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WCC-CCS-4000 - MacNeil Wash Systems

1. 15 16 Relay 16 5 7 View Input Terminals cere re pen bu i 16 OVEA 17 17 10 Ghaf e sollware Passworas ig 17 O WasHhi SeliuiDu uuu Gum asuaka E aa 18 6 IModilvina Wasi Setup 18 Page numbers CCS4000 Software Manual Appendix 20 E 418 mir a Savers nae 20 2 ni 20 AS 20 POA WDD CE Ve u 21 FANE ay A WILK 22002552 2516 21 15829 011611 Butt
2. ERE 22 22 U 23 FAS ese 112525 455 22220258 23 uman 23 za a i unuman a a 24 ATZ 25 BUON BOX tt Pe 25 PAA Prep GU ages a a 25 Appendix B Qulput Reference iii 20 56100085 0000 50021560 0000 56 08061 88 26 P EA 26 P 2 2 u 12584420 Aa 26 Front 27 TOD BUSA roenn a ia a sates salina ys tg ama 28 B9 Double 5 i 29 6 Puls
3. 54000 is state of the art tunnel controller capable of multiple output functions Using a standard PLC the whole vehicle is mapped The front back tires as well as the windshield and truck bed values are entered into seperate shift registers This allows the controller to perform all wash functions and retracts independent of operator input The features include a remote HMI display showing wash status input states and overrides In addition a television remote is used for data entry allowing function overrides tunnel reset and input overrides without having to open the high voltage cabinet A P C Is required to program the wash but is not necessary to operate the wash controller Hardware Main panel disconnect switch depress button on top with screw driver to defeat interlock 24 120 AC control transformer power indicator on front panel HMI display Estop disrupts 120V to PLC Override key switch panel serial ee ee amp Maintenance Guide Laptop power outlet Main panel high voltage fuses High voltage control transformer fuses Adjustable motor overloads Motor contactors 4 2 Pesa z lez 24V DC power supply status LED 4 output relay circuit board status LED 10amp Double Pole 24V DC opto isolated output relay outputs
4. 11 22 2 11 Input Se 05 11 OT AIP UTNE NG PT 11 43 2 1618 i i uuu um 12 MNS chee 555554 12 2 24 1 0 12111111 342216 m tasu Sua sam tua isa a 12 4 5 13 4 6 Getting the Program From the 13 A samma a es at 13 4 8 Reverting to Last Saved Settings 13 AO SOT GS AI 13 2104 taa bla 13 B Diagnosti s ana 15 ST o a sas 15 AUO DUIS 15 DO MOSEL NUNN GS m saya 15 S VIEW Wasti Stats ii 25 a
5. MC Os KE A 634 is RS 1000 EXTEND SOLENOID MACNEIL WASH SYS Page numbers CCS4000 Software Manual Table of Contents 1 Instructions 55 24 156 2 05502 2400 81 08010850 0 8 54002220 008105 60440800 04004 056 6090 3 Tt 3 1 2 Floppy Installation Windows 3 3 1 3 Floppy Installation Windows TM 95 98 2000 3 1 4 CD Installation Windows 95 98 2000 3 2 Getlin Started G ld oxu abu 08 e 56615200 504084 2 66254255 03 162 568242432024128 4 2 Opening th Sotware Windows TM 971 u uu y a 4 2 2 Opening the Software Windows 95 98 2000 4 2 3 eC a 5 250 MENU BG ha nya f 5 FUNDE VEW 5 PEARS 5 ATO iets esau eis pee eather alco ec at 6 2010 4 9 AVC eo ianiuaces
6. the Power Pack output will automatically start when a menu 15 selected through a Menu input This is needed in an unattended tunnel to start the wash Example Wire the Power Pack motor starter to output relay 32 Set output 32 to a Power Pack output type Set the Shut Off Distance to 1320 inches 110 feet for a 100 foot conveyor Set the Power Surge value to 15 to delay any other outputs from coming on until this one has had 1 5 seconds to get the motor up to speed B 10 Roller Gate The Roller Gate output controls the roller up function of the conveyor Values Open Distance 1 The first Open Distance value determines how many inches of conveyor travel the roller gate must be open to call up rollers For a front wheel pull conveyor this should be set to the roller spacing of the chain so that only one roller will come up With a rear wheel push conveyor the Open Distance should be set to double the roller spacing so two rollers will be called and the Closed Distance and second Open Distance should be set to zero Closed Distance The Closed Distance controls in inches how long the gate should be closed before the safety roller is called on a Front Wheel Pull conveyor Open Distance 27 The second Open Distance value determines how many inches of conveyor travel the roller gate must be open to call up the second roller for a front wheel pull conveyor Like the first Open Distance this should be approximately the same as the roller
7. then go to section 1 troubleshooting DC power supply Observe the LED on the receiver The green one indicates power The yellow one indicates signal strength alignment If no green light is observed follow the procedure outlined in servicing the emitter If the green light is on but no yellow light re aim the photo cells according to the procedure outlined in the Beam tracker instruction sheet no yellow LED is on after checking alignment replace the receiver If input fails to turn off check the wiring to the CCS4000 for a short The black wire from the receiver should go to IP 01 or IP 02 depending if you are working on the upper or lower photo cell Input will not turn on This usually indicates a shorted receiver Check wiring to the photo cell for shorting Replace the photo cell receiver Under certain conditions the receiver can become washed out by a strong infrared light source causing the input not to turned on You can change the position of the receiver from left to right or try blocking the offending light source Button box The button box will allow the PLC to accept 32 different wash packages The connections to the PLC are usually 11 to RO IP 12 to IP 13 CO 14 to IP 15 to C2 When buttons are pressed IP 11 and 12 are lit on the PLC Refer to the wiring diagram for the correct wiring of the button box The virtual inputs can be checked by pluging your laptop into the PLC the sof
8. a edd 7 ac 7 2 5 4 0 NAON us ata 7 2 5 ete ee 8 2 7 2 22552205 le Sawaal 8 3 COMMUNICATIONS 5 255 155 144514 2 a Sad 9 5980 01 02 8 EG HO a 9 2 0 06 0 an 9 32 Connecting VV 126 Mode uuu u uuu 9 5100 68 25 a E 10 Returns the message Can not find a modem connected to this computer 10 Returns the message Can not find PLC connected to this computer 10 A4 Programmin 9ouxu ou uu 00 wear uk tte de aa aa 11 tie um chee ins r asam 11 SC 11 219228 COOK ARMING
9. an option button programmed to start the wash or the start button on the 12 button menu station needs to be pressed to start the wash Enable Stacking Default Off Turns on the stacking functionality for use with a 12 button menu station when it is checked See Car Stacking Original Chain Length Default 2400 Length in inches of the chain ie Conveyor length times 2 It is important to have the correct value here for accurate measurement of chain stretch Chain Removed Default 0 The number of 8 links removed from the conveyor chain to account for chain stretch This value when used with a correct Original Chain Length value will adjust all output distances after the chain has stretched Page numbers CCS4000 Software Manual Appendix A Input Reference A 1 Spare Description The spare input type is used as a placeholder on input terminals that are not wired to anything There are no options and it will not affect any functionality of the PLC Values None Options None Example Use on an input terminal that is not connected to an input source A 2 Pulse Switch Description The pulse switch input is used to read the speed of the conveyor from an encoder This pulse information is needed to calculate the position of vehicles in the wash This input can be replaced by the Auto Pulse function but is recommended because any change in the speed of the conveyor will make the Auto Pulse inaccurate Values None Op
10. an output relay that is not used to control any device B 2 Wraparound Fold Description If the CCS4000 controller is also used to control a wraparound brush this output tvpe can be used to control the function of the secondary arm It can be set to activate when the front of the car reaches a certain distance or can be set to activate when the front tire of the vehicle reaches a certain distance The output will deactivate when the rear of the car reaches a programmed distance into the wash Values Fold Front 1 Tire This value represents the distance from the Entrance eye the front of the car 15 tire must be at for the output to activate Unfold Rear This value is the distance in inches the rear of the car must have traveled from the Entrance Eye to turn off the output Options Fold at 15 Tire If this option is checked the output will activate when the tire reaches the Fold distance If left unchecked the output will activate when the front of the vehicle reached the Fold distance To activate at the 1 tire there must be a Page numbers CCS4000 Software Manual Tire switch input installed and programmed Every Car With this option selected This output will activate on every vehicle that passes through the wash Selective With this option selected the output will only activate if it is selected by a menu This option will enable the Select Menus button where the menus that can activate this output can
11. and off at one second intervals for the entire time it is active This is useful for signs Include In Wet Down checked this option will include the output in the wet down sequence of the wash This is good for brush water solenoids and brush motors Interlocked This option will cause the output to turn off if the Conveyor Running input turns off When the Conveyor Running input comes back on so will the output if it is supposed to be active This is recommended for outputs that control chemical or water application or brush motors Selective De Selective this option is checked the output will act as a selective output meaning that it will only activate on vehicles that have a menu associated with this output applied to them There must be a menu associated with this output if Selective mode is chosen If it is unchecked the output will activate on every car except ones that have a menu applied to them that is associated with this output If there are no menus associated with this output it will be active on every car See section 4 4 Menus Example Connect the main arm solenoid of an RS 701 to this output Set the Tunnel Position value to the number of inches from the Entrance Eye the vehicle must have traveled to extend the brush Set the Lengthen option and enter Lengthen Shorten value that will keep the brush extended until the back of the car has been cleaned Leave the Power Surge Value at 0 Turn on the look ahead o
12. are prewired 120V or 24V Qutput distribution circuit board 24V 120V circuit breakers Network cable standard ethernet cable 24V DC input terminal strip 24V DC terminal block Ground Block 24V AG terminal block supply voltage for tunnel accessories do not exceed 4 amps 120V AC terminal block supply voltage for tunnel accessories do not exceed 4 amps Neutral AC terminal block for landing field wiring MCR Master control relay disrupts power to outputs tA 2 l sab 1 P JEN 2244 bu 7 mg Circuit bree ice pors 14 l 11 11 111 111 1 5 14 ia aster control relay relay circuit board Gie 10 DE e lt wow k s DC i status LED ethernet cable connector jie output distribution circuit board 2 Safety Requirements 9 Only those employees specifically approved by the location Manager will be permitted to enter the wash tunne
13. be chosen See Section 4 4 Menus De selective With this option selected the output will activate on every car except ones that are assigned the menu associated with this output This option will enable the Select Menus button where the menus that can activate this output can be chosen See Section 4 4 Menus Example Connect an RS 701 to the CCS4000 Controller Use On Front Off Rear output to control the main arms See Appendix Wire the secondary arm solenoids to Wraparound Fold outputs Check the Fold at 1 Tire option Measure the distance in inches from the Entrance Eye to where the tire should be when the secondary arm folds and put that in the Fold Front 1 Tire value box Measure the distance in inches from the Entrance Eye to where the rear of the car should be when the secondary arm unfolds and put that value in the Unfold Rear value box This will cause the secondary arm to fold at the front wheel well and unfold across the back of the vehicle On Front Rear Description This is the most general and useful output type available It will activate when the front of a vehicle reaches a certain distance from the entrance eye It deactivates when the rear of the vehicle reaches the same location The deactivation at the rear of the car can be delayed to extend the length of a vehicle It can also be set to be a power surge output by programming a time value that this output will use to allow a high
