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Easy Loading Control

1. 0 ccc eee eee ee ee ee 6 8 A Appendix We re here to help iis cee eee tee A 1 How to contact customer Service 0 0 c eee eee A 1 Before vou Gal uie ei RE inten in tonsa noes ek ls ah oa to Sao ee A 1 Equipment guarantee ccc ee ees A 2 Performance warranty 0 ccc eee eee eee eee ees A 2 Warranty limitations 0 0 ccc cee eee ees A 2 B Appendix ELC circuit board connectionS 000eee eee e cease B 1 Control board diagram es ee ee se ee eee B 3 C Appendix Purge valve wiring connections optional 05 C 1 Table of Contents iii iv Table of Contents SECTION Introduction Purpose of the user guide 1 2 How the guide is organized 1 2 Your responsibilities as a user 1 3 ATTENTION Read this so no one gets hurt 1 4 Introduction 1 1 1 2 Introduction ue Purpose of the User Guide This User Guide describes the Conair Easy Loading Control ELC 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 information in the instruction packet You also should review manuals covering associated equipment in your system This review won t take long and it could save you valuable installation and operating time later How the Gui
2. qp ep Maintenance 5 1 Replacement ControlMate communication cables are available from Conair Contact Conair Parts 800 458 1960 From outside of the United States call 814 437 6861 5 2 Maintenance Preventative Maintenance Checklist Routine maintenance will ensure optimum operation and performance of the ELC control and optional ControlMate pendant We recommend the following maintenance schedule and tasks e Every six months O Inspect all wiring connections Power and cable connections between the ELC and conveying loaders or receivers may become loose or wires may become worn Tighten any loose connections and replace any wire or cable that has become worn or damaged O Inspect optional ControlMate pendant connection Check ControlMate pendant for any loose connection points or frayed wiring Replace as necessary O Inspect the installation Check installed mounting hardware to make sure that the installation is secure SECTION Troubleshooting Before beginning 005 6 2 A few words of caution 6 3 DIAGNOSTICS Troubleshooting ELC M control 6 4 Troubleshooting ELC 16 control 6 6 Troubleshooting Optional ControlMate pendant and pump control 6 8 ie ei oO CD de 3 ie O g 5 Q Troubleshooting 6 1 Before Beginning You can avoid most problems by following the recommended installation and maintenance pro
3. Troubleshooting ELG M Control Problem The ELC M does not have power The ELC M has power but it fails to start a load cycle Demand LED is off 6 4 Troubleshooting Possible cause The ELC M s power switch is not turned on Power connection is loose or detached Circuit breaker has been tripped Incoming voltage is incorrect Demand sensors are dirty or need adjusted Material line is clogged Material line does not have vacuum Solution Turn the ELC M s power switch to the On position See Installation section entitled Powering the ELC Control Ensure that the ELC M s power supply is connected See Installation section entitled Connecting Main Power to the ELC M Control Turn the ELC M s power switch Off and then On See Installation section entitled Powering the ELC Control Checking for correct incoming power voltage and amp ratings WARNING Any electrical checks should be performed by a qualified electrician Check demand sensors reed switch or optional capacitive demand sensors Clean or adjust if necessary Check material lines clean as nec essary Disconnect any compressed air source See loader manual to cor rect vacuum connections Loader motor has failed replace motor Troubleshooting ELC M Control continued Problem Alarm has sounded during a load attempt Demand LED is flash ing Possible cause Materi
4. continued 3 Remove the ELC control cover and place it along side the control box Terminal Ports 8 5 Attach the wiring connection from the terminal box to the appropriate port inside the ELC that is used by your specific option See Appendix B entitled ELC Circuit Board Connections Control Board Diagram Remove the terminal plug from the outside of the ELC s enclosure Route the wiring through the hole secure with a proper strain relief 6 Reassemble the ELC control module by following steps 1 3 in reverse order ELC Circuit Board Connections continued Control Board Diagram Load Output Alarm Output Ratio Output Blowback Output 421 BBK Purge Output Positive Discharge Output Demand Sensor Input Fill Sensor Input Appendix B 3 AN GAUTION Always discon nect and lock out the main power sources before accessing the ELC s internal connections Electrical con nections should be made only by dualified personnel AN IMPORTANT Always refer to the wiring diagrams that came with your equipment to locate specific electrical components Adjustable Purge Valve APV Inline connection C 1 Appendix Purge Valve Wiring Connections optional To wire the purge valve connection to the ELC control 1 Unplug the power supply of the loader receiver and remove its compressed air source It is recommended that the loader receiver be removed f
5. CONAIR www conairgroup com USER GUIDE UGC034 1208 Easy Loading Control Models ELC M and ELC 16 Corporate Office 724 584 5500 Instant Access 24 7 Parts and Service 800 458 1960 Parts and Service 814 437 6861 Please record your eguipment s It s a good idea to record the model and serial number s of your equipment and model and serial number s and the date you received it in the User Guide Our service department uses this infor MEd ae pec eec JEN Ahe mation along with the manual number to provide help for the specific equipment spaces provided you installed Please keep this User Guide and all manuals engineering prints and parts lists together for documentation of your equipment Date Manual Number UGC034 1208 Serial Number s Model Number s DISCLAIMER The Conair Group Inc 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 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 Copyright 2008 The Conair Group All rights reserved Table of Contents 1 1 Introduction Purpose of the user guide 0 ccc cee ee ees 1 2 How the guide is organized 0c cece eee ee eee 1 2 Your responsibilities as a USeF ee 1 3 ATTENTION Rea
6. pendanl 44 vaca Sw wee we wee eS Bane 4 21 Operation 4 1 4 2 Operation Easy Loading Control Control Panel Layout Loading Indicator LED Demand No Material Illuminates when the receiver or loader is conveying material Alarm Horn The Alarm Horn will only sound if the loader receiv er fails to satisfy the demand switch or when a conveying issue results in lack of material See the Troubleshooting section of this manual to diag nose alarm condi tions Alarm Acknowledgement button Silences and acknowledges an alarm when it is present Pressing the Alarm Acknowledgement button for 3 seconds will change the tone of the alarm Load Time Increment Decrement buttons Used to increase or decrease the duration of load time of the loader receiver in increments of one second Holding down the increment decrement buttons will cause the load time to ramp up or down at a faster rate Indicator LED Illuminates when material is needed Communication Terminal Connection for the optional ControlMate pendant This terminal will allow the ControlMate pendant to change the settings of the ELC control remotely See Operation section enti tled Connecting the ControlMate pendant ELC Loading Control Operation How it Works The start of a loading sequence is triggered by the loader receiver s demand switch The demand switch will signal the ELC M to energize its loader s vacuum motor pu
7. When there is demand for material on the CAN open powering the pump control first before powering the ELC 16 controls that are on network the pump control s the CAN open network This is to ensure that power can be detected on the system Demand LED will illuminate If truck cable and unwanted activation of ELC 16 s and their respected receivers is there is no demand on the CAN open network the Demand LED will not be illu minated avoided To turn on the pump control 1 Push the toggle switch to the On position The pump control switch Q will illuminate green NOTE When the vacuum pump is running the Loading LED will be illuminated If the vacuum pump is not running the Loading LED will not be 2 illuminated gt z 0 Loading LED o Demand LED Power Toggle Switch Circuit Breaker To reset the pump control circuit breaker 1 Push the circuit breaker toggle switch that is located to the right of the power toggle switch Installation 3 19 Powering the ELC Control The ELC M and ELC 16 controls have built in power toggle switches located on the right side of their enclosures Each control will need to be turned on to start a loading cycle The ELC 16 control will have an additional toggle switch located to the nght of the main power toggle switch This toggle switch is the individual 4 amp circuit breaker for the ELC 16 control The ELC M s power switch also acts as a circuit b
8. time Operation 4 19 amp NOTE The number of blowback pulses depends on the total unload time amp Q NOTE Depending upon loader receiver model the ELC s default settings may not allow the maximum number of blowback puls es IMPORTANT Any adjustments made with the ControlMate pendant will not take effect until the loader starts a new loading cycle 4 20 Operation GontrolMate Pendant Operation continued Using Blowback continued Adjustment Readout Blowback Pulse LED Function Button Increase and Decrease Increment Buttons To adjust the number of blowback pulses 1 Press the Function button until the Blowback Pulse LED is illuminated 2 Use the and buttons to the left of the Function button to increase or decrease the number of blowback pulses Holding down the or buttons will cause the number to ramp up or down at a faster rate The blowback pulse range is 0 10 pulses Changes will be displayed in the ControlMate s three digit adjustment readout display 3 The control will automatically return to its default Power on screen after 30 seconds continued User Level 2 Settings for the ControlMate Pendant SS NOTE All User Level 2 set tings will be set at Conair D NOTE Activating and altering this setting is possible only through the optional Priority Demand will be the ControlMate pendant See Operation Section entitled ControlMate P
