sonable number (550).

TEMP OVERRANGE - ULTIMA" - the actual temperature is above thehigh limit of the temperature range (550). This would indicate a possible shortedoutput module in the temperature control module and would most likely occur withan error message concerning the output.

NOTE: For any temperature message the field "********" could represent - JAWFRONT / JAW REAR / PLATEN / AUX. zones. _

******** _= the specific temp zone of the error.

15-16 11/93



SAFETY ERRORS -Immediate Shutdown

Safety errors are errors that will cause an immediate shutdown of your machine.These are generated by the MASTER RELAY line or in componentry associated withthe safety string. Examples of these errors are:

"NO + 24V SUPPLY - ULTIMA" - indicates the ULTIMA lost its +24 volts. Possiblecauses include:

blown fuse in the 120 vac source to the 24 VDC supplyblown fuse in the 24 VDC line in the power supplyexternal short on the 24 VDC circuitry of the system

"RIGHT DOOR OPEN -ULTIMA" - means the right door is open.

"LEFT DOOR OPEN - ULTIMA" - means the left door is open.

"LOW AIR PRESSURE - ULTIMA" - indicates the air pressure has dropped belowthe limit set on the pressure switch.

"LOW OIL DETECTED - ULTIMA" - means the oil level for the pneumatic oiler istoo low.

"WATER LEVEL EXCEEDED - ULTIMA" - means the container used to collect thewater condensate from the pneumatic lines is full.

"MASTER STOP PUSHBUTTON - ULTIMA" - indicates that the emergency stoppushbutton was pushed or is locked in.

"AUX STOP PUSHBUTTON - ULTIMA" - means the aux. stop pushbutton waspressed.

"PRESS RESET BUTTON - CC"- means the display's MASTER RELAY hasdropped.

"MASTER RELAY - ULTIMA" - means the ULTIMA MASTER RELAY has dropped.

NOTE: The above 10 messages are displayed for safety strings faults. They all willdrop the ULTIMA MASTER RELAY. The message displayed will specify which onecaused the string to go down. When the MASTER RELAY is dropped the +24V sup-ply and air are also dropped from the machine.

15-17 11/93

SCC ULTIMA CONTROL SYSTEMError Message Definitions con't.

"WATCHDOG - ULTIMA" - means the power watchdog for the ULTIMA was lost,the CPU stopped processing. The processor will attempt to reset and restart on itsown if possible. Failure to reset will result in board replacement.

"SHUTDOWN TIMER -ULTIMA" - the ULTIMA Was left idle longer than the shut-down time (approx. 30 minutes)."NO ENCODER -ULTIMA" - the encoder pulses are not being detected by theprocessor board. One possible cause for this error would be the transmission lever isnot engaged in either the long or short bag position.

"JAM DETECTED -ULTIMA" - the jaws were jammed for the second consecutivecycle. The jaw closed cycle is timed each cycle. If the jaw closed proximity switch isnot detected in the amount of time required for the last cycle plus a safety factor, thejaw closed signal is terminated for that cycle. If the situation continues for two con-secutive cycles, the machine cycles are terminated. ^~

"COMMUNICATION ERROR - CC" - the display did not acknowledge one of thecommands the ULTIMA sent to it.

"CPU BLOCK ERROR *** -ULTIMA" - is displayed when one of the blocks (orareas) of the ULTIMA control boards did not initialize properly after power up orreset.

*** = the specific areas that had errors.

"OUCH ERROR #*** -ULTIMA" - is displayed when the control boards have a fatalerror and processing is halted.

*** = the specific type of error to cause the fault.

NOTE: If everything is hooked up properly and operating correctly, the "ZF" mes-sages should drop the MASTER RELAY in the SCC ULTIMA Display which in turnwould drop the MASTER RELAY of the ULTIMA. Even the "ZF" errors that are notpart of the safety string will indirectly drop the ULTIMA MASTER RELAY.

15-18 11/93

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