14. is used to generate a conveyor motion signal which is processed by the PLC It indicates the speed of the chain in inches per second This signal in conjunction with the vehicle detector signal allows the PLC to turn on and off all the tunnel functions for the length of car only Giving precise control over application of water and chemicals In normal operation when the conveyor is running you will see input 00 flash on and off when the magnet passes the sensor located on the conveyor drive sprocket Pulse stays on all the time Override the conveyor to determine that the chain is moving inspect the switch for proper operation and clean debris or fillings away from the magnets Disconnect the wires in the junction box at the switch to identify a short in the wiring If input turns off when the wires diconnected replace the pulse switch If input stays on but turns off when the wire is disconnected in the CCS4000 panel replace the wiring to the switch The voltage should read 24V DC across both wires going to the switch Pulse does not come on Override the conveyor to determine that the chain is moving inspect the switch for proper operation and clean debris or fillings away from the magnets Disconnect the wires in the junction box at the switch and touch them together If the input turns on replace the switch If not measure voltage across both wires It should read 24V DC if not measure voltage in the CCS 4000 between 24DC and IN 00 If volt
15. it does exceed 2 amps there is a short in the input section of the wiring or input device is drawing excessive load See sec 3 troubleshooting inputs 2 Troubleshooting high voltage Qualified personel only With the main switch on measure the voltage across all 3 phases on the left side of the main fuses The voltage should be the same as noted on the panel serial number plate located on the front door of the panel If no voltage or partial voltage is displayed disconnect main power from the panel and check continuity of each fuse If the fuses are ok source voltage should be checked If voltage is present on the main terminal buss but no voltage is present on the primary side of the control transformer check the fuse or circuit breaker feeding the transformer lf no voltage is present replace the fuse or circuit breaker If the fuse blows disconnect hot wires leave ground attached from the secondary side of the control transformer and retry If the fuse still blows replace the control transformer If the fuse is ok but blows when hot wires are installed check wiring for short on the secondary side of the transformer going to the circuit breakers If the PLC or DC power supply is not live check the panel Estop circuit estop switch is located the front of the panel It dissrups power to the master control relay witch in turn distributes control voltage to all the 120V 24V tunnel accesories With the estop pulled
16. measured in inches Set the 1 On Period and the 2 On Period to 24 so the output is on for 2 of travel for each tire Create a Menu input and make it assign menu B1 Click the menus button and assign this output to be selected by Menu B1 This will now be set to control an optional Tire Chemical Applicator There are some locations where boosting the top brush down at the rear bumper would be helpful for a better clean of the rear of the car To do this clear the 1 Position and the 1 On Period so this output will do nothing at the front of the car Select the Use Bumpers Option Set the 2 Position to the distance in inches from the Entrance Eye Page numbers CCS4000 Software Manual to where the rear bumper should be when the boost is applied Clear the 2 Seconds Inches option to make the 2 On Period measured in inches Set the 2 On Period to 36 so the output will be active for 36 inches of the car s travel This will make a boost solenoid on the RS 1000 activate when the rear bumper of the car passes under the brush B 6 Pulse Out Description The Pulse Out output will create a pulsed output that that is a cleaned up version of the incoming pulses from the Pulse input or a regular pulse based on the Auto pulse value Values None Options Input Terminal With this option selected the output will repeat exactly the pulse on the incoming signal from the Pulse input Internal Flag With this option selected the ou
17. of the vehicle reaches this point 2 Rear Position This is the distance in inches from the Eyes that the output activates when the second appropriate part of the vehicle reaches this point 1 On Period The amount of 1 10 seconds or inches after the output activates for the first time before the output stops this value is zero the output will only activate on the 2 Position 1 On Period The amount of 1 10 seconds or inches after the output activates for the second time before the output stops If this value is zero the output will only activate on the 1 Position Options 1 Seconds Inches If this option is checked the 1 On Period will be measured in 1 10 second values 10 1 second If it is left Page numbers CCS4000 Software Manual unchecked the 1 On Period will be measured in inches 2 Seconds Inches If this option is checked the 2 On Period will be measured 1 10 second values 10 1 second If it is left unchecked the 2 On Period will be measured in inches Selective De Selective this option is checked the output will act as a selective output meaning that it will only activate on vehicles that have a menu associated with this output applied to them There must be a menu associated with this output if Selective mode is chosen If it is unchecked the output will activate on every car except ones that have a menu applied to them that is associated with this output If there are
18. place in the software It displays information about the settings of the PLC as well as displaying what inputs and outputs are active as the vehicles move through the tunnel Double clicking on an Input or Output description will bring up an edit screen where you can change settings 20 WASH CONTROLLER 2003128 NEW SITE 54000 J 16 32 Program Connect Service Change Help Loading settings fram file COMPLETE NoController Port Closed Show Default Function 00 Power Pack 00 Pulse Switch 01 0000 Eliminator pump ALL CARS 01 Entrance Eye 0000 Oryer 1 2 ALL CARS 02 Upper Eye 03 0000 3 4 ALL CARS 03 Tire switch 04 05 0000 Mitter ALL CARS _04 Spare 0000 Nozzle flip ALL CARS 05 Spare roller up 06 E stop OF lamp Input lamp 07 Start Pause NO Start Pause 09 0000 0000 CTA ALL CARS 08 Override_key 09 0000 ALL CARS 03 SysError 0 Chain Tension 10 Alarm 10 SysError Overload Stop 11 0000 rs 400 extend ALL CARS 11 Button box F 12 0000 rs 7012 soap CARS 12 Button box 1 13 0000 Eliminator flip ALL CARS 13 Button box LU 14 0000 Triple foam MENUS 14 Button box LI 15 0000 0000 RS 1 000 lift ALL CARS 15 Button box C2 2 3 1 Menu Bar The Menu Bar is the t
19. software is connected to the PLC and you have chosen to View Input Terminals or View Wash Status there will be a square light between the output section s scroll bar and the input title Each light will be green if the input is on and red if the input 15 off Input Terminal 03 Input Type Option Buton we Clear all Wash Options from Car Add Vash Options to Car TAF BS 1000 Truck bed override System Start Call Roller Up Save carto stack Keep Cancel Help 2 4 Edit Settings Window The Edit window is opened any time an output or input is double clicked in the main window This is the place where all input and output settings are modified The Edit Window will change for each input or output that is selected See sections 4 2 Output Settings and 4 3 Input Settings for more information 2 5 Change Info Window You can change the name of the file as it appears in the initial Site Selection screen or you can add notes to the file using this window These notes are stored only on the computer they are entered on and will not be available to anyone else using another computer To access and edit this information 1 Click on the Change menu in the Menu Bar 2 Select Info to open the Change Info window 3 If you want to add to modify the description the new description in the File Description text box at the top of the window 4 To add notes that pe
20. spacing of the chain Options Code Entry Starts Page numbers CCS4000 Software Manual When this option is selected the Roller Gate output will automatically activate when a menu is selected through a Menu input This is needed in an unattended tunnel to start the wash Example In a front wheel pull conveyor with a 34 roller spacing at an unattended site set the first Open Distance value to 40 the Closed Distance to 132 the second Open Distance to 40 and select the Code Entry Starts Option B 11 Alarm Horn The Alarm Horn output is activated for the programmed duration before the wash will start There must be an Alarm Horn output for the wash to work Values Duration The Duration is the time in 10s of a second that the alarm horn will sound for before the wash will start Options None Example Set the duration to 40 to have the alarm horn sound for 4 seconds B 12 Prep gun You can control up to 4 prep guns or vacumes by selecting this output Values Auto off after 0 1 sec Enter the time value 10 sec you wish the prep gun to stay After the time has expired the prep gun will turn off Power surge Set the start delay you wish to use in a emergency restart Channel Check the box with the prep gun number you wish to control You must select the same number when you select an input button to control the prep gun timer Example Set the duration to 300 and the prep gun will turn on
21. the power on and turn the override switch on This will start the test sequence The PLC will turn on each output starting with output 00 for 1 second then advance to the next output advancing through all 32 to 64 ouputs When the cycle is complete it will repeat until the key switch 15 turned off You must connect to the PLC and transfer the program to remove the test program The HMI display is a rendition of the tunnel inputs It is not a true indicator of the pulse or entry switch status but the input status as accepted by the programmed PLC HMI display The HMI human machine interface display is a display interface attached to the WCC Inside the cover there is a modem as well as all the comunication ports used to connect a point of sale and a PC to the CCS4000 controller The display requires a 5 volt DC power supply to operate The HMI accepts information from the PLC as well as a standard RCA TV remote controller With the display you can reset the wash override outputs test inputs and view system information It is not necessary to have the high voltage cabinet open for access to any of these features HMI Display Unit Remote control Menu Buttons used on remote control TV mode power button 1 volume channel buttons Number buttons Note The mute button is a shortcut to Exit on most screens Screen Menus and editing or text Edit number or Selection by scrolling or entering digits with nu
22. used to view the status of the inputs It transfers a small amount of data so it is able to accurately represent a pulse switch or an intermittent input or button push To view the Input Terminals 1 Open the software 2 Make sure the PC is connected to the 54000 Controller see Section 3 Communications 3 Click on the View Menu on the Menu Bar Page numbers CCS4000 Software Manual 4 Select Input Terminals To stop viewing 1 Click on the View Menu on the Menu Bar 2 Select Stop Viewing 5 8 Output Override For various reasons it may become necessary to override the state of an output Through the CCS4000 software it is possible to force the output on or off Any output that is forced on will turn off when an Emergency Stop input is triggered To force the state of an output or to return the state to the control of the PLC 1 Open the software 2 Make sure the PC is connected to the Mac4000 Controller see Section 3 Communications 3 Double click on the output that you want to change 4 The Output Programming screen will appear At the bottom of this screen are three options for override These options are Run Override On and Override Off Run sets the PLC to take control of the output in normal operation Override On forces the PLC to keep that output on at all times NOTE This ignores power surge settings on the outputs that have them See Appendix B Output Reference for details on Power Surge O