9. ControlMate pendant does not have power Replacement ControlMate pendants and communication cables are available from Conair Contact Conair Parts 800 458 1960 From outside of the United States call 814 437 6861 6 8 Troubleshooting Possible cause The ControlMate pendant is not connected to the ELC module The ControlMate communication cable is loose The ControlMate communication cable is damaged ELC s power is not turned on ELC s circuit breaker has been tripped ELC 16 s pump control is not turned on The pump control s circuit breaker has been tripped The ControlMate pendant is damaged Solution Check communication connection points between the ELC module and ControlMate reconnect if necessary See Operation section entitled ControlMate Pendant Operation Connecting the ControlMate Pendant Replace damaged ControlMate communication cable Turn on the power to the ELC See Installation section entitled Powering the ELC Control Reset the ELC circuit breaker See Installation section entitled Powering the ELC Control Turn on the power to the pump control See Installation section entitled Powering the Pump Control Reset the pump control s circuit breaker See Installation section entitled Powering the Pump Control Replace ControlMate pendant Troubleshooting Optional ControlMate Pendant and Pump Control continued Problem ControlMate has po
10. active to both the ControlMate pendant and the ELC control module when they are disabled This function only disables the loader receiver NOTE The ControlMate loading control s default load time is loader receiver model depend ent and will be set by Conair Operation GontrolMate Pendant Operation continued Connecting the ControlMate Pendant Adjustment Readout Control Heartbeat Enable Disable LED Function Button Increase and Decrease Increment Buttons The ControlMate Pendant automatically shows an enable screen when it is initially connected to the ELC control module To connect the ControlMate to the ELC module 1 Plug the communication cable into the terminal port at the top of the ControlMate pendant 2 Plug the communication cable into the terminal port on the ELC module The ControlMate pendant will illuminate showing the default Power on readout and the control heartbeat will pulse to show that it is communicating with the ELC and or pump control GontrolMate Pendant Operation continued Enabling Disabling the ControlMate Pendant To deactivate the ControlMate pendant along with the loader receiver QD NOTE Activating and altering this setting is possible only 1 Press the Function button until the Enable Disable LED is illuminated through the optional GontrolMate pendant See 2 Adjust the Enable Disable setting by using the and buttons to the Operation Sect
11. complete the following checklist before calling Conair OD Make sure you have all model control type and serial numbers from the serial tag and parts list numbers for your particular equipment Service personnel will need this information to assist you Make sure power is supplied to the equipment Make sure that all connectors and wires within and between control systems and related components have been installed correctly OD Check the troubleshooting guide of this manual for a solution Thoroughly examine the instruction manual s for associated equipment especial ly controls Each manual may have its own troubleshooting guide to help you OD Check that the equipment has been operated as described in this manual OD Check accompanying schematic drawings for information on special considerations Additional manuals and prints for your Conair equipment may be ordered through the Customer Service or Parts Department for a nominal fee Most manuals can be downloaded free of charge from the product section of the Conair website www conairgroup com Appendix A 1 A 2 Appendix Equipment Guarantee 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 normal use and service for which it was recommended except for parts that are typically replaced after normal usage such as filters liner
12. in one box or will be shipped previously mounted to your loader or receiver The box could include depending on the options selected Easy Loading Control ELC M or ELC 16 ControlMate pendant optional ControlMate pendant cradle optional Communication cord 10 or 15 ft 3 1 or 4 6 m optional A loader or receiver if ordered as a unit User Guide 1 Carefully remove the ELC and its components from their shipping box 2 Remove all packing material protective paper tape and plastic 3 Carefully inspect all components to make sure no damage occurred during shipping and that you have all the necessary hardware 4 Take a moment to record serial numbers and electrical power specifications in the blanks provided on the back of the User Guide s title page The informa tion will be helpful if you ever need service or parts 6 You are now ready to begin installation See Installation section entitled Preparing for Installation Preparing for Installation The ELC is easy to install if you plan the location of the ELC unit along with its associated loader or receiver to ensure adequate space for access and wiring The optional ControlMate pendant should also be mounted within easy reach and visi bility using its associated optional cradle 1 Check individual loader receiver manuals for proper installation procedures of equipment O Provide a clean dry vibration free environment Exposure to wide
13. plates etc Conair s guarantee is limited to replacing at our option the part or parts determined by us to be defective after examination The customer assumes the cost of transportation of the part or parts to and from the factory Performance Warranty Conair warrants that this equipment will perform at or above the ratings stated in specific quotations covering the equipment or as detailed in engineering specifica tions provided the equipment is applied installed operated and maintained in the recommended manner as outlined in our quotation or specifications Should performance not meet warranted levels Conair at its discretion will exercise one of the following options Inspect the equipment and perform alterations or adjustments to satisfy performance claims Charges for such inspections and corrections will be waived unless failure to meet warranty is due to misapplication improper installation poor maintenance practices or improper operation Replace the original equipment with other Conair equipment that will meet original performance claims at no extra cost to the customer Refund the invoiced cost to the customer Credit is subject to prior notice by the customer at which time a Return Goods Authorization Number RGA will be issued by Conair s Service Department Returned equipment must be well crated and in proper operating condition including all parts Returns must be prepaid Purchaser must notify Co
14. positive discharge hopper see Operation section entitled ControlMate Pendant Operation Adjusting Unload Time the loader receiver to prevent material interference when the positive discharge valve is either opened or closed The primary use of positive discharge loading is for when using hoppers that may contain pressurized air high CFM drying hoppers or crystallizers which may restrict the free motion of gravity discharge flappers Operation 4 11 SS NOTE Activating and altering 4 12 GontrolMate Pendant Operation continued Adjusting Unload Time Adjustment Readout Unload Time LED Function Button Increase and Decrease Increment Buttons this setting is possible only through the optional l l ControlMate pendant See To adjust the duration of Unload Time Operation Section entitled ControlMate Pendant Operation 4 Press the Function button until the Unload Time LED is illuminated 2 Use the and buttons to the left of the Function button to IMPORTANT Any adjustments increase or decrease the unload time duration Holding down the or made with the ControlMate buttons will cause the number to ramp up or down at a faster rate The pendant will not take effect Unload Time range is 3 120 seconds Changes will be displayed in the until the loader receiver starts ControlMate s three digit adjustment readout display a new loading cycle 3 The control will automa
15. temperature variations high ambient temperatures power line fluctua tions caustic fumes or excessive amounts of dust dirt vibration shock and moisture could harm performance and reduce the life of this equipment O Provide a grounded source of 115VAC 60 Hz 230VAC 50 400VAC 50 Hz or 460VAC 60 Hz power depending on the ELC model See Description section entitled Specifications Easy Loading Control ELC 2 Plan the power communication cable routes if the ELC 16 model is used O Review all wiring guidelines and diagrams provided in with this manu al and your conveying equipment manuals before beginning installation O Keep communication wires away from sources of static electricity AN WARNING Wires Static electricity can damage the controls Communication cables should should be routed neat not be installed near material lines and hoses which produce large ly away from any hot amounts of static electricity when material is conveyed surfaces of areas of O Avoid running cables across power feed lines If you must run the Wee i i fae d cable across power feed lines run the cable at right 90 degree angles to away from normal the lines machine maintenance AE er or traffic areas O Do not run communication cables along side existing power cable trays AN WARNING Voltage hazard A properly sized conductive ground wire from the incoming power supply must be connected to the chassis ground or P E physical earth terminal
16. the On position See Installation section entitled Powering the ELC Control Turn the pump control s power switch to the On position See Installation section entitled Powering the Pump Control Ensure that the ELC 16 s power supply is connected See Installation section entitled Connecting the ELC 16 Control to the Junction Box Drop Cable Reset the ELC 16 s or pump con trol s circuit breaker See Operation section entitled Powering the Pump Control and Powering the ELC Control Checking for correct incoming power voltage and amp ratings JN WARNING Any electrical checks should be performed by a dualified electrician Check the incoming power connec tion from the pump control to the junction box See Installation sec tion entitled Wiring the ELC 16 Control Junction Boxes ZN WARNING Any electrical checks should be performed by a gualified electrician Check all pump control connec tions secure if necessary See wiring diagram for reference Troubleshooting ELG 16 Control continued Problem The ELC 16 has power but it fails to start a load cycle Demand LED is off CAUTION Wear eye protection If you use compressed air to clean the equipment you must wear eye protection and observe all OSHA and other safety regula tions pertaining to the use of compressed air Alarm has sounded during a load attempt Demand LED is flash ing Possible cause Deman
17. the closure brackets on the right side of the pump control cabinet with an appropriately sized screwdriver Brackets 2 2 Swing open the pump control cabinet access door 3 Refer to wiring diagrams 10765904 and 10765905 depending on your power supply for the control pump s wiring connections 3 8 Installation ELC 16 Control Junction Boxes ELC 16 Only Loading controls on the ELC 16 system are supplied by a trunk cable The cable is a 4 conductor shielded cable with two twisted pairs One pair supplies power and the second pair is used for CAN communications The trunk cable starts at the pump control located near the vacuum pump and ends at the ELC 16 control fur thest from the pump control Connections for each control will require a junction box for example a ten 10 receiver system would need ten 10 ELC 16 controls connected to ten 10 junc tion boxes which are then connected to the ELC 16 trunk cable Each individual junction box provides a 3 way T connection at each receiver along with a pre wired ground line to connect the ELC 16 and its receiver to a structural ground At the bottom of the junction box a 10 15 or 20 ft 3 1 4 6 or 6 1 m drop cable is connected This drop cable is fitted with a quick disconnect circular connector that interfaces directly with the control itself The junction box end of the drop cable is pre connected and can be shortened as needed for neat installation Trunk Ca
18. the digital readout Enable Disable LED Illuminates when the enable disable adjustment is selected Settings will be displayed in the digital readout Unload Time LED Illuminates when the unload time adjustment is selected Settings will be displayed in the digital readout Load Attempts Before Alarm LED Illuminates when the load attempts before alarm adjust ment is selected Settings will be displayed in the digital readout amp S NOTE The functions described above can only be altered with the addition of the optional ControlMate pendant with the exception of Load Time Blowback and Alarm Acknowledgement See the Operation section entitled ELC Loading Control Operation ControlMate Pendant Operation If the optional ControlMate was purchased along with the Easy Loading Control ELC it will offer more conveying abilities such as blowback pulses ratio loading percentage ratio layering number of loading attempts before an alarm purge time and unloading time The ControlMate can be used interchangeably between each receiver or loader The changes that are made will be saved within the ELC module The following chart shows what parameters and capabilities are available at each User Level and the ranges of each setting that can be changed with the optional ControlMate pendant Parameters are listed in the order that they appear when the Function button is pressed and will correspond to a LED indicator t
19. ANT Always refer of the ELC 16 network Cord grips are provided to allow interconnection with the to the wiring diagrams that came with your equipment to locate specific electrical f ts Illustrations in The pump control s enclosure is equipped with wall mounting accommodations and rie is pyp EP 8 the User Guide are intended can be mounted to a flat surface using the supplied mounting holes The pump control to be representative only should be located so access to its switches and viewing of its lights are not obstructed See Description section entitled Specifications Easy Loading Control ELC Pump Control ELC 16 system s trunk cable dust collector and idle mode valve connections dp D 0 h O gt Refer to Drawing No 10765904 or 10765905 depending on your supply voltage for a full example of the pump control s wiring Terminal strips are provided inside the pump control for all connections Mounting Holes 4 Installation 3 7 Wiring the ELC 16 Pump Control ELC 16 Only continued AN CAUTION Always disconnect and lock out the main power sources before making electrical connections Electrical connections should be made only by a qualified electrical technician After mounting the pump control access to its internal wiring components is required for power connections ELC 16 trunk cable etc To open the pump control cabinet 1 Loosen the two 2 retaining screws that secure
20. TE The ELC loading control s default load time is loader receiver model dependent and will be set by Conair IMPORTANT Any adjustments made with the ControlMate pendant will not take effect until the loader receiver starts a new loading cycle 4 18 Operation GontrolMate Pendant Operation continued Adjusting Load Time Adjustment Readout Load Time LED Increase and Decrease Increment Buttons Setup for Load Time using the optional ControlMate pendant will operate exactly as the ELC control See Operation section entitled ELC Loading Control Operation Load Time Adjustment To adjust Load Time 1 Press the Function button until the Load Time LED is illuminated 2 Adjust the Load Time through trial and error using the and buttons to the left of the Function button to increase or decrease the amount of load time Several adjustments may be needed to optimize your loading time Holding down the or buttons will cause the number to ramp up or down at a faster rate The range of Load Time adjustment is 3 120 seconds Changes will be displayed in the ControlMate s three digit adjustment readout display 3 The control will automatically return to its default Power on screen after 30 seconds ControlMate Pendant Operation continued Adjusting Load Time continued If your loader receiver is equipped with a fill sensor a capacitance sensor mounted in the loader
21. al plug within the conveying line has stopped the flow of material Foreign object within the material Material line is damaged Optional internal fill sensor has not been satisfied before the load time setting has expired Demand sensor is damaged or not adjusted properly Optional remote demand sensor is dirty Solution Check the material line clear any obstructions Check the material line clear any foreign objects Check the material line replace any damaged hoses Reset the ELC M s load time slightly higher than the time required to meet the loader s optional internal fill sensor See Operation section entitled ELC Loading Control Operation Load Time Adjustment See Operation section entitled ControlMate Pendant Operation Adjusting Load Time Check the demand sensor replace as necessary Clean the optional remote demand sensor Troubleshooting 6 5 Troubleshooting ELC 16 Control Problem The ELC 16 does not have power 6 6 Troubleshooting Possible cause The ELC 16 s power switch is not turned on The pump control s power switch is not turned on Power connection is loose or detached Circuit breaker has been tripped Incoming voltage is incorrect The incoming power connection from the pump control to the junction box is loose or not con nected The pump control is not connected to a power source Solution Turn the ELC 16 s power switch to
22. ase and Decrease Increment Buttons To adjust the number of Ratio Layers 1 Press the Function button until the Ratio Layers LED is illuminated 2 Use the and buttons to the left of the Function button to increase or decrease the number of layers Holding down the or buttons will cause the number to ramp up or down at a faster rate The range is 1 5 or A for automatic layering Changes will be displayed in the ControlMate s three digit adjustment readout display 3 The control will automatically return to its default Power on screen after 30 seconds Operation 4 15 YQ NOTE Purge time setup varies depending on the model of purge valve you 4 16 ControlMate Pendant Operation continued Using Purge Operation D NOTE Activating and altering this setting is possible only through the optional ControlMate pendant See Operation Section entitled ControlMate Pendant Operation The first stages of the loading cycle for a loader receiver using the purge func tion will operate exactly as a normal load cycle Only after the end of the user are using Reference your set load time will the material valve purge or APV be signaled by the ELC to purge valve manual for change state and stop the flow of material into the material line The material proper setup Operation line will then be purged with air for the amount of time set by the user for purge time See Appendix B entitled ELC Ci
23. aterial to be conveyed to satisfy its demand The ELC M sends a signal to the vacuum motor on the loader to energize and start a loading cycle The material is then drawn in by the loader s vacuum motor If the hopper is filled the demand switch will remain open Fig 1 and no further load cycles are needed However if the demand was not satisfied and the demand switch closes Fig 2 the loader will continue with loading cycles until the demand is satisfied Fig 1 ELC 16 Control Pump Control Motor Starter Overload Line Voltage Idle Mode Valve Output Fe PEN Idle Mode Valve CON ve EE Pump Motor Starter Vacuum Pump Dust Collector o D gt l A signal from the receiver s demand switch indicates to the individually mounted ELC 16 on the receiver that it requires material to be conveyed to satisfy its demand The ELC 16 then communicates its need for material to the pump control via a CAN open network The demand signal from the ELC 16 is then added to the pump con trol s queue The vacuum pump control will then permit the receiver to load on a First In First Out FIFO basis Dust Collector Output Ground Junction a N g h K gt More Receivers Up to 16 Couture ControlMate The ELC 16 control is used for a number of receivers up to 16 on a CAN ope