23. vehicle Set the 1 Position to activate when the front of the vehicle is still approaching the wraparound Set the 1 On Period to 50 and select the 1 Seconds Inches check box so the boost will stay on for 5 seconds Set the 2 Position to the distance the rear bumper should be from the Entrance Eye when the boost should come back on again to move the brush across the back of the vehicle Select the 2 Seconds Inches check box and set the 2 On Period value to 25 so the 2 boost will be active for 2 5 seconds This output may also be used to only fire once on one of the vehicle features available to this output type For example this output type could be used to trigger the Mirror Flip option on a Tech 21 Smart Nozzle system Connect the Mirror input of the Smart Nozzle controller to this output Select the Use Tires option Check the 1 Seconds Inches check box to make the 1 period measure in seconds Set the 1 Front Position so that it is 51010 before the dryer arch Set the 1 On Period to 20 so the output 15 triggered on the front tire location for 2 seconds Leave the 2 Rear Position and 2 On Period at zero so that it does not fire on the rear tire Another likely use for this output is for a Tire Chemical Applicator Set the 1 Front Position and the 2 Rear Position values to the distance in inches from the Entrance Eye to the Tire Chemical Applicator Clear both the 1 Seconds Inches and 2 Seconds Inches check boxes so both tires are
24. washing solutions and oils in a well ventilated area 9 Clean up fluid spills immediately to prevent hazardous safety conditions 9 Be certain to follow all safety procedures on MSDS sheets for each chemical product used All new employees must be thoroughly trained in safe operating and maintenance practices 9 Do not operate any piece of equipment that requires safety covers or guards with those covers removed or improperly installed 9 Do not allow any portion of your body or other objects to come in contact with moving machinery 9 Do not wear loose fitting clothing around moving machinery 9 At least two qualified maintenance people must be present when performing equipment repairs or preventative maintenance 9 When working on any equipment that is higher than a person s shoulders always use a non conductive ladder that is in good condition Never use equipment pipe conduit etc as a step MACNEIL WASH SYSTEMS LIMITED 90 Welham Road Barrie Ontario Canada L4N 8Y4 Phone 800 361 7797 705 722 0582 3 Specification sheet 1 Panel voltage 208 240 460 575 AC 2 Control voltage 24 V DC 3 Tunnel device voltage 24 4 Tunnel sign voltage 120 V AC 5 Minimum water flow 60 6 Minimum water pressure 45 psi 7 Maximum water pressure 100 psi 8 Minimum air pressure 100 psi 15 cfm 9 16 32 inputs 10 32 or 64 inputs 11 Dimensions Height 77 Length 72 Width 27 4 Installation In
25. 17 74 CCS 4000 GREAT IDEA 5 GREAT RESULTS MACNEIL WASH SYSTEMS LIMITED WASH CONTROL CENTRE CCS4000 SERVICE MANUAL January 30 2004 90 Welham Road Barrie Ontario Canada L4N 8Y4 Phone 800 361 7797 or 705 722 7649 FAX 705 722 0582 email info macneilwash com web site www macneilwash com ESM WCC CCS 2004 CCS 4000 GREAT IDEAS RESULTS Table of contents 1 Introduction 2 Safety Requirements 3 Specification Sheet 4 Installation Instruction 5 Start up Instruction 6 Troubleshooting CCS 4000 7 Parts List 8 Software Manual MACNEIL WASH SYSTEMS LIMITED 90 Welham Road Barrie Ontario Canada L4N 8Y4 INTRODUCTION This Equipment Manual contains information that is vital to the successful installation operation performance and maintenance of your CCS 4000 Wash Control Center Please read and understand the full content of this manual before installing or operating the CCS 4000 Wash Control Center Keep this manual in a location where it may be used as an ongoing reference Should you have any questions on the installation operation or servicing of the CCS 4000 Wash Control Center please contact your Authorized MacNeil Distributor For further support contact TECHNICAL SERVICES DEPARTMENT MACNEIL WASH SYSTEMS LTD BARRIE ONTARIO CANADA TELEPHONE 800 361 7797 or 705 722 7649 FAX 705 722 0582 Email info macneilwash com 1 Introduction
26. C Try using another cable if you have one If it still will not work make sure that there are no other programs using this port such as a synchronization program from a PDA or a driver for hardware that is sometimes connected to this port If you are using a USB serial adapter type the command commkludge 9 inthe status box and try again Returns the message hardware does not match can t connect This message will be displayed if you connect to the PLC with a different PLC code version or a different laptop than the last one used to program You must contact Macneil wash systems technical support for the correct autherization code This prevents over writing a wrong PLC program Page numbers CCS4000 Software Manual 4 Programming 4 1 Introduction The main purpose of the CCS4000 Software is to allow changes to be made to the way the wash operates Before the wash can be used values must be programmed into the controller that are specific to each site This software makes it simple to do this by representing the settings in inches and other human terms and does the programming based on what the user has entered There are three main categories of information that need to be programmed before the CCS4000 will work Outputs activate the actions of the wash based on how they are programmed and the information provided by the inputs Inputs tell the PLC where the car is how fast it is moving in the tunnel and other inform
27. C and you have spare outputs available simply change the software to a spare on the bad output and program another output with the same function Change the wire to the new output make sure that the voltage feeding the common on the new relay is the same as the bad relay Output turns on but circuit breaker trips Disconnect the common feed wire on the relay circuit board that operates the outputs in question Install your meter test lead on the common terminal and the other lead on the circuit breaker that trios Override the function and record the amperage draw If it exceeds 10 amps you have a defective device or a shorting output Measure the resistance on that circuit and compare it to a circuit that is ok If the load is less than 5 amps but the circuit breaker when all the outputs on the relav boards are turned on find the circuit that draws the most amps and relocate it to another relay board with less outputs on it Check that the voltage required for the device is correct lf the load is less than 10 amps on the circuit breaker and it still trips replace the circuit breaker Output stays on won t turn off Determine if the PLC is turning on the output Is the green LED on under the relay If it is then the PLC is activating the relay Check the program to see if the Output is in override Make sure that the function is programmed correctly If the LED is not on unplug the relay from the circuit board If the device turns off re
28. Double click on Setup exe Follow the on screen instructions 3 Floppy Installation Windows 95 98 NT ME 2000 XP Insert the installation disk into the floppy drive Double click on My Computer on the Desktop Double click on 3 1 2 Floppy A or 3 1 2 Floppy B depending on which is the correct drive Double click on Setup exe Follow the on screen instructions 4 CD Installation Windows 95 98 NT ME 2000 XP Insert the installation disk into the floppv drive Double click on Mv Computer on the Desktop Double click on CCS4000 D where D is the drive letter of your CD ROM drive Double click on Setup exe Follow the on screen instructions Page Page numbers Page numbers CCS4000 Software Manual 2 Getting Started Guide 2 1 Opening the Software Windows 3 1 1 Make sure windows is running If in DOS type win enter 2 In the program manager open the CCS 4000 window by clicking on the CCS4000 window icon if it is not already open or clicking in the CCS4000 window s title bar if the window is already open the 54000 window double click on the CCS4000 program icon 4 there is more than CCS4000 site file on this computer you will see a list of the installed sites Select the file you want to open and click OK 5 Enter your password and click OK There are three passwords one for the owner one for the service contractor and one for the sit
29. EIL WASH SYS JANUARY 2004 PAGE 6 MACNEIL WASH SYS WCC CCS4000 EPL WCC CCS 2004 HMI DISPLAY amp ACCESSORIES 22 gt VA lu ik u amp 9 GREAT IDEAS WCC CCS4000 JANUARY 2004 EPL WCC CCS 2004 mee TRIPLE FOAMER ASSEMBLY 49 326 00 MP 2 7 7 9 2 e O00000 MACNEIL WASH SYS JANUARY 2004 PAGE 8 WCC CCS4000 TA EPL WCC CCS 2004 VALVE STATION 4 POSITION SHOWN MACNEIL WASH SYS WCC CCS4000 JANUARY 2004 EPL WCC CCS 2004 PAGE 9 AIR REGULATOR ASSEMBLIES e DOUBLE AIR REGULATOR 0 60 PSI COMPLETE ASSEMBLY 49 321 00 MP AIR REGULATOR 0 160 PSI AIR REGULATOR 0 60 PSI COMPLETE ASSEMBLY 49 3322 00 MP COMPLETE ASSEMBLY 49 320 00 MP MACNEIL WASH SYS WGG GCS4000 JANUARY 2004 EPL WCC CCS 2004 ROLLER UP SOLENOID VALVE D MACNEIL WASH SYS JANUARY 2004 PAGE 11 EPL WCC CCS 01 2004 AIR LUBE FILTER ASSEMBLY ME a Y NAA MACNEIL WASH SYS WCC CCS4000 JANUARY 2004 EPL WCC CCS 2004 WATER TUBING MANIFOLDS MACNEIL WASH SYS WCC CCS4000 4 HEPL WCC CCS 2004 32 JUNCTION BOX ASSEMBLY SHOWN MACNEIL WASH SYS lt 2 es Sa SA
30. age is present in the CCS 4000 but not at the switch replace the wire to the switch If no voltage is present go to sec 1 troubleshooting DC power supply You can switch to auto pulse at any time consult software manual Photo cell 01 02 The Macneil IR 110 1 IR 110 2 Vehicle detector is used to measure the length of car in relation to conveyor movement It requires 24V DC to operate The Output occurs when a car breaks the beam between the receiver and emitter The lower beam measures the length of the car and the upper beam measures the cab area only This information is used by the PLC program to retract a top brush on a pickup truck Many problems occur if the photo cells are misaligned or dirty False triggering of the input will cause equipment to stay running longer than it should or count an over length car It is imperative that the Banner Beam Tracker part 4 70 080 20 be used to align the photo cells and used to determine the signal strength of the emitter see back of section 6 Output is on all the time no car in the eyes Observe the LED indicators on the photo cells On the emitter there is a green LED When lit it indicates power and transmiting a beam If it is not lit open the junction box and measure the voltage across both wires to the photo cell It should read 24V DC If not disconnect the emitter and recheck If there is 24V DC then replace the emitter If the voltage is below 12V DC when the emitter is wired
31. al If no voltage is present check the circuit breaker that feeds the relay bank If voltage is present on the common of the relay but not on the NO terminal replace the relay With the wires disconnected measure resistance in the circuit to make sure that there is not a short causing the relay contacts to burn out Typical resistance values for 24V AC circuits are 8 ohms for a chemical pump and 8 to 24 ohms for a motor starter If the NO relay terminal shows voltage but the device does not turn on check or replace the device or wiring to the device f the device operates in an override situation then check the software to make sure it is programmed correctly the output relay fails to turn on and you have verified that 24V DC is available at the relay board and the HMI display indicates the relay is on you could have bad relay circuit board or ethernet cable If the corresponding output is on on the PLC but the relay will not turn on measure voltage on the circuit board across the diode directly below the relay If no voltage is present change the circuit board If still no voltage is present change the ethernet cable If still no voltage is present change the Distribution board li the relay does not turn on change the cable from the PLC output board to the distribution board If the relay fails to respond there is a bad output on the PLC and the PLC output board must be changed f you have determined that there is a bad output on the PL
32. an output that is supposed to turn on within this distance it will turn off when the minimum car length is not satisfied Any menus being entered will not be erased so they will remain with the proper vehicle that has not yet entered the wash The recommended value is 24 60 inches Options Normally Closed This option if selected will tell the PLC to treat this input as a Normally Closed electrical connection The input then will be see the front of the car when the input signal is turned off and the rear of the car when the input signal comes back on Without this option it will see the front of the car when the input signal comes on and the rear of the car when the input signal turns off Example Connect its input terminal to a photo eye at the entrance of the wash Set the Delay On and Delay Off distances to 6 to offset the vehicles by 6 inches and to ignore any quick changes in the state of the photo eye Set the minimum car length to 24 inches to ignore any interruption of the photo eye that is less than two feet A 4 Upper Eye Description The Upper Eye input is used by some outputs to detect the presence and dimensions of pickup trucks and vans This input measures the high portion of taller vehicles and this measurement is compared to the Entrance Eye measurements to determine if the vehicle is a pickup truck or not The PLC determines a vehicle is a pickup truck if the high part of the vehicle is greater than the programmed minim