24. ble Drop Cable Ground Cable AN CAUTION Always dis connect and lock out the main power sources before making electrical connections Electrical connections should be made only by a qualified electrical technician Installation 3 9 AN CAUTION Always dis connect and lock out the main power sources before making electrical connections Electrical connections should be made only by a qualified electrical technician 3 10 Installation Mounting the ELC 16 Control Junction Boxes cetc 16 only The ELC 16 T junction boxes can be top mounted using the pre drilled 0 375 inch 9 525 mm hole located at the top of the junction box Use of a pre determined length of All Thread steel rods are recommended to accurately mount the junction boxes in the desired location Junction boxes can also be flush mounted to a wall or other flat surface by drilling through the back of the box and anchoring it with appropriate hardware Pre drilled Mounting Hole Connecting the Junction Box Ground Wire etc i6 oniy AN WARNING Voltage hazard A properly sized conductive ground wire from the incoming power supply must be connected to the chassis ground or P E physical earth terminal inside the electri cal enclosure Each junction box includes a pre wired ground connection that is connected directly to the internal terminal block Conair recommends that you to connect the ground wire to a structural ground to eliminate an
25. cedures outlined in this User Guide If you do have a problem this section will help you determine what caused it and how to fix it LJ Diagnose causes from the ELC control 1 Press once to acknowledge and silence the audible alarm and resume control if reguired Alarm acknowledgements can also be done from the optional ControlMate pendant 2 Address the alarm and fix the problem 3 Ifthe alarm reappears the problem was not fixed OREO Demand No Material LED D Alarm Acknowledgement Button 6 2 Troubleshooting A Few Words of Caution Improper corrective actions can lead to hazardous conditions and should never be attempted to sustain production IN WARNING Improper installation operation or servicing may result in equipment damage or personal injury This equipment should be installed adjusted and serviced by quali fied technician who is trained in the operation and troubleshooting of this equipment AN DANGER Electrical shock hazard Only a qualified electrical technician trained in the use of this equip ment and in avoiding exposure to voltage hazards should perform procedures that require access to the ELC while power is on N DANGER Electrical shock hazard The ELC loading control allows operators and maintenance personnel to disable and enable conveying system components Unexpected energization of these components could result in equipment damage or injury Troubleshooting 6 3
26. d sensors are dirty or need adjusted Material line is clogged Material line does not have vacuum There is no communication between the ELC 16 and the pump control Material plug within the conveying line has stopped the flow of material Foreign object within the material Material line is damaged Optional internal fill sensor has not been satisfied before the load time setting has expired Demand sensor is damaged or not adjusted properly Optional remote demand sensor is dirty Solution Check demand sensors reed switch or optional capacitive demand sensors Clean or adjust if necessary Check the material line clear any obstructions See receiver manual to correct vacuum connections Check all ELC 16 connections See Installation section entitled Connecting the ELC 16 Control Junction Boxes and Wiring the ELC 16 Pump Control Check the material line clear any obstructions Check the material line clear any foreign objects Check the material line replace any damaged hoses Reset the ELC 16 s load time slightly higher than the time required to meet the receiver s optional internal fill sensor See Operation section entitled ELC Loading Control Operation Adjusting Load Time Check the demand sensor replace or adjust as necessary Clean the optional remote demand sensor Troubleshooting 6 7 Troubleshooting Optional ControlMate Pendant and Pump Control Problem
27. d this so no one gets hurt 6 1 4 2 1 Description What is the Easy Loading Control ELC 0 2 2 Typical AD DIIGATIONS oe Se eisai akin elaine eee 2 2 HOW IE WOIKS Ius EIER GOED SO SS OG ie GE BE GE EG GE 2 3 Specifications Easy Loading Control ELC 2 4 Optional ControlMate pendant 0 00 2 5 Pump GOOSE tte crt re EAEAN 2 6 3 1 Installation Unpacking the DOKOS iv RE RE RE ER ai an are ear RE EE WE EE RES E 3 2 Preparing for installation 1 0 0 cece eee eee eee 3 3 Wiring considerations 0 0 0 es se ek ee ke ee ees 3 4 Mounting the ELC control 0 0 cece eee eee 3 5 Connecting main power to the ELC M control 3 6 Wiring the ELC 16 pump control 0 0 00 c eee 3 7 ELC 16 control junction boxeS 0 0 0 cee eee ees 3 9 Mounting the ELC 16 control junction boxes 3 10 Connecting the junction box ground wire 3 10 Wiring the ELC 16 control junction boxes 6 3 11 Connecting the trunk cable termination resistor 3 14 Table of Contents i Mounting the ELC ControlMate pendant optional 3 17 Connecting the ELC 16 control to the junction box drop cable 3 18 Powering the pump control 0 eee eee eee 3 19 Powering the ELC control 0 0 0 ccc cee eee 3 20 4 1 Operation Easy Loading Control Co
28. de is Organized 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 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 circle marks items in a list Indicates a tip A tip is used to provide you with a suggestion that will help you with the maintenance and the operation of this equipment Indicates a note A note is used to provide additional information about the steps you are following throughout the manual Your Responsibility as a User You must be familiar with all safety procedures concerning installation opera tion and maintenance of this equipment Responsible safety procedures include Thorough review of this User Guide paying particular attention to hazard warnings appendices and related diagrams Thorough review of the equipment itself with careful attention to voltage sources intended use and warning labels Thorough review of instruction manuals for associated equipment Step by step adherence to instructions outlined in this User Guide Introduction 1 3 1 4 Introduction ATTENTION Read this so no one gets hurt We
29. design equipment with the user s safety in mind You can avoid the potential hazards identified on this equipment by following the procedures outlined below and elsewhere in the User Guide N WARNING Improper installation operation or servicing may result in equipment damage or personal injury This equipment should be installed adjusted and serviced by a qualified technician who is familiar with the construction operation and potential hazards of this type of machine All wiring disconnects and fuses should be installed by a qualified electrical technician 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 machine serial tag and data plate AN WARNING Voltage hazard The ELC M is powered by single phase alternating current 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 or P E physical earth terminal inside the electrical enclosure Improper grounding can result in severe personal injury and erratic machine operation 120 Volt units come with a grounded plug that must be plugged into a grounded out The ELC 16 is powered by three phase alternating current via a pump control then converted to 24 VDC control voltage Always disconnect and lock out the incoming main power source before open
30. e or buttons will cause the number to ramp up or down at a faster rate The percentage range is 0 or 5 100 Changes will be displayed in the ControlMate s three digit adjustment readout display 3 The control will automatically return to its default Power on screen after 30 seconds continued GontrolMate Pendant Operation continued Adjusting Ratio Layers The Ratio Layering setting allows the ELC to control the number of S NOTE Activating and altering alternating layers of virgin and regrind material To make ratio loading as this setting is possible only simple as possible the ControlMate pendant has a setting A to automat through the optional ically calculate the maximum number of possible layers based on the ControlMate pendant See ratio percentage and total load time Using the automatic layer number Operation Section entitled ControlMate Pendant selection is recommended unless you require special conveying parame Operation ters in those cases a number of to 5 layers is recommended QD NOTE Careful examination of your material s unique flow characteristics and conveying distances will aid in adjusting for proper ratio layering settings Adjustment Readout Ratio Layers LED IMPORTANT Any adjustments made with the ControlMate pendant will not take effect until the loader receiver starts a new loading cycle O ze o A Function Button Incre
31. e ControlMate Pendant continued 1 0x Priority Demand This feature allows you to override the FIFO First 2 0x 3 0x 4 0x 5 0x 6 0x 7 0x 0x In First Out standard demand setting Receivers with this option activated will always be the first to receive material regardless of other receiver demand signals If more than one receiver is set with priority demand the control with setup receiver demands with two demand tiers 1 Installed 0 Not installed Demand Sensor Logic This setting determines the type of circuit used for the demand sensor The setting is defaulted to a normally closed circuit which will provide a demand signal when it senses there is no material 1 Close on demand 24 VDC 0 Open on demand 0 VDC Fill Sensor Logic This setting determines the type of circuit used for the fill sensor The setting is defaulted to a normally closed circuit which will provide a fill signal when it senses material at the level of the sensor 1 Close on full 24 VDC 0 Open on full 0 VDC Fill Sensor Present 1 Installed 0 Not installed Load and Hold 1 Installed 0 Not installed Purge Material Valve Option 0 Not installed 1 Purge Valve 2 Material Valve Ratio Option 1 Installed 0 Not installed Blowback Option 1 Installed 0 Not installed SECTION Maintenance Preventative maintenance checklist 5 2 s et so gt et