33. are Manual the location of the tire Example Connect this input to a tire switch located in the floor Enter the distance from the Entrance Eye and take into account the Entrance Eye Delay On value Use a Double Hit output that is programmed to use tire information to send the tire information to a Tech 21 Smart Nozzle Controller for the mirror flip function Use Front Off Rear output to send the Tech 21 Front Rear information for its start and rear flip functions See Appendix Output Reference A 10 Start Pause Description The start Pause can start or pause the conveyor It is used by any output that has an interlock function activated If so these outputs will not turn on if the conveyor is not on Values None Options Normally Closed If this is checked the interlocked outputs will only run if the input signal is off instead of on System Start If this is checked the conveyor will pause and restart Interlock Toggle If this is checked the outputs that are interlocked will turn off Example If an electric drive RS 1000 is being controlled by this controller Front Off Rear output can be set with the interlock option and a Conveyor running input can be used to turn off the electric drive if the main tunnel controller stops the wash A 11 System Error Description Several system error inputs can be created to that will stop the wash under various conditions Values None Options Normally Close
34. ation from the real world Menus can be programmed to change the way the wash operates depending on choices made by an attendant or entry system NOTE Any changes made in the CCS4000 software will not take effect until the program has been transferred to the PLC See section 3 2 Connecting and section 4 5 Transferring the Program to the PLC 4 2 Output Settings 4 2 1 Programming Programming the outputs is a simple procedure but it varies depending on the type of output being programmed Appendix B lists all of the settings of each output type and should be referenced to along with sections 4 2 2 Standard Outputs and 4 2 3 Optional Outputs which describe the required and optional output types The basic programming procedure is as follows 1 Open the CCS4000 Software 2 In the Output Area double click the output you want to edit This will open the Output Programming window 3 In the Output Type drop down box select the output type that you want to use if it isn t already set 4 Modify the settings for the output as described in Appendix B 5 If you have set this output to be Selective or De Selective or it has other functionality that can make use of a menu click the Select Menus button This will change the output description section to a menu display Any menu that is green will include this output 6 To toggle the menu states click on the menus that you want to change 7 Click the Keep button if you are satisfied with t
35. change 7 Click the Keep button if you are satisfied with the settings Otherwise click on the Cancel button and the changes will be discarded 8 Click the Program menu on the Menu Bar 9 Select Save to Disk 4 3 2 Required Inputs There are a few inputs that are necessary for the wash to operate They are e Emergency Stop The wash will not start if there is no Emergency Stop input programmed for safety reasons e Entrance Eye e Menu Button At least one is needed by the roller up and power pack outputs to tell them to activate 4 4 Menus Menus are optional and only apply if there is a Menu Button input programmed and there are outputs that are set as Selective or De selective or every car outputs that have extra functionality when coupled with a menu Programming a menu is a multi phase procedure where you determine which menu a button will activate and then program each output that needs to correspond to that button 4 4 1 Programming These steps are a generalization that represent steps that are also outlined in the Input and Output Programming sections 1 Open the CCS4000 software 2 Double click on the Input for the button you are programming 3 Click the Show Menus button This will change the input description section to display the selected menus this button will activate deactivate Any menu that is green will be activated or deactivated by this input 4 To toggle the menu states click on the menus that you want
36. ct adaptors 3 2 Connecting With a Modem To allow the CCS4000 software to communicate with the CCS4000 controller you can also connect to the PLC viaa modem First the software has to be set up to dial the site 1 Make sure the Modem is properly installed 2 Click on the Connect menu 3 Select Modem Settings 4 Enter the phone number of the line connected to the PLC s modem including the area code and any number that needs to be entered to get an outside line into the Phone Number box 5 The Pager Number can be left blank unless you are initializing the PLC modem Otherwise enter the pager number that the PLC will if there is a system error initializing the PLC modem you should contact your distributor for assistance 6 You should be able to get an appropriate initialization string for the modem from the modem manuals If not enter AT amp F into the Init String box This works on most modems 7 In the Dial Sting Box enter ATDT for touch tone dialing or ATDP for pulse dialing If you are calling from a line that has touch tone service and call waiting enter the command 70 the comma is required 8 When the settings are entered click OK Page numbers CCS4000 Software Manual To connect to the PLC with a modem 1 Make sure that the modem is properly installed and is connected to a phone line 2 Click on the Connect menu Select Find modem If it can t find one make sure it i
37. d If this is checked the system will stop if the circuit to the input is broken If unchecked the system will stop if the circuit to the input is closed Low Air If the Low Air option is selected the input will stop the wash and generate a low air error Low Oil If the Low Oil option is selected the input will stop the wash and generate a low oil error Overload If the overload option is selected the input will stop the wash and generate an electrical overload error Low Temp Page numbers CCS4000 Software Manual If the Low Temp option is selected the input will stop the wash and generate an electrical overload error Example Four system error inputs should be programmed one of each type The Low Air System Error Input should be connected to an air switch in the main air system The Low Oil System Error input should be connected to the float switch in the power pack If there are more than one power pack then the input should be connected to all of them in series for normally closed switches or in parallel for normally open switches The Overload System Error input can be connected to the power pack motor starter if the system is sending a power pack output and the Overload Input does not receive a signal back from the motor starter it will stop the rest of the wash and generate an overload error In areas where the climate can make the temperature in the tunnel go below freezing a System Error input can be created wit
38. down Enable Time has elapsed This is most beneficial on mitters or cloth brushes to make the cloth wet after a prolonged shutdown Reset Timeout Default 6000 This is the time 1 10 second units that the PLC will wait before resetting when the E Stop is pressed This allows the system to be restarted if there is no working computer or wired reset input at the site Minimum Pickup Cab Default 24 Minimum distance of conveyor travel that the upper photo eye must be blocked before the PLC will recognize the high part of a vehicle This is like the Minimum Car Length on the lower photo eye Minimum Pickup Bed Default 54 The minimum difference in inches of conveyor travel between the end of the high part of a vehicle and the end of the low part before the PLC will recognize the vehicle as a pickup truck This Page numbers CCS4000 Software Manual is mainly used for the topbrush output to raise the brush at the back of pickup cabs while being able to wash the back of vans Tire Switch Location Default 12 The distance in inches between the photo eye and the tire switch Alarm Horn Start Delay Default 30 The time in 1 10 second units that the alarm horn will sound for before any outputs will come on when the wash is started Auto Restart Default Either When this option is checked the wash will automatically restart when the E Stop is reset after it has been hit This is the default for unattended sites If it is unchecked
39. e kha 30 Entrance a A 2485 8818 085142 31 B S Eliraliee 14525 SS 31 P S Power PACK E aksu sua ukna Shaan ankapa ri tatu 31 B y uu u ba ee eee ej 32 32 B 12 33 P IO u a ee ati jat 33 CCS4000 Software Manual 1 Installation Instructions 1 1 System Requirements ok oO fF oR OM PC Compatible 386 or higher processor 8 MB RAM varies with operating system requirements Microsoft Windows 3 1 95 98 NT ME 2000 XP RS 232 Serial Communications Port 19 2Kbaud or faster modem for remote communication 1 44MB Floppy Drive or CD ROM Drive 4MB Free Hard Drive Space more space to store reports 2 Floppy Installation Windows M 3 1 Insert the installation disk into the floppy drive Open the File Manager Select and open the floppy drive A or B
40. e This is the time in 10ths of a second that the relay will deactivate for the Windshield Relief function Options Wash Open Pickup Beds Page numbers CCS4000 Software Manual With this option checked the brush will descend into all pickup beds unless a Menu input as been hit that 15 programmed with the RS 1000 Truck Bed Override option set If left unchecked the brush will retract for all pickup beds unless a Menu input as been hit that is programmed with the RS 1000 Truck Bed Override option set Include In Wet Down If checked the output will activate during a wet down cycle Interlocked If checked and a conveyor running input exists the output will deactivate if the conveyor running output turns off If the output was activated when the conveyor stopped it will reactivate when the conveyor starts again Selective De Selective With this option checked the output will be a selective output This means that it will only extend the brush if a menu it is associated with has been applied to that vehicle If it is checked a menu must be applied for the output to function If the option is left unchecked the output will be de selective meaning that it will function for every car except ones that have a menu that is associated with this output applied to them If the output is de selective and then are no menus associated with it the output will function on every car See section 4 4 Menus Example With an RS 1000 installed
41. e Is being done on the equipment A 8 Reset Description The reset input will reset the controller in the case that it becomes erratic or a car has been removed manually from the wash due to an extended power failure or other reason Values None Options Normally Closed This option if selected it will invert the meaning of the input This means that if the input signal is turned off it will reset the controller Example Connect this input terminal to a key switch in the back room car rolls of the track and needs to be driven out of the wash with the conveyor off turning this key will remove all information in the controller returning it to it s standby state with no car data A 9 Tire Switch Description This input type will read the signal from a tire switch located anywhere in the tunnel This information can be used by some of the output types to affect their operation Values Tunnel Position This value is the distance in inches that the tire detector is placed from the Entrance Eye Remember to lower this value by the Entrance Delay On value so the distance is accurate to where the car is being measured from Options Normally Closed This option if selected it will invert the meaning of the input This means that if the input signal is turned off it will represent the tire With this option unchecked the input will function normally where the input turning on will signal Page numbers CCS4000 Softw
42. e manager 2 2 Opening the Software Windows 95 98 NT ME 2000 XP 1 Click the Start Menu Go to Programs Then CCS4000 Click on the CCS4000 program icon O N there is more than one CCS4000 site file on this computer you will see a list of the installed sites Select the file you want to open and click OK 7 Enter your password and click OK There are three passwords as follows owner total access to everything service access to programming manager to view operations These passwords must be changed for securiry reasons Page numbers CCS4000 Software Manual 2 3 Main Screen Once the software is started you will see the main screen This is where most of the functionality of the program is located Across the top of the window is the Menu Bar This bar contains the tools needed to connect with the PLC to get reports and to update the settings on the PLC The Tunnel View is located directly below the Menu Bar It appears as a horizontal bar When connected to the PLC this box will show a representation of the vehicles as they travel through the wash To the right of the Tunnel View is a box that displays what the software is doing as you do various things in the program This is the Status Box This box will also show any errors if they occur The rest of the window is divided into the Output display on the left and the Input display on the right This is the most important
43. e voltage at the DC power supply With the output wiring plug disconnected on the power supply and the panel live install test leads on terminals marked You should have 23 to 25V DC The green power LED should Plug the connector back in and recheck the voltage the voltage drops below 12V DC there could be a possible short in the input wiring in the panel or one of the 24V DC input accessories Or there could be a defective power supply 1 Troubleshooting a DC power supply With the output wiring plug disconnected measure the input voltage on the power supply The input voltage should be 110 120 AC If no voltage is present locate the circuit breaker that feeds the power supply and measure the voltage from the lower terminal to a neutral terminal make sure that the Estop button on the front panel is pulled out and the main disconnect switch is on If voltage is present on the upper terminal of the circuit breaker but not on the lower terminal disconnect the power and replace the circuit breaker If no voltage is present on the upper terminal see sec 2 troubleshooting main feed If feed exists but there is no 24V DC output with the output connector disconnected replace the power supply If 24V DC is present but drops below 12V DC when the output wiring plug is inserted disconnect the plug and measure the amperage of the output circuit It should not exceed 2 amps If it doesn t exceed 2 amps replace the power supply If
44. ew box Do this for either or both of the other passwords if you want to change these as well gt Click Ok to save the new passwords Page numbers CCS4000 Software Manual 6 Wash Setup The CCS 4000 software has a special place to program values that affect the entire wash such as chain length or minimum car length These values are programmed through the Change Wash Setup window 6 1Modifying Wash Setup values Click the Change menu Select Wash Setup Modify one or more values see below Click keep when done 6 2 Wash Setup values Conveyor Auto Stop Default 1200 The length in inches of the conveyor between the photo eyes and the exit end of the conveyor The conveyor will stop after the last car has passed this distance plus the Maximum Car Length Minimum Car Length Default 48 The Number of inches the conveyor must travel after the photo eye has seen the front of the car before the car will be accepted and the next can be programmed If the photo eye turns back off within this distance any outputs that came on will turn back off and the car will be allowed to start again without being reprogrammed This will count an under length car The Minimum Car Length is to prevent ghost cars from attendants walking in front of the photo eyes or from the cars rolling ahead Maximum Car Length Default 360 If the photo eye is blocked for this length of conveyor travel t
45. for 30 sec if the prep gun button is pressed B 13 indicator You can use this output to send a signel to a point of sale if one is used After a wash has been entered the output will fire and release after the photo eyes are blocked indicating that the wash has been accepted Values Input Lamp If this is checked the output will turn on a program light in the button box if a wash is selected Wash in use If this is checked the output will fire a relay for a point of sale to accept as a wash in use signal Page numbers CCS4000 Software Manual
46. g Page numbers CCS4000 Software Manual With this option selected the output will flash when it is activated Example Set the Flashing option and connect the output relay to an instructional sign at the entrance of the wash or with the Flashing option off connect the output relay to a traffic light to control traffic at the entry station or as a wash in use signal to the entry station to tell it to hold its signals until the current is through the photo eye B 9 Power Pack The Power Pack output controls a power pack or other device that needs to be on the entire time a car is in the tunnel Values Shut Off Distance The Shut Off Distance should be set to be a few feet longer than the conveyor This is the distance that the rear of the last car in the tunnel must reach before the power pack output will turn off Power Surge The Power Surge value represents the amount of time it takes a high power electric motor to start on this output It will delay all other outputs with power surge until it s delay is done This prevents a large power drain when multiple motors start If Two outputs with power surge values are supposed to start at the same time the one with the lower output relay number will start first For this reason it is best to have the Power Pack output at a high numbered output This will allow all other outputs to start back up first after an E Stop Options Code Entry Starts When this option is selected
47. ge numbers CCS4000 Software Manual A 5 Auto Pulse Description The Auto Pulse input will force the PLC into Auto Pulse Mode whenever it is active Auto Pulse mode will be enforced until the input becomes inactive Activating this input is the same as using the Force Auto Pulse feature in the Software Deactivating this input is the same as using the Clear Auto Pulse feature of the Mac4000 software Values None Options Normally Closed This option if selected it will invert the meaning of the input This means that if the input is off it will be in auto pulse mode and if the input is on it will be in normal mode Example Connect this input terminal to a key switch in the back room Make sure that the Auto Pulse rate is updated in the PLC regularly to account for changes in the conveyor speed If something happens to the Pulse Input source for example the drive hose breaks turn the key switch to force the PLC into Auto Pulse Mode A 6 Option Button Description The Option button input can be connected to a button that will allow the operator to select or turn off optional functions of the equipment controlled by the CCS4000 Controller Values None Options Add Wash options If this option is selected this input will apply the chosen menu to the current car Remove Wash Options If this option is selected this input will remove the chosen menus from the current Clear All Wash Options If this option is selected this inpu
48. h the Low Temp option selected This should be connected to a temperature sensor that will activate when the temperature goes below a certain point A 12 Override key Description This input is used to allow outputs to be overriden when activated Value none Options None Example Connect this input to a key switch When active this will allow overrides to occure A 13 Button Box Description This input is for the Macneil button box used to program the wash Value None Options RO Check this box and Wire this to button box terminal RO R1 Check this box and Wire this to button box terminal R1 CO Check this box and Wire this to button box terminal CO C1 Check this Box and Wire this to button box terminal C1 C2 Check this box and Wire this to button box terminal C2 Example Program all 5 inputs for a button box installation In the input section MOO through M31are the simulated Page numbers CCS4000 Software Manual inputs from the button box There are 32 option buttons avaliable in this configuration A 14 Prep Gun description This output will turn on for a programed intervel then turn off This operates independently from the tunnel Value None options 1 2 3 4channels Example Program this input to turn on the prep gun Toggle off Appendix B Output Reference B 1 Spare Description This output type is used as a placeholder for output relays that are not connected Values None Options None Example Use on
49. he controller will simulate the end of the car and count an over length car This will happen of the photo eyes come out of alignment become blocked or become very dirty The wash will very likely not operate properly on any cars following and the photo eyes should be checked immediately Headswitch Delay On Default 6 This is the length in inches that the conveyor must travel before the controller will recognize that the photo eye is on This prevents the PLC from activating if someone walks in front of the eyes or sprays a prep gun through the eyes Headswitch Delay Off Default 6 This is the length in inches that the conveyor must travel before the controller will recognize that the photo eye is on This prevents the PLC from things like seeing the gap between a pickup cab and its bed as being the end of one vehicle and the start of the next This should be set to be the same as the Headswitch Delay On value or it will misread the length of cars by the difference Shutdown Timeout Default 6000 This is the time in 1 10 second units that the conveyor will run if the system is started an no car enters the photo eyes Wetdown Enable Time Default 9000 This is the time in seconds the tunnel must be off before the wetdown sequence will be activated on the next start Wetdown Run Time Default 600 This is the time in 1 10 second units that any output that is programed with the Wetdown option selected will run when the system starts after the Wet
50. he settings Otherwise click on the Cancel button and the changes will be discarded 8 Click the Program menu on the Menu Bar 9 Select Save to Disk 4 2 2 Required Outputs There are some outputs that must be created before the tunnel can operate See the Appendices for full descriptions The mandatory outputs are e Power e Alarm Horn Tunnel will not start without an alarm horn for safety reasons 4 3 Input Settings 4 3 1 Programming Programming the inputs is a simple procedure but the procedure varies depending on the type of input being Page numbers CCS4000 Software Manual programmed Appendix A lists all of the settings of each input type and should be referenced to along with sections 4 3 2 Standard Inputs and 4 3 3 Optional Inputs which describe the required and optional input types The basic programming procedure is as follows 1 Open the CCS4000 Software In the Input area double click the input you want edit This will bring up the Input Programming Window Inthe Input Type drop down box select the input type that you want to use if it isn t already set Modify the settings for the input as described in Appendix O N If this is a Menu Button input click the Select Menus button This will change the input description section to a menu display Any menu that is green will be activated by this input 6 To toggle the menu states click on the menus that you want to
51. ing used in the wash tunnel should be 14 16 gage stranded copper wire The panel Estop disrupts 120 volts to the PLC and master control relay coil Do not wire the tunnel Estop to this circuit The panel is designed for the high voltage to feed from the top RH entry The output relays are rated for 10 amps do not exceed this rating After landing all the wires test each output using the test program installed in the PLC Testing outputs When the unit is shipped there is a test program installed in the PLC To initiate this program turn the power on and turn the override switch to on This will start the test sequence The PLC will turn on each output starting with output 00 for 1 second then advance to the next output advancing through all 32 or 64 outputs When the cycle is complete it will repeat until the key switch is turned off You must connect to the PLC and transfer the program to remove the test program Follow the procedure outlined in the software manual for programing instructions Testing inputs With the TV remote program the HMI for input test must have a warning horn installed and programed Test all inputs in sequence Caution When the panel is open there is a switch bar protruding from the main disconnect switch Use caution when working this area 5 Start up Instructions Test all outputs When the unit is shipped there is a test program installed in the PLC To initiate this program turn