32. ed Optional ControlMate Pendant The optional ControlMate pendant is used with either the ELC M or ELC 16 control modules for increased control functionality ratio layering ratio percent age unload time load attempts blowback pulses purge and load time along with enabling disabling of the ControlMate and its associated loader or receiver 5 6 in 141 1 mm GontrolMate Pendant Cradle An optional surface mountable docking cradle is available for the ControlMate pendant The cradle can be mounted to any vertical or horizontal surface by TE re using M3 flat head mounting screws 44 5 mm 88 9 mm A cable clip on the control cradle keeps the ControlMate s communication cable up and out of the way for neat installa MS screw hole tion It can also be used for a permanent communication cable location when the GontrolMate is being used elsewhere 1 75 in 44 5 mm 1 2 in 30 6 mm 2 9 in 72 5 mm TPC052 0108 Description 2 5 Specifications Easy Loading Control ELC continued Pump Control ELC 16 Only The ELC 16 pump control provides power and communications to all the ELC 16 controls within the CAN open system via a 4 conductor trunk cable The pump control also provides the start signal to the vacuum pump used in the conveying process in the ELC 16 system Cord grips are provided to allow interconnection with the ELC 16 system s trunk cable dust collector and idle mode valve co
33. endant Operation only user changeable set ting that does not require additional hardware The settings in User Level 2 of the ControlMate pendant are configured to match your associated loader receiver operation features To access User Level 2 settings 1 Press the Function button down for 5 seconds A three digit number will appear displaying the first option of User Level 2 The first number will be En Option Activated 1 the option number then a decimal point followed by a zero and then either Deactivated 0 the digit one or zero The last digit represents whether the option has been activated 0 signifies that the option is not activated and 1 indicates that it has been activated Each function will have a corresponding number 1 8 2 Use the Function button to scroll through the user level options There are eight functions in User Level 2 priority demand demand sensor logic fill sensor logic fill sensor present load and hold purge APV option installed ratio option installed and blowback option installed 3 Use the or buttons to activate or deactivate the options setting If no changes have been made the ControlMate will return to the User Level 1 default screen after 30 seconds Oo ge ap v A User Level 2 Readout User Level 2 Adjustment Buttons Function Button Operation 4 21 4 22 Operation User Level 2 Settings for th
34. epeat above steps for all junction boxes within your CAN open network AN CAUTION Always dis connect and lock out the main power sources before making electrical connections Electrical connections should be made only by a qualified electrical technician 1 Installation 3 13 Connecting the Trunk Cable Termination Resistor ELc 16 oniy AN CAUTION Always dis While laying out the trunk cable to each individual junction box you will need to connect and lock out terminate the trunk cable line Depending on your individual layout the trunk the main power sources cable may terminate from either the left or right side of the junction box A trunk before making electrical cable termination resistor is used to end the CAN open network s communications connections Electrical when there are 16 or less junction boxes in use connections should be made only by a qualified electrical technician To terminate the trunk cable using the termination resistor 1 Remove the junction box cover by unscrewing the four 4 retaining screws that secure the cover with an appropriately sized screwdriver If not previously removed during junction box mounting 2 Unscrew and remove the left or right depending on trunk cable routing black strain relief counterclockwise and remove the inner mount fitting from inside the junction box Inner Mount Fitting 3 14 Installation continued Connecting the Trunk Cable Termination R
35. esistor ELc 16 oniy continued 3 Thread the termination resistor s two 2 wires through the knock out AN GAUTION Always dis hole on the side of the junction box connect and lock out the main power sources before making electrical connections Electrical connections should be made only by a gualified electrical technician de fa D 4 Hold the termination resistor in place while screwing on the inner mount fitting ensuring to thread the two 2 resistor wires through the inner mount fitting before tightening continued Installation 3 15 Connecting the Trunk Cable Termination Resistor ELc 16 oniy continued AN CAUTION Always dis 5 Connect the termination resistor wiring to only the BLUE and connect and lock out WHITE terminals by using an appropriately sized screwdriver or the main power sources similar See Installation section entitled Wiring the ELC 16 Control before making electrical Junction Boxes Depending on your cable routing the resistor may need connections Electrical to be wired at the top row of terminals for resistors that are placed on the connections should be left side of the junction box or at the bottom row for resistors that are made only by a qualified placed on the right side of the junction box electrical technician a ay du E Bip ik Bo P gt 4 vo Top Row Terminals Bottom Row Terminals T ie e rd Ad Red B
36. g Retaining Screws 4 continued Installation 3 11 Wiring the ELC 16 Control Junction BOXES ELc 16 Only continued AN CAUTION Always dis 3 Unscrew the left or right depending on trunk cable routing black connect and lock out strain relief counterclockwise Thread the trunk cable through the the main power sources detached section of the strain relief before making electrical connections Electrical connections should be made only by a qualified electrical technician 4 Thread the trunk cable through into the junction box ensuring not to insert the cable too far into the junction box Reattach and tighten the removed strain relief continued 3 12 Installation Wiring the ELC 16 Control Junction BOXES ELc 16 Only continued 5 Connect the individual trunk cables to the terminal block using an appropriately sized screwdriver or similar Each terminal block within the junction box is color coded to correspond to the supplied trunk cable wire Except the trunk cable ground wire which will be connected to the yellow terminal There are five 5 terminals for the trunk cable Trunk cables entering from the right will need to be inserted into the bottom row of terminals Trunk cables entering from the left will need to be inserted into the top row of terminals Top Row Terminals Bottom Row Terminals Red Black Blue White Yellow 6 Replace the junction box cover tighten retaining screws 7 R
37. hat will illuminate when adjustments are made User Level 2 parameters will also be in the order that they appear but will not have a corresponding LED Only a three digit number will appear on the ControlMate s digital display See Operation section entitled User Level 2 Settings for the ControlMate Pendant On Off model dependent 3 120 sec Load attempts before alarm Ratio percentage Oors 100 o 3 Purge ime 0 Ma0see o ooo o n 0 10 counts User level 2 is accessed by holding the Function button down for five seconds Description Rage Defaul __ User Level Priority demand Se 0O 2 Demand sensor logic SS NOTE 0 off and Fill sensor logic 1 Purge valve on for Fill sensor present ol o f 2 ee EE Load and holdt Ca a Ti Eed ae Purge Material valve Purger 2E tion installed option installed parameter Ratio option installed 2 APV Blowback option installed APPLICATION NOTES Only visible when activated by altering the setting in User Level 2 t User must have a positive discharge loader or receiver to use this function which can be acti vated through altering this setting in User Level 2 Operation 4 9 D 4 10 NOTE If the ControlMate is deactivated the loader receiver will not function until it is enabled however if the ControlMate pendant is not available cycle the standard ELC control module s power to enable the loader receiver NOTE Power will remain
38. ing the electrical enclosure or performing non standard operating procedures such as routine maintenance Only qualified personnel should perform troubleshooting procedures that require access to the electrical enclosure while power is on SECTION Description z What is the Easy Loading Control ELC 2 2 E Typical applications 0 2 2 HOW ML WOKS ig yd ae Hee eee OR Gate ko Yas 2 3 specifications Easy Loading Control ELC 2 4 Optional ControlMate pendant 2 5 PUMD CORTON n sy vs i Gee Re OD De ee oe 2 6 2 2 Description What is the Easy Loading Control ELC Conair s Easy Loading Control ELC provides users with individual controls at each loader or receiver to allow for specific material and conveying requirements Two models are available e ELC M Used to operate a single self contained loader e ELC 16 Used over a CAN open network for receiver material demand Up to sixteen ELC 16 controls can be connected to the CAN open network Typical Applications e ELC M Self contained unit mounted to a single loader for stand alone applications such as filling a large hopper or surge bin e Up to 16 ELC 16 Controls mounted to individual receivers communicating over a CAN open network for multiple hopper material filling or conveying applications How it works ELC M Control A signal from the loader s demand switch indicates to the ELC M on the loader that it requires m
39. inside the electrical enclosure 1 Connect the ground cable lead from individual ELC 16 junction boxes to a structurally grounded physical earth source Installation 3 3 Wiring Considerations AN WARNING Improper installation may result in equipment damage or personal injury 1 Disconnect and lock out the main power supply to equipment in the conveying system before attempting to wire power and communication cables between the ELC control loader receivers junction boxes pumps dust collectors and material valves 2 Install all wiring disconnects and fuses in accordance with electrical codes in your region All electrical installations should be completed only by qualified electrical technician 3 Always refer to the wiring diagrams supplied with your control before making electrical connections The diagrams show the most accurate electrical component information 4 Protect communication cables from sources of static electricity and electrical noise O Use shielded cable or run wire through a contiguous metal con duit or wireway Failure to use a metal shield can expose the con trols to static electricity which can damage electronic components O Do not run communication cables near material lines and hoses which produce large amounts of static electricity when conveying material O Keep communication cables at least 5 ft 1 5 m from electric motors transformers rectifiers arc welders generators induction fu
40. ion entitled left of the Function button to activate or deactivate the ControlMate ControlMate Pendant Operation pendant and the ELC s loader receiver Pressing the button will acti vate the ControlMate Pendant and a 1 will be displayed in the Adjustment Readout pressing the button will deactivate the pendant and a 0 will be displayed Hopper Loading with Positive Discharge Option How it Works Loaders receivers equipped with positive discharge valves operate exactly as other loaders receivers however instead of having a simple gravity discharge amp D NOTE When using the Load Hold function of the GontrolMate pendant you must use a positive discharge valve flapper valve its valve is driven open by an air cylinder linked to its flapper The time of the discharge valve open cycle is controlled by the Unload Time setting adjustable only with the ControlMate pendant Positive discharge valves require remote demand sensors which sense the level of material within a hopper A rotary switch can be used that has a motor driven paddle that when stopped by material indicates a full hopper However when the paddle is able to move freely it signals the loader receiver that there is a demand for material and signals the controller to load Rotary switches are amp S NOTE To adjust the duration equipped with long shafts to allow the paddle to be located far enough below of unload time when using a
41. lack Blue White Yellow Left side termination resistor connection 3 16 Installation Mounting the ELC ControlMate Pendant optional The optional ControlMate pendant can be remotely mounted with an optional surface mountable docking cradle for quick and easy retrieval Be sure to locate the control within the length of the supplied remote control cabling 10 ft 3 05 m and route the cable away from hot surfaces or moving parts A cable clip on the control cradle keeps the ControlMate s communication cable up and out of the way for neat installation It can also be used for a permanent communication cable location when the ControlMate is being used elsewhere 1 75 in 1 75 in 3 5 in 44 5 mm 44 5 mm 88 9 mm 1 2 in 30 6 mm M3 screw hole 2 9 in 72 5 mm Installation 3 17 3 18 Installation Connecting the ELC 16 Control to the Junction Box Drop Cable The ELC 16 must be connected to the junction box drop cable via a 5 pin connector to receive power and communications To connect the 5 pin connector from the junction box drop cable to the ELC 16 control 1 Push the drop cable connector into the 5 pin receptacle on the ELC 16 Turn the connector fitting clockwise hand tighten Powering the Pump Control The pump control has built in toggle switches for both main power and a 4 amp circuit breaker located at the bottom right of the front panel Conair recommends amp S NOTE
42. lumi nated 6 10 Troubleshooting Possible cause No demand signal on the CAN open network There is no communication between the ELC 16 and the pump control The pump control does not have power The pump control s circuit breaker has been tripped Solution Check all ELC 16 connections See Installation section entitled Connecting the ELC 16 Control Junction Boxes and Wiring the ELC 16 Pump Control Turn on the power to the pump control See Installation section entitled Powering the Pump Control Reset the pump control s circuit breaker See Installation section entitled Powering the Pump Control We re Here to Help Conair has made the largest investment in customer support in the plastics indus try Our service experts are available to help with any problem you might have installing and operating your equipment Your Conair sales representative also can help analyze the nature of your problem assuring that it did not result from misapplication or improper use How to Contact Customer Service To contact Customer Service personnel call CONAIR N 24 noua DAY 7 DAYS A WEEK p INTERNATIONAL Q NOTE Normal operating hours are 8 00 am 5 00 pm EST After hours emergency service is available at the same phone number You can commission Conair service personnel to provide on site service by contacting the Customer Service Department Before You Call If you do have a problem please
43. matically return to its default Power on screen after 30 seconds Operation 4 13 QD NOTE Careful examination of your material s unique flow characteristics and conveying distances will aid in adjusting for proper ratio percentage settings S NOTE The ratio setting is altered using percentage amounts of total load time IMPORTANT Any adjustments made with the ControlMate pendant will not take effect until the loader receiver starts a new loading cycle 4 14 Operation GontrolMate Pendant Operation continued Adjusting Ratio Percentage D NOTE Activating and altering this setting is possible only through the optional ControlMate pendant See Operation Section entitled ControlMate Pendant Operation Ratio percentage and ratio layering parameters will need to be altered when operation of a ratio valve is required Ratio Percentage is a percentage of load time For example If your loader or receiver has a 20 second load time and your ratio percentage is set at 25 the regrind load time will be 5 seconds of regrind material and 15 seconds of virgin material Adjustment Readout Ratio Percentage LED Function Button Increase and Decrease Increment Buttons To adjust Ratio Percentage 1 Press the Function button until the Ratio Percentage LED is illuminated 2 Use the and buttons to the left of the Function button to increase or decrease the ratio percentage Holding down th
44. mends using this receptical as a power source for the ELC M control See your particular loader manual for information Installation Connecting Main Power to the ELC M Control The ELC M loading controls are self contained and operate a single loader This loading control is not used on a CAN open network and is wired to provide its own power to the vacuum motor on top of the loader to receive material When ordered from Conair the loader s specific conveying functions will be pre wired to communicate with the ELC M AN CAUTION Always disconnect and lock out the main power sources before making electrical connections Electrical connections should be made only by qualified personnel To connect power to the ELC M and its associated loader 1 Plug the loader s power cable to the female receptical on the ELC M ELC M Female Receptical 2 Connect the ELC M s power cable plug to an appropriate power source ELC M Power Cable Plug Wiring the ELC 16 Pump Control ELC 16 Only AN CAUTION Always disconnect and lock out the main power sources before making electrical connections Electrical connections should be made only by a gualified electrical technician The ELC 16 pump control provides power and communications to all of the ELC 16 controls within the CAN open system via a 4 conductor trunk cable The pump con AN trol also provides the start signal to the vacuum pump used in the conveying process IMPORT
45. mp to start conveying material to its hopper or surge bin When the ELC 16 is used the loading sequence is started the same as the ELC M However instead of signaling a vacuum motor located on the actual loader to start the loading process the control s demand for material will be added to the pump control s queue On its turn the vacuum pump will convey material to the individual receiver On a loader receiver there is a material flapper integrated into the gravity dis charge valve located at the bottom of the loader receiver that will trigger the demand switch During operation the flapper will be held shut by its own counterweight which will signal the ELC that there is a demand for material and will start a loading cycle Standard demand switches are a reed type that magnetically interact with a small magnet located on the flapper weld ment As the magnet approaches the switch it will close providing a demand signal i SS NOTE If your loader After discharging material into the vessel below the cycle may repeat or the receiver has a capacitance sensor refer to the loader discharge flapper may become lodged open with material If the flapper clos ee eae es the cycle will repeat If the flapper is held open by the material this is an adjustment procedures indication that there is no need for another load cycle and the loader receiver will then wait until the material level falls and the flapper closes again causing
46. n network The ELC 16 control uses First In First Out FIFO for receiver demand The FIFO setting works within your CAN open network and will allow the receiver that demanded material first to receive it first For example if there are four 4 receivers in a series that have demands for material but the third receiver demanded material first regardless of the receiver s physi cal location on the CAN open network it will be provided with material TPO Description 2 3 Uu0ndi2sag 2 2 4 Specifications Easy Loading Control ELC 3 in 76 2 mm M5 Tapped MODELS ELC M ELC 16 Supply voltage 115VAC 60Hz 230VAC 50 60Hz 24VDC from pump control Fai a wage ba a Ee 230VAC 60Hz p pply g l A tf le slack at each loadi AOOVAC 50Hz ccount for reasonable slack at each loading station for connections cable routing etc AGOVAG 6OHZ EE n dedi Control dimensions inches mm unction boxes must be provided to connect between the system trunk cable and each ELC 16 control 6 0 152 4 6 0 152 4 ie ek 2 9 73 0 2 9 73 0 Control weight Ib kg Installed 7 6 3 4 7 6 3 4 Shipping 9 1 4 1 9 1 3 4 SPECIFICATION NOTES The ELC 16 system trunk cable is a 4 conductor shielded cable with two twisted pairs Specifications can change without notice Check with a Conair representative for the most current information TPC052 0108 Description Specifications Easy Loading Control ELC continu