52. ion is the most complete representation of the activity of the wash It shows the status of all of the inputs and outputs as well as a graphical representation of the cars in the wash This view transfers a large amount of data from the PLC so it will not accurately show a fast moving pulse switch properly or any flashing outputs It is useful however to see that everything is happening in the right sequence To view fast outputs or inputs see sections 5 6 View Relay Outputs and 5 7 View Input Terminals To view the PLC Status 1 Open the software 2 Make sure the PC is connected to the 54000 Controller see Section 3 Communications 3 Click on the View menu on the Menu Bar 4 Select Status To stop viewing 1 Click on the View Menu on the Menu Bar 2 Select Stop Viewing 5 6 View Relay Outputs The View Relay Outputs option is used to get a real time view of the status of the outputs on the PLC This option transfers only a small amount of data from the PLC so it is very accurate on flashing and fast outputs To view the Relay Outputs 1 Open the software 2 Make sure the PC is connected to the 54000 Controller see Section 3 Communications 3 Click on the View Menu on the Menu Bar 4 Select Relay Outputs To stop viewing 1 Click on the View Menu on the Menu Bar 2 Select Stop Viewing 5 7 View Input Terminals The View Input Terminals option is similar to the View Relay Outputs option except it is
53. l to perform inspections or maintenance 9 Do not enter the wash tunnel when the equipment is operating 9 Always exercise caution when walking through the wash area The wet floor may cause slippery conditions 9 cautious when walking through the wash tunnel to avoid bumping into or tripping over equipment 9 Do not run through the wash area 9 Do not install maintain or repair equipment unless you have witnessed a lock placed on the appropriate power disconnect for lock out safety protection 9 When maintenance requires that a piece of equipment be in operation while servicing one qualified maintenance person must stay at the power disconnect switch while that equipment is operating 9 All electrically powered equipment must have manually operated disconnects capable of being locked in the position Equipment that has been locked out for any reason can only be restarted by the person who performed the lock out operation 9 Do not attempt to repair or adjust any pressurized liquid or pneumatic part hose pipe or fitting while that equipment is in operation Prior to performing this type of work be certain the electrical disconnect for the appropriate equipment is locked out 9 When any stop switch is operated it is to be reset only by the person who initially stopped the operation 9 Electrical connections and repairs are to be performed only by licensed Electricians 9 Store all cleaning and
54. mber button or text Move between Selections Select highlighted item or switch between edit mode and move Press the power button the remote to enter the main menu Menus 00 Exit menu return to Status display Displays current tunnel status of the inputs and overrides 01 Reset tunnel Resets the tunnel Any cars in the tunnel will be removed from the program 02 Set Autopluse Turns on the current programmed auto pulse value Forces the controller into auto pulse mode 03 Clear Autopulse Turns off the auto pulse mode 04 System Test Stop Wash 05 Output Test Overrides any programmed outputs Turns any outputs that you specify 06 Input test Tests specified inputs by turning on the alarm horn when the input is activated 07 View Outputs Shows current output status 08 View Inputs Shows current input status 09 Edit overrides Allows you to change the state of the overrides of any outputs 10 Find PLC Locates any PLC wired to the system used for communication 11 Laptop Baud Rate Allows you to change baud rate to communicate with the PLC 12 POS Baud Rate Allows you to change the baud rate to communicate with a point of sale 13 Test Dialout Forces the modem to dial a pager number 14 reserved for wash counters Displays car counts if enabled 15 reserved for wash counters Displays car counts if enabled see the next page for instructions on how to use the TV remote Troubleshooti
55. ment 5 2 Auto pulse In the case of pulse or clock switch malfunctions the 54000 system can be made to simulate the pulse signal to allow the wash to continue running until the switch is replaced It is best to set the auto pulse rate on a regular basis including any time the conveyor speed is changed This way if the pulse switch fails you can force the system into auto pulse mode and it will work as if the pulse switch were still working You can also calculate the correct pulse rate manually Run the conveyor and measure the time it takes for the chain to travel 40 ft Divide by 60 and multiply by 1 000 eg 45sec divided by 60 75 X 1000 750 Enter 750 in the Pulse Rate window To set the auto pulse rate Open the software Make sure the PC is connected to the CCS4000 Controller see Section Communications Click on the View Menu Select View Wash Status Read the Value of the Pulse Time Click on the Service menu select Set auto Pulse Rate Enter the value of the pulse time from the actual Pulse input that you read earlier Click Ok B ee I 5 3 Reset Tunnel Occasionally the controller may become erratic This can be caused by several things the most common is that there is something blocking one of the photo eyes either repeatedly while the conveyor is off or rapidly while the conveyor is running This can be the result of high pressure prep guns spraying into the beam an intermitte
56. ng HMI Display No display when main power is on Check that the Estop is pulled out if it is measure voltage at the outlet plug on the side of the cabinet If 120V AC is present measure output voltage of the voltage adaptor It should read 5V If DC voltage is present replace the HMI display Cannot change modes with TV remote Replace batteries on the remote Wait 10 min before installing new batteries remote must not be programmed to any other settings Make sure that remote is set to TV Stand 4 feet from display point the remote directly at the receiver window If no signal is received check that the LED on the TV remote lights up when you press the power button If no signal is received try another remote If still no change replace the HMI Unit will not display information With the TV remote go to menu 10 find PLC If no PLC is found try another communication cable Plug the cable directly into the front of the PLC and into the HMI make sure the PLC is powerd up and the run light is on If it still can t find the PLC replace the HMI Modem will not respond won t pickup Determine that the unit has power If yes check that the phone line is plugged in Are you dialing the correct number If yes try plugging a test phone into the line and dial out If you get a dial tone but no response replace the HMI Modem responds but times out Determine if PLC is on line Change the cable from the PLC to the HMI Replace HMI Modem
57. no menus associated with this output it will be active on every car See section 4 4 Menus Interlocked If checked and a conveyor running input exists the output will deactivate if the conveyor running output turns off If the output was activated when the conveyor stopped it will reactivate when the conveyor starts again Use Bumpers With this option selected the output will fire the first time when the front bumper reaches the distance from the Entrance Eye entered in the 1 Front Position and again when the rear of the car reaches the 2 Rear Position Use Tires With this option selected the output will activate when the front tire reaches the distance from the Entrance Eye entered in the 1 Front Position and again when the rear tire reaches the 2 Rear Position Use Upper Eye With this option selected the output will activate when the windshield of a pickup or van reaches the distance from the Entrance Eye entered in the 1 Front Position and again when the rear window reaches the 2 Rear Position Use Pu Beds With this option selected the output will activate when the rear window of a pickup truck reaches the distance from the Entrance Eye entered in the 1 Front Position and again when the rear bumper reaches the 2 Rear Position Examples This output can be used to control the boost function of an RS 701 wraparound Select the Use Bumpers option so the boost functions using the front and rear of the
58. nt wiring fault or people walking between the eyes If it happens on a regular basis it should be investigated When this does happen you can fix the problem simply by resetting the tunnel There is a reset input type available so that you can reset the controller from the tunnel You can also hit the Emergency Stop button for at least 10 minutes or reset it through the software To reset the controller through the software 1 Open the software Make sure the PC is connected to the CCS4000 Controller see Section 3 Communications Click on the Service menu on the Menu Bar Make sure that there are no vehicles in the wash ey Select Reset Tunnel 5 4 View Wash Status The View Wash Status option allows you to quickly determine important information about the wash and how it is operating It will display a graphical representation of the cars in the wash what the auto pulse rate is what the actual pulse switch rate is and whether it is in auto pulse mode It will also show the status of the Pulse Entrance Eye and Upper Eye inputs To view the Wash Status Page numbers CCS4000 Software Manual 1 Open the software 2 Make sure the PC is connected to the 54000 Controller see Section 3 Communications 3 Click on the View menu on the Menu Bar 4 Select Wash Status To Stop Viewing 1 Click on the View Menu on the Menu Bar 2 Select Stop Viewing 5 5 View I O Status The View PLC Status opt
59. op portion of the main window that contains the Program Connect Service View Change and Helo menus Other than programming this is where all functionality of the CCS4000 Software is contained To access any of these menus just click on them and then click on the selection from the menu you want to access 2 3 2 Tunnel View The Tunnel View box is the long horizontal gray bar on the top left of the main window If the software is connected to the PLC and you have chosen to View Cars or View Wash Status the Tunnel View will display a graphical representation of the vehicles as they progress through the tunnel 2 3 3 Status Box The Status Box is the large text box on the top right of the main window This is where the software prints information about what it is doing and any errors that may occur Commands can also be entered here as instructed by the Page numbers CCS4000 Software Manual troubleshooting sections of this manual by your distributor or by MacNeil Technical Support Staff 2 3 4 Output Area The Output area is the large area on the lower left portion of the main window This area displays all available outputs what type they are their main values whether they are Selective blue De Selective red or Every Car black There is a scroll bar on the left side of the Output area this is used to scroll the outputs to be able to access all of them If you double click on any of the outputs the software will bring u
60. ouble check that the settings you are going to send are accurate 4 Click the Program menu and select Send to PLC 4 6 Getting the Program From the PLC there is more than one computer that can access the CCS4000 controller it is a very good idea to get the settings from the PLC before you make any changes If you don t any changes made by the other computer will be lost 1 Make sure that the PC is connected to the PLC and that the connection works See section 3 Communications 2 Click the Program menu and select Load From PLC Your computer will now be up to date with the settings on the PLC 4 7 Saving Changes When changes have been made and transferred to the PLC they should be saved so that the PC has the latest settings the next time it is used To save the settings 1 Click on the Program menu on the Menu 2 Select Save to Disk 4 8 Reverting to Last Saved Settings If changes have been made that do not work properly it is possible to load the previously saved settings and restore the old values as long as the new changes have not been saved revert to the previous settings 1 Click on the Program menu on the Menu Bar 2 Select Load From Disk 3 The software will ask if this is what you want to do Click OK 4 9 Exporting Settings Sometimes it is necessary to move the settings from one place to another If there is more than one site that has an identical layout it would be easier to import