47. nair in writing of any claim and provide a customer receipt and other evidence that a claim is being made Warranty Limitations Except for the Equipment Guarantee and Performance Warranty stated above Conair disclaims all other warranties with respect to the equipment express or implied arising by operation of law course of dealing usage of trade or otherwise including but not limited to the implied warranties of merchantability and fitness for a particular purpose ELC Circuit Board Connections AN CAUTION Always disconnect and lock out the main power sources before accessing the ELC s internal connections Electrical connections should be made only by qualified personnel Loaders Receivers that have purge valves added in the field require internal wiring from the ELC control to the purge valve Internal access to the ELC s circuit board is required for installing and wiring the purge valve To access the ELC s internal circuit board 1 Unplug the loader s receiver s power supply and remove its compressed air source 2 Remove the four 4 screws that secure the ELC s front cover with an appropriately sized Allen wrench Allen Wrench Screws 4 continued Appendix B 1 AN CAUTION Always disconnect and lock out the main power sources before accessing the ELC s internal connections Electrical connections should be made only by qualified per sonnel B 2 Appendix ELC Circuit Board Connections
48. needs 4 4 Operation ELC Loading Control Operation continued Alarm Acknowledgement Audible Alarm Horn Alarm Acknowledgement Load Time Adjustment To silence the audible alarm horn 1 Press the Alarm Acknowledge button located to the left of the Load Time Adjustment or buttons Failure to correct the cause of the alarm will result in the the alarm reoccurring until the problem is corrected See the Troubleshooting section to diagnose the possible cause of an alarm A OD v A 5 amp Q NOTE Silencing of any alarm condition can also be done by pressing the Function button on the optional ControlMate pendant See Operation section entitled ControlMate pendant LED Descriptions Operation 4 5 ELC Loading Control Operation continued AN GAUTION Always disconnect and lock out the main power sources before accessing the ELC s internal connections Electrical connections should be made only by qualified personnel Using Blowback Loaders receivers equipped with blowback functionality use air pulses to clean their internal filter Internal jumpers on the ELC s control board are set to acti vate three blowback pulses as standard These jumpers can be configured to active one to seven pulses by removing or relocating the jumpers However when blowback is accessed through the optional ControlMate pendant it is pos sible to override the internal setting of the blowback jum
49. nnections The pump control enclosure is equipped with wall mounting accommodations and can be mounted to a flat surface using the supplied mounting holes The pump control should be located so access to its switches and viewing of its lights are not obstructed 0 31 in 7 92 mm e 10 0 in 254 0 mm 11 5 in 292 1 mm is lt 6 0 in j 152 4 mm TPC052 0108 8 0 in 203 2 mm 10 9 in J 277 7 mm 2 6 Description SECTION Installation Unpacking the boxes 3 2 Preparing for installation 3 3 Wiring considerations 3 4 Sy Mounting the ELC control 3 5 Connecting main power to the ELC M control 3 6 Wiring the ELC 16 pump control 3 7 ELC 16 control junction boxes 3 9 Mounting the ELC 16 control junction boxes 3 10 Connecting the junction box ground wire 3 10 Wiring the ELC 16 control junction boxes 3 11 Connecting the trunk cable termination ies tol 44 224 05 e405 9 04 ee e528 2 3 14 Mounting the ELC ControlMate pendant optional 3 17 Connecting the ELC 16 control to the junction Do Grop BAble soe gore BR Gee RE EG 3 18 Powering the pump control 3 19 Powering the ELC control 3 20 Installation 3 1 3 2 Installation Unpacking the Boxes The Easy Loading Control ELC comes
50. ntrol panel layout 4 2 ELC loading control operation 0 0 0 cee eee eee 4 3 BASIC OD rI Oe EE EE EE EE EE EE EE EE EE EE esata EE 4 3 Load time adjustment 0c ccc cece eee eee 4 4 Alarm acknowledgement 0 000 cee eens 4 5 USING DIOWBAEK sos ESE ER DEER EERDER DEER DERE RR 4 6 ControlMate pendant LED descriptions 05 4 8 Connecting the ControlMate pendant 08 4 10 Enabling disabling the ControlMate pendant 4 11 Hopper loading with positive discharge option 4 11 Adjusting unload time 0 Es EE EE ee Ee ee eee 4 12 Adjusting the number of load attempts before an alarm 4 13 Adjusting ratio percentage 0 0 ccc eee 4 14 Adj sting rato laye S esses dna rini aie whee ead EE DE ea 4 15 Using purge operation 0 0 ccc eee 4 16 Adjtistifig load me EE SR EE ee deen aerate 4 18 User level 2 settings for the ControlMate pendant 4 21 5 1 Maintenance ii Table of Contents Preventative maintenance checklist 000e000e 5 2 6 1 Troubleshooting Before DEGINNING iis os ed edd a a es ed A we we wk Se 6 2 A few words of caution EE EE Ee Ee Ee se ge se ee 6 3 DIAGNOSTICS Troubleshooting ELC M control sees ee ee se es eee 6 4 Troubleshooting ELC 16 control ese ee ee ee eee 6 6 Troubleshooting optional ControlMate pendant and pump control
51. owback quantity change to take affect Operation 4 7 4 8 Operation ControlMate Pendant LED Descriptions Ratio Layers LED Illuminates when the ratio layers adjustment is selected Settings will be displayed in the digital readout Ratio Percentage LED Illuminates when the ratio percentage adjustment is selected Settings will be dis played in the digital readout Purge Time LED Illuminates when the purge time adjustment is selected Settings will be displayed in the digital readout Increment Decrement buttons The increment decrement buttons are used in conjunc tion with the Function but ton to alter conveying param eters Press the Function button until the correspon ding conveying parameter LED is illuminated then use the increment decrement but tons and to change their settings Communications Interface Connection terminal for commu nications between the ELC and ControlMate pendant Function button Used to scroll through all the ControlMate s convey ing parameter selections Corresponding LED indica tors will illuminate when a parameter is selected The Function button can also be used to acknowledge alarm conditions Load Time LED I luminates when the load time adjustment is selected Settings will be displayed in the digital readout Blowback LED Illuminates when the blowback adjustment is selected Settings will be displayed in
52. pers in favor of the amount set using the pendant To manually adjust the blowback setting of the ELC 1 Remove the incoming power to the ELC control 2 Remove the four 4 screws that secure the ELC M s front cover with an appropriately sized Allen Wrench Allen Wrench Screws 4 continued 4 6 Operation ELC Loading Control Operation continued Using Blowback 3 Remove the ELC control cover and place it along side the control box AN CAUTION Always disconnect and lock out the main power sources before accessing the ELC s internal connections Electrical connections should be made only by qualified per sonnel SS NOTE The number of blowback pulses depends on the total unload time Jumpers 3 amp S NOTE To increase the number of blowback puls es total unload time must be extended 5 Remove corresponding jumpers to equal the amount of blowback pulses to be used Each jumper adds or removes a number of blowback pulses SS NOTE Depending upon The range of blowback is one to seven pulses depending on the configura loader receiver model the ELC s default settings may not allow the maximum number of blowback represent 4 2 1 pulses tion and amount of jumpers used For example the jumper switches in the picture above are labeled with the number of blowback pulses they 6 Re assemble the ELC control by following steps 1 3 in reverse order 7 Cycle the ELC s power for the bl
53. r valve operation 3 Reapply main power and reconnect compressed air source
54. rcuit Board Connections and Control Board Diagram and Appendix C entitled Purge Valve Wiring Connections for instructions to connect the ELC control to the purge valve RY aww la Z TT 2 ET Q O j po Z G EE C O Bi g G Sy Q Gp API 5 AMS Purge Valve Purge valve example shown continued GontrolMate Pendant Operation continued Using Purge Operation continued Adjustment Readout YQ NOTE When using purge the ratio layer settings will default to one 1 One layer of virgin material and one layer of regrind material regardless of Purge Time the ratio percentage setting LED Function Button IMPORTANT Any adjustments made with the ControlMate pendant will not take effect until the loader receiver starts a new loading cycle Increase and Decrease Increment Buttons O D 5 A Oo To adjust the duration of Purge Time 1 Press the Function button until the Purge Time LED is illuminated 2 Use the and buttons to the left of the Function button to increase or decrease the Purge Time duration Holding down the or buttons will cause the number to ramp up or down at a faster rate The purge time range is 0 120 seconds Changes will be displayed in the ControlMate s three digit adjustment readout display 3 The control will automatically return to its default Power on screen after 30 seconds Operation 4 17 AQ NO
55. reaker To turn on and activate either ELC control 1 Push the toggle switch to the On or Reset position The ELC 16 switch will illuminate green and the ELC M switch will illuminate amber ELC M Power Toggle Switch ELC 16 Power Toggle Switch Circuit Breaker Power and Communications Terminal To reset the ELC 16 circuit breaker 1 Push the circuit breaker toggle switch that is located to the right of the power toggle switch ELC 16 Power Toggle Switch Circuit Breaker 3 20 Installation SECTION Operation Easy Loading Control Control panel layout 4 2 ELC loading control operation 4 3 Basic operation iis ET ee eee eee as 4 3 Load time adjustment 4 4 Alarm acknowledgement 4 5 Using blowback 4 6 ControlMate pendant LED descriptions 4 8 ControlMate pendant operation 4 9 Connecting the ControlMate pendant 4 10 Enabling disabling the ControlMate pendafi si s42 Ms DRR Re ee a ees 4 11 o Hopper loading with positive discharge S A OBLOR 2 2 AA bad Ge ea 4 11 S Adjusting unload time 4 12 Adjusting the number of load attempts before an alarm 4 13 Adjusting ratio percentage 4 14 Adjusting ratio layers 4 15 Using purge operation 4 16 Adjusting load time 4 18 Using blowback 4 19 User level 2 settings for the ControlMate