61. out the master control relay should be engaged If it is not engaged install a jumper wire between the 2 terminals on the estop switch If the relay engages replace the estop switch If it does not engage measure continuity through the coil on the relay There should be 115V AC at the coil on the master control relay If there is but the relay is not engaged replace the relay 3 troubleshooting inputs The PLC is wired with all field inputs being or Ov DC It requires a ground to register an input Below the input terminal strip is the DC terminal strip By installing a jumper wire from 24 to any of the input terminals you can check the inputs With the TV remote program the HMI display for menu 08 view inputs using your jumper wire touch each terminal seperately the coresponding output should register on the HMI display as well as the PLC If it does not check the input wire from that terminal to the input terminal on the PLC If none of the outputs light verify 24V DC 15 available With a volt meter install 1 test lead on the input common terminal of the PLC lower right terminal on front of PLC install the other lead on DC terminal strip The meter should read 24V if not see sec 1 troubleshooting DC power supply If only 1 input does not register and wiring has been verified there is a chance that the input is defective You can make that input a spare in the program or replace the PLC Pulse switch IP 00 The Macneil pulse encoder
62. p the output programming screen for output When the software is connected to the PLC and you have chosen to View Relay Outputs or View Wash Status there will be square lights to the left of each output Each light will be green if that output is on and red if that output is off If you right click on any of the Output labels a menu will appear that will present several options including Edit Output Copy Paste Swap Clear and Help Edit Output will open the Output Edit Window where you can change the settings and type for this output Output Relay 01 Output On t front rear Look Ahead Enabled Tunnel Position 0000 shorten LENGHTEN Flashing Length Adjust 4 l 0000 Include down Power surge 0 1 Sec 10025 Interlocked selective 7 DESELECTIVE Use Power surge Override Run Override Qn Override Off Channel JEliminator pump Page numbers CCS4000 Software Manual 2 3 5 Input Area The Input area is on the lower right portion of the main window The Input area displays all available inputs what type they are and whether they are Normally Open black or Normally Closed red There is a scroll bar on the right side of the input area this is used to scroll the inputs to be able to access all of them If you double click on any of the inputs the software will bring up the input programming screen for that input When the
63. place the relay and check the wiring for an intermittent short If the device still does not turn off look for a short or wet box in the wiring going to the device JANUARY 2004 WCC CCS 2004 WASH CONTROL CENTER PERFORMANCE PLUS PARTS LIST WCC CCS4000 GREAT RESULTS W API gt 22 A 9 92 AES Aw ii lt 59 S fa 97 2 2 MACNEIL WASH SYS JANUARY 2004 PAGE 2 SEE PAGE 6 PANEL MOUNTING HARDWARE WCC CCS4000 EPL WCC CCS 2004 MACNEIL WASH SYS WCC CCS4000 EPL WCC CCS 2004 AIR WATER CONTROL PANEL FRONT VIEW SEE PAGE 13 SEE SEE PAGE 10 tA i 02 UN mx y YX lt A 2 5947 MACNEIL WASH SYS JANUARY 2004 5 PAGE 4 WCC CCS4000 1 157175 98 EPL WCC CCS 2004 AIR WATER CONTROL PANEL BACK VIEW 2 8 lt LLI LLI 9 ta gt 085 N lt 9 A AN W lt AN NI k AN bi A l 4 1 D cy 9 1678 ISEAN gt 1 w 2 Ye X N 5 gt N 2 4 9 3 MACNEIL WASH SYS WGG GGS4000 JANUARY 2004 EPL WCC CCS 2004 me PANEL INTERIOR CCS4000 32 SHOWN MACN
64. power electric motor to start before other outputs with power surge outputs can start Values Tunnel Position This value is the distance in inches from the Entrance eye that the front of the car will activate the output Length Adjust This value will extend or shorten the length of the car by the programmed number of inches delaying the deactivation of the output This value is linked to the Extend Shorten option Power Surge The Power Surge value represents the amount of time it takes a high power electric motor to start on this output It will delay all other outputs with power surge until it s delay is done This prevents a large power drain when multiple motors start If Two outputs with power surge values are supposed to start at the same time the one with the lower output relay number will start first Options Look Ahead Enabled When checked this option will prevent the output from deactivating if there is another car on its way to this output If this output is selective or de selective it will stay active even if it is not supposed to stay on for the next car It will however turn off when the next car gets to the output if that is the case Lengthen Shorten When unchecked the Length Adjust value will shorten the vehicle by the set amount If it is checked it will lengthen the vehicle by the set amount Flashing Page numbers CCS4000 Software Manual When checked this option will cause the output to flash on
65. ption to keep the brush extended for the next car Leave all remaining options unchecked B 4 Top Brush Lift Description This is designed specifically for extending and retracting a top brush while using an Upper Eye and Entrance Eye inputs to detect pickup trucks so it can retract before it tries to clean into the truck bed Values Down Position This is the position in inches from the Entrance Eye where the front of the vehicle must reach before the brush will lower to clean it It is best to lower the brush before the car arrives at it so that it has time to lower to clean the front Up Position This value lengthens or shortens the vehicle by delaying or advancing the deactivation of the output lt lengthens or shortens by the value entered depending on the Lengthen Shorten option described below Pickup Bed Retract Position This is the distance in inches from the Upper Eye to the core of the brush When the back of the cab pickup truck reached this position the brush will retract This should be adjusted so that the brush retracts right at the back window Windshield Relief Position When the windshield on a vehicle detected by the upper eye reached this distance from the eye the Top Brush Lift output will temporarily deactivate for the time entered into the Windshield Relief Time value This removes pressure from the steep windows on trucks and vans to allow the brush to contour the vehicle better Windshield Relief Tim
66. rtain to this controller enter them in the Notes text box 5 Click the OK button when finished Page numbers CCS4000 Software Manual 6 Click the Program menu on the Menu Bar 7 Select Save to Disk to save the changes 2 6Change Wash Setup This is he area of the software where the wash parameters are stored and modified The Minimum and maximum car lengths are here as well as wet down enable and reset time out You will find the tire switch location as well 1 Click on the Change menu in the Menu Bar 2 Select Wash Setup to open the Change Wash Setup Window 3 Click on the box you wish to change 4 Change the values 5 Click keep cancel or help if you require clarification on an item 2 7 Exiting the Software To exit the 54000 Programmer Software 1 Click the Program menu on the Menu Bar on the main window 2 Select Quit If changes were made and not saved to disk the software will ask if you want to save them before you exit Click on yes or no to finish exiting Page numbers CCS4000 Software Manual 3 Communications 3 1 Introduction The CCS4000 Controller system is divided into two parts the Controller itself and the CCS4000 software that runs on a PC or laptop running Windows Because of this the two parts need to be able to communicate effectively to function properly However once programmed the controller does not need to be connected to the software This communication is done thro
67. s connected properly and see the troubleshooting section below 4 Click the Connect menu again 5 Select Dial If it does not connect the modem on the other end may not be connected or you may have dialed the wrong number Call your distributor if everything is connected properly and you still have difficulty 6 The software is now connected to the PLC To disconnect 1 Click the Connect menu 2 Select Disconnect 3 3 Troubleshooting Returns the message Can not find a modem connected to this computer In the status window on a blank line tvpe find modem 123456789 This command will tell the software to detect any modems on comm ports 1 to 9 and save this information for later You will only have to do this once If you are using a USB modem the command commkludge 9 in the status box and try again If it still will not connect check the following that the modem is not in use by another program that you are not the Internet or that the modem is installed properly see modem computer manufacturer Returns the message Can not find a PLC connected to this computer In the status window blank line find plc 123456789 This command will tell the software to detect any PLC s connected to comm ports 1 to 9 and save this information for later You will only have to do this once If it still will not connect make sure that the cable is connected properly to the computer and the PL
68. so the brush core is 120 inches from the Entrance Eye and the Upper Eye is directly above the Entrance Eye Set the Down Position to 80 to bring the brush down 40 inches before the vehicle arrives Set the length adjust to 60 to retract the brush 20 inches behind the back bumper of the vehicle 60 inches delay 40 inches early 20 behind Set the Pickup Bed Retract value to 120 inches to retract the brush at the back window of a pickup truck Set the Windshield Relief Position to 115 inches to relieve the pressure before the windshield reaches the brush Set the Windshield Relief Time to 5 to relieve the pressure on the windshield for 5 10ths of a second Check the Lengthen Shorten option and leave all other options unchecked This will lower the brush for all vehicles relieve pressure on the windshields of trucks and vans and retract the brush at the back of the cab of a truck or the back bumper of other vehicles B 5 Double Hit dbl hit Description The double hit output is a very useful output because it can activate once or twice per vehicle based on various parts of that vehicle It can be made to use the bumpers tires front and back of the tall section of a van or pickup or the front and back of a pickup box The amount the output stays on can be either time or distance depending on what options are selected Values 1 Front Position This is the distance in inches from the Eyes that the output activates when the first appropriate part
69. structions Uncrating Care should be taken not to damage the procoat finish of the WCC when it is removed from the crate Location Locate the WCC in a dry area of the equipment room Avoid overhead pipes or tanks which may leak on the panel causing damage Installation Install the panel per all local and national electrical codes with the recommended wire size and disconnects as required Input wiring All field DC input wiring to be no less than 18 gage stranded copper wire 16 gage shielded cable is recommended Avoid installing input wiring in the same conduit as output wiring input wiring is installed in the same conduit as output wiring all input wire must be shielded and the cable ground terminated in the CCS4000 panel Under no condition is input wiring allowed in the same conduit as high voltage wiring to pumps or motors an external point of sale is used all communication wiring should be fully shielded 18 gauge with a maximum length of 100 ft DB9 connectors should be used at both ends with the shield ground Output wiring Consult the factory if additional motor starters are required in the panel Do not exceed the maximum amperage rating of the panel Do not change the main fuses to a higher rating without consulting the factory f additional 120v or 24v tunnel accessories are wired to control transformer do not exceed 5 amps on either circuit All output wir
70. t will clear all menus from the current car RS 1000 Truck Bed Override If this option is selected this input will override the truck bed retract on all Brush Lift outputs causing the brush not to retract for truck beds System Start If this is selected this input will sound warning horn and start the power pack Call Roller Up If this is selected the input will activate the roller gate Save car to stack If this is selected the car will be entered into a stacking register Example Connect this input to a button at the entrance of the wash that the operator can press if a truck enters the wash with a tonneau cover that needs to be washed Choose the RS 1000 Truck Bed Override When a truck enters Page numbers CCS4000 Software Manual that has a cover over the box this button can be pressed so that the cover will be washed by the top brush A 7 E Stop Description This input will turn off all outputs when activated This is a normally closed input only so there must be an input signal present before the controller will operate Values None Options None Example Connect this input to one or more normally closed Emergency Stop buttons wired in series soaced throughout the wash This can also be wired in parallel with the E Stop input on the main tunnel controller When the circuit 15 broken all outputs including the ones that are on because of an override This is used in case of an emergency or if maintenanc