56. receiver body the load time should be set slightly higher than your typical load time due to the fill sensor terminating the loading cycle once it detects material A correctly adjusted fill sensor will automatically opti mize your loading cycles The ELC control will signal an alarm if the fill sensor does not see any material by the time the load time setting expires TIP To avoid nuisance alarms set the load time duration higher than the duration it takes to satisfy the fill sensor ControlMate Pendant Operation continued Using Blowback D NOTE Activating and altering this setting is possible only through the optional ControlMate pendant See Operation Section entitled ControlMate Pendant Operation Loaders receivers equipped with blowback function use air pulses to clean their internal filter Internal jumpers on the ELC s control board are set to activate three blowback pulses as standard These jumpers can be configured to active one to seven pulses by removing or relocating the jumpers However when blowback is accessed through the optional ControlMate pendant it is possible to override the internal setting of the blowback jumpers in favor of the amount set using the pendant See Operation section entitled ELC Loading Control Operation Using BlowBack SS NOTE One blowback cycle is 1 5 seconds 0 5 second pulse followed by 1 second off The amount of blow back pulses is limited to the total amount of unload
57. rnaces and sources of microwave radiation O Avoid running communication cable across power feed lines If you must run the cable across power feed lines run the cable at right 90 degree angles to the lines Keep the cable at least 6 in 15 2 cm from AC power lines of less than 20 A 1 ft 30 5 cm from lines of 20A to 100 kVA and 2 ft 60 9 cm from lines of 100 kVA or more 5 Always maintain a safe ground Follow the safe grounding proce dures in the wiring diagram package Ground the shielded cable inside the Input Output enclosure only 6 Do not operate the equipment at power levels other than those ified on the th i t data plate 3 4 Installation specitied on the the equipment data plate Mounting the ELC Control All ELCs are directly mounted to their respective loader or receiver from Conair Follow the user manual that is supplied with your loader or receiver for proper mounting procedures to your hopper or vessel ZN CAUTION Controls mounted to the loader receiver are NOT intended to be used as a handle to lift the loader receiver or to provide bal ance assistance to users during maintenance etc Doing so could result in seri ous injury or damage to the equipment T ek D Z Access Loader with ELC M standard Access Receiver with ELC 16 optional Installation 3 5 TIP Some Conair loader mod 3 6 els will have a convenience receptical already installed Conair recom
58. rom the hopper or vessel to a well lit work area for this conversion Remove the four 4 screws that secure the ELC s front cover with an appropriately sized Allen wrench See Appendix B entitled ELC Circuit Board Connections Connect the purge valve cable 10765507 to the Purge connection port on the ELC s circuit board See Appendix B entitled ELC Circuit Board Connections Control Board Diagram Route the cable through the wiring ports located on the side of the ELC Remove one of the cabling plugs and secure the cable with an appropriately sized strain relief included Close the ELC s control front cover and secure the four 4 bolts after all internal connections have been made See Appendix B entitled ELC Circuit Board Connections To connect the purge valve cable to customer supplied cable extension 1 Connect the wire end of the purge valve cable 10765507 to the customer supplied cable extension of your purge valve The purge valve cable will have a male and female connection inline for ease of servicing and wiring The purge valve cable is labeled as follows red wire is 24 VDC white is purge output and green is ground Refer to the wiring diagrams that were shipped with your purge material valve for the proper wiring procedures of the cable extension to the purge material valve It is necessary to determine the correct termination points for the supplied wiring harness of your purge material valve for prope
59. the flapper to engage the reed switch that will signal for another loading cycle Operation 4 3 ELC Loading Control Operation continued Load Time Adjustment When using single material hopper loading only the load time can be changed See your loader receiver manual for recommended load time duration settings SS NOTE The ELC loading Load time settings can be changed by using the or buttons located on the control s default load time ELC The control s load time should be adequate enough to just fill the loader eager esi model receiver Using too long of a load time will cause unnecessary material to clog dependent and will be set by Conair the conveying inlet tubes to the loader or receiver amp NOTE The use of the and buttons represents the addition or subtraction of load time in one second increments Holding down the or buttons will cause the load time to ramp up or down ata faster rate Alarm Acknowledgement Load Time Adjustment NOTE Cycling the ELC s To adjust Load Time power will enable the loader receiver if it was 1 Use the and buttons to the right of the Alarm Acknowledgment disabled with the optional button to increase or decrease the amount of load time in one second GontrolMate pendant increments 2 Adjust the load time through trial and error Several adjustments may be needed to optimize your particular conveying
60. tically return to its default Power on screen after 30 seconds Operation GontrolMate Pendant Operation continued Adjusting the Number of Load Attempts Before an Alarm Adjustment Readout Load Attempts LED Increase and Function Button Decrease Increment Buttons D NOTE Activating and altering CD a gt this setting is possible only se through the optional On initial start up and fill up of your vessel the Load Attempts setting will be ControlMate pendant See ignored Only after the initial fill up will the Load Attempts setting be used by Operation Section entitled the control However if you are using the loader receiver to convey regrind ControlMate Pendant Operation from a granulator setting the Load Attempts to 0 will allow unlimited load attempts to avoid nuisance alarms To adjust the number of Load Attempts IMPORTANT Any adjustments made with the ControlMate 1 Press the Function button until the Load Attempts LED is illuminated pendant will not take effect until the loader receiver starts 2 Use the and buttons to the left of the Function button to a new loading cycle increase or decrease the amount of Load Attempts Holding down the or buttons will cause the number to ramp up or down at a faster rate The range is O 50 attempts Changes will be displayed in the ControlMate s three digit adjustment readout display 3 The control will auto
61. wer but is not communicat ing with the ELC control No heartbeat Replacement ControlMate communication cables are available from Conair Contact Conair Parts 800 458 1960 From outside of the United States call 814 437 6861 The pump control s Demand LED is not illu minated Possible cause The ControlMate communication cable is damaged CAN open network is not commu nicating with the ELC 16 control Junction box connections are loose or detached No demand signal on the CAN open network There is no communication between the ELC 16 and the pump control The pump control does not have power The pump control s circuit breaker has been tripped Solution Replace damaged ControlMate communication cable Check junction box connections See Installation section entitled Wiring the ELC 16 Control Junction Boxes WARNING Any electrical checks should be performed by a qualified electrician Check all ELC 16 connections See Installation section entitled Connecting the ELC 16 Control Junction Boxes and Wiring the ELC 16 Pump Control Turn on the power to the pump control See Installation section entitled Powering the Pump Control Reset the pump control s circuit breaker See Installation section entitled Powering the Pump Control Troubleshooting 6 9 Troubleshooting Optional ControlMate Pendant and Pump Control Problem The pump control s Load LED is not il
62. y static electricity that may occur from nearby conveying lines To connect the junction box ground wire 1 Connect the green ground wire to a structural ground typically a steel beam or similar using an appropriate screw or bolt Ground Cable Wiring the ELC 16 Control Junction BOXES ELc 16 only Carefully lay out the path of the 4 conductor trunk cable from the pump control AN CAUTION Always to each junction box and its associated receiver See Installation section entitled disconnect and lock out Wiring the ELC 16 Pump Control If you must run the cable across power feed the main power sources lines run the cable at right 90 degree angles to the lines This will minimize the before making electrical amount of noise on the ELC 16 CAN open network connections Electrical connections should be The ELC 16 system utilizes low voltage signals 24 VDC to communicate made only by a qualified between ELC loading controls and the pump control electrical technician amp NOTE Install the ELC 16 with wiring as appropriate for your local and industrial electrical codes To connect individual junction boxes 5 dp D 0 Et O 1 Mount the junction box in the desired location Ensure proper wiring support between junction boxes 2 Remove the junction box cover by unscrewing the four 4 retaining screws that secure the cover with an appropriately sized screwdriver If not previously removed during junction box mountin

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