71. the settings from another site It is also sometimes necessary for Technical Support personnel to have the same settings as those at the car wash to help them determine programming problems To do this 1 Open the software 2 Click on the Program menu on the Menu Bar 3 Select Export Setup This will create a file in the folder where the CCS4000 software was installed called SETUP CSV This file then can be imported into another site file or copied to or emailed to another location Page numbers CCS4000 Software Manual 4 10 Importing Settings When a file has been exported you can import it into another site file 1 Make sure the SETUP CSV file is in the correct location It should be in the folder where the 54000 software was installed This is usually the CCS4000 folder on the C drive in a sub folder with the site job number as its name 2 Open the Software 3 Click on the Program menu on the Menu Bar 4 Select Import Setup This will take the settings from the file and insert them in this site file Page numbers CCS4000 Software Manual 5 Diagnostics and Service 5 1 Introduction You can use the CCS4000 software to diagnose wash malfunctions By watching the status of the outputs inputs menus and cars it is possible to determine what part of the system is the cause of the malfunction or maladjustment These problems can be remedied either by programming changes or by adjusting to the equip
72. tions None Example Connect its input terminal to an encoder on the conveyor to measure the speed of the conveyor A 3 Entrance Eye Description The Entrance Eye input is required for the CCS4000 controller to function It detects the front of the car and measures the pulses from the Pulse Input or Auto Pulse system to determine the length of the car This information is then used by the outputs to turn on and off at the appropriate times Values Delay On Distance Delays the detection of the front of the car for the entered amount of inches This is useful to avoid detecting people walking in front of the Entrance Eye over spray from a prep station or other short interruption of the Entrance Eye This value has the effect of offsetting the front of the car by the amount entered Recommended value is 6 inches Delay Off Distance This value delays the detection of the rear of a vehicle by the entered amount of inches This is useful to Page numbers CCS4000 Software Manual prevent detecting the gap between a pickup cab and its box as being the back of one vehicle and the front of another This has the effect of of offsetting the rear of the car It is recommended that this value be set to the same value as the Delay On distance so that the length of the car is not altered Recommended value is 6 inches Minimum Car Length This value tells the PLC to ignore any blockage of the Entrance Eye less than this amount If there is
73. to change 5 Click the Keep button if you are satisfied with the changes Otherwise click the Cancel button 6 Double click on one of the outputs that you want included with this menu The output must be Selective or De selective 7 Click the Select Menus button This action will change the output description section do display the menus that will activate deactivate this output Any menu that is green will activate this output if it is Selective If the output is De Selective the menus that are chosen will be red 8 To toggle the menu states click on the menus that you want to change Repeat this step for each menu that you want this output associated with 9 lf you are satisfied with the settings click the Keep button If not click on the Cancel button and the changes will be discarded Page numbers CCS4000 Software Manual 10 Repeat steps 5 to 9 for each output you want to associate with the menu 11 Click the Program menu on the Menu Bar on the main window 12 Select Save to Disk 4 5 Transferring the Program to the PLC Because the PC does not need to be connected to the PLC for the software or controller to operate any changes made in the software are not updated in the PLC until the user specifically requests this to happen To update the controller 1 Make sure that the PC is connected to the PLC and the connection works See chapter 3 Communications 2 Ensure that there are no cars in the tunnel 3 D
74. tput will create a 4 on 4 off pulse based on the internal Auto Pulse value or the pulse signal cleaned up from the timing of the Pulse input Example A another controller s pulse input can be connected to the Pulse output to be able to use the CCS4000 controllers Auto Pulse Value or if the electrical connections from the pulse switch to the different controllers are incompatible For example one controller requires AC inputs while the CCS4000 15 wired using DC inputs 7 Entrance Eye The Entrance Eye output will repeat the Entrance Eye input exactly or the resulting Entrance Eye information after the Delay On and Delay Off values have been applied Values None Options Input Terminal With this option selected the output will activate and deactivate exactly as the Entrance Eye Input Internal Flag With this option selected the output will activate after the Delay On distance has been applied on the Entrance Eye input and Deactivate after the Delay Off distance has been applied Example With the Entrance Eye Internal Flag option set the output can be connected to another controller s Entrance Eye input that has problems where it detects the gap between a pickup cab and its box as being the end of one vehicle and the beginning of another B 8 Entrance Sign The entrance Sign output will activate when a menu has been entered and will deactivate when the vehicle has passed the Entrance Photo Eye Values None Options Flashin
75. tware manual follow the steps in connecting and view the inputs By viewing the inputs you can determine if there is a button failure or a program issue External Point of Sale POS The CCS4000 can also accept inputs from a point of sale at the entrance of the wash common from DC is required and the PLC is usually wired IN 11 wash package 1 IN 12 wash package 2 IN 13 wash package 3 and IN 14 wash package 4 Consult the software manual and follow the steps in connecting to the PLC and view inputs You can also view the inputs on the HMI display With the TV remote program the HMI for menu 06 view inputs By entering in a valid wash code you should see one of the inputs11 through 14 turn on This will allow you to verify that the PLC program and the input correspond to each other If no inputs turn on put a jumper wire from DC to terminal IP11 If the input lights up the problem is in the POS If the input does not light up check the DC power supply Troubleshooting Outputs Output does not turn on First determine if the output relay is functioning properly With the TV remote program the HMI display for menu 05 output test With the key switch in the override on position enter the relay number you wish to test Use the volume button to turn on the relay and observe the relay that it clicks on The LED below the relay should light up Measure the voltage at the terminal marked NO from NO on the output relay to a neutral termin
76. ugh a cable connected to the communication ports of the controller and the PC or through modem at each end for remote communications 3 2 Connecting Directly To allow the CCS4000 software to communicate with the CCS4000 controller you need to connect the laptop or PC directly to it through the Communications port on the computer to the port on the controller To do this you need a special cable assembly from MacNeil Wash Systems The part numbers for this assembly are PC Adapter gt 70 306 00 MP PLC Adapter gt 70 305 00 MP RJ 11 Cable gt 70 311 00 PP NOTE Itis best to have a spare of each of the above parts in case one is lost or damaged NOTE lf your laptop does not have serial port consult Macneil wash systems technical support for adapters 1 Plug the PC adapter into the computer It is the only adapter that will fit Plug the PLC adapter into the CIFO1 adapter in the control box Make sure that the CIFO1 adapter is connected to the PLC The port is under a door on the left side of the PLC Plug the RJ 11 cable between the PC adapter and the PLC adapter Check the connection by clicking on the connect Menu and selecting Search for PLC If one is found the program will tell you in the Status Box on the upper right side of the main window Otherwise see the troubleshooting section later in this chapter Note If your laptop doesn t a serial port consult MacNeil Wash Systems Tech support for corre
77. um and the back of the cab is greater than the programmed distance from the back of the rest of the vehicle Values Minimum Cab Length This value is the minimum distance that the upper eye needs to measure for the high part of a vehicle before the vehicle will be considered a pickup truck This value should be between 24 and 54 inches Minimum Box Length This value is the minimum distance that can be measured from the back of the tall part of the vehicle to the back of the vehicle as read by the Entrance Eye before the vehicle will be considered a pickup truck Options Normally Closed This option if selected will tell the PLC to treat this input as a Normally Closed electrical connection The input then will be see the front of the cab when the input signal is turned off and the rear of the cab when the input signal comes back on Without this option it will see the front of the cab when the input signal comes on and the rear of the cab when the input signal turns off Example Connect its input terminal to a photo eye at the entrance of the wash that is mounted in such a way that it will look over cars but will be blocked by pickup trucks and vans Set the Minimum Cab Length to 24 inches so that a block of the eye less than that will not be counted as a pickup truck Set the Minimum Box Length to 54 inches the diameter of the top brush so that any box measurement less than that will not cause the RS 1000 to retract Pa
78. verride Off forces that output to always be off Select the option that is appropriate 5 Click Keep 6 Click the Program menu on the Menu Bar 7 Select Send To PLC 5 9 Set PLC Clock CCS4000 PLC has an internal clock To set the PLC s clock 1 With the software open click on the Service menu Select PLC Clock A window will appear that displays the date and time that is set in the PLC Change these values The format is displayed in the window When done click Set ee 5 10 Change Software Passwords The CCS4000 Software has three security levels These are Owner Service and Manager The Owner level allows all features to work including changing the passwords The Service password allows the same options as the Owner password except the ability to change passwords The Manager passwords provides the ability to view the tunnel and read information from the PLC but does not allow any changes to be made to the operation of the wash To change the passwords 1 With the software open click on a blank line in the Status box If there is no blank line visible scroll the box to the bottom or go to the end of a line with text on it and press CTRL ENTER at the same time on the keyboard Type change password Enter the existing owner password in the first box Enter the new password for the owner in the first New Owner Password box or the first Service or Manager box Repeat the password in the second N
79. will not dial out Determine if the modem is programed In the software under the change menu make sure the dialout number is correct If it is with the remote go to menu 13 test dialout If it will not dial out make sure there 15 dial tone present a dial tone is persent but it will not dial out replace HMI Unit will not communicate with POS With your TV remote go to menu 12 POS baud rate and change the port speed If you still get no communication try connecting the point of sale cable directly into the port on the PLC Check cable connections Consult the factory for correct pin outs Cannot connect laptop to HMI Try connecting to the PLC directly If you can establish communication than the connection on the HMI is bad If you can t communicate try another cable you must use the cable and DB9 connectors supplied by Macneil a regular phone cable won t work If you still can t connect to the PLC check your port setting on your laptop close other programs that use your serial port If your laptop doesn t have a serial port consult Macneil Wash Systems Tech support for the correct adaptors 6 Troubleshooting CCS 4000 This guide is intended to be used by qualified personnel only High voltage is present during most of the test procedures Due to the risk of electrical shock only persons trained in the repair of high voltage equipment should attempt to use this guide or make repairs Method With a digital volt meter measure th

WCC-CCS-4000 - MacNeil Wash Systems

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