SCC ULTIMA CONTROL SYSTEM

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15-1
SCC ULTIMA CONTROL SYSTEM
E-2.2 SCC HARNESS WIRING
1 Interface Board (EV221) 7
2 DC Power Supply g
3 Main Control Board (EV203F) 9
4 EL Display 10
5 Touch Screen Control Board 11
6 Battery
Connector for Printer
Reset Button
Muster Stop Button
Speaker
Printer
SCC ULTIMA CONTROL SYSTEM
Single Tube: CPU Board
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SCC ULTIMA CONTROL SYSTEM
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15-4
11/93
SCC ULTIMA CONTROL SYSTEM
Twin Tube - CPU Board
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SCC ULTIMA CONTROL SYSTEM
SCC ULTIMA OUTPUT FAILURE ANALYSIS
A failure of a function will usually be accompanied by one of the following error
messages:
DEFECTIVE OUTPUT K/F XX: (XX is a value from 1 to 40)
1. Replace relay K XX with a known good relay (module).
2. Replace the PICO-fuse F XX with a good fuse.
K1 K2 K3 K4 K5 K38 K39 K40
f\ F3 F4 F5
10 ID 10 ID ID ID ID
F38 F39 F40
10 ID ID
I/O BOARD
PRE-MODULE FAULT:
Indicates a failure in the logic or buffer circuitry and a board
replacement is necessary.
+24Vdc.
KXX FXX
LOGIC
BUFFER
PRE-MODULE FAULT
SENSING LINE
ODC5
S.S.R. PICO
FUSE
DEFECTIVE OUTPUT SENSING LINE
-0o-
VALVE
FEEDBACK LINES VERIFY CIRCUIT OPERATON
SCC ULTIMA CONTROL SYSTEM
SCC ULTIMA Output Failure Analysis con't.
NO ERROR MESSAGE:
If a function fails to operate, and there is no error message, make sure that:
1. The function is turned on.
2. Timing is correct.
3. There is no mechanical problem. (Try MAC valve mechanical override).
4. There are no loose or broken wires.
15-8
11/93
SCC ULTIMA CONTROL SYSTEM
I/O Assignments for Single Tube and Twin Tube Application
K/F OUTPUT #
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
SINGLE TUBE / TWIN TUBE
JAW CLOSE
PLATEN
KNIFE
STRIPPER
PRINTERS!
QUALI-SEAL
HOLE PUNCH
AUX#1
SHAKER
STAGER/SHAKER JAWS
MEASURE ROLLS (INT)
PULL BELTS (INT)
AUX#2
AUX#3
PRINTER #2
REG WINDOW (INT)
END SEAL AIR
SEAM SEAL AIR
BAG EJECT
BAG DROP
TUBE AIR
POKER
POKER AIR
AUX TIMER 1
AUXTIMER2
WATER VALVE
PACER
SHUTDOWN TIMER
FILL #1
FILL #2
SPARE 110 VAC OUTPUT
DOUBLE LENGTH BAG
AGITATOR
AUGER CLUTCH
15-9 11/93
SCC ULTIMA CONTROL SYSTEM
I/O Assignments for Single Tube and Twin Tube Application con't.
K/F OUTPUT #
35
36
37
38
39
40
SINGLE TUBE /TWIN TUBE
WEB GUIDE LEFT
WEB GUIDE RIGHT
REGISTRATION ROLL CLUTCH
REGISTRATION ROLL BRAKE
PULL BELT CLUTCH
METAL DETECT INDICATOR
INPUT #
201
203
205
207
209
211
213
215
223
225
227
229
231
233
235
237
SINGLE TUBE / TWIN TUBE
N/C SIDE (L/R)
N/C LEFT SENSE WEB GUIDE
N/C RIGHT SENSE WEB GUIDE
TEST BAG COUNT
CC RESET
EXTERNAL ENABLE
HIGH WATER
LOW OIL
MASTER RELAY
AUX. STOP / DOOR GUARD
MASTER STOP / METAL DETECT
LOW AIR PRESSURE / AUX. STOP
LEFT DOOR/LOW AIR
RIGHT DOOR / MASTER STOP
CC MASTER RELAY
24 VDC SUPPLY
INTERRUPT INPUTS
INPUT #
162
164
166
168
170
172
174
SINGLE TUBE
LOW FILM
TRANSMISSION ENCODER
AUGERCOUNT
EXTERNAL GO
TEST ENCODER
REGISTRATION EYE
JAWPROX
15-10
11/93
SCC ULTIMA CONTROL SYSTEM
Registration Roller Clutch/Brake Problems
1. Using an oscilloscope, check the registration roller brake voltage while the
machine is idling to generate a steady brake voltage signal at the circuit board.
Check the registration roller clutch voltage by having someone press "continuous
tube" to generate a steady clutch voltage signal at the circuit board. To avoid
wasting packaging material, do not thread the machine.
2. Connect the oscilloscope to the clutch and brake terminals on the circuit board.
Set the oscilloscope sweep time to 2 ms/div. at 5 Vdc/div. (.5 Vdc with 10X
probe).
3. Examine voltage trace. A single 40 ms overexcite pulse will occur and then the
pulses should be as shown in figure 3.
The brake voltage should show 24 Vdc pulses, approximately 1.2 ms wide, at
10 ms intervals.
The clutch voltage should show 24 Vdc pulses, approximately 1.5 ms wide at
10 ms intervals.
30V
25V
20V
15V
10V
5V
0V
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1.2ms for brake
1.5ms for clutch
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15-11
10 12 14 16
11/93
SCC ULTIMA CONTROL SYSTEM
Registration Roller Clutch/Brake Problems
4. If the trace is different than this:
a. Turn all power OFF.
b. Disconnect the wires of the circuit under test.
c. Restore power.
5. Re-examine the voltage trace.
a. If the trace is correct, troubleshoot the coil circuit.
b. If the trace is incorrect, replace the circuit board.
15-12 11/93
SCC ULTIMA CONTROL SYSTEM
Error Message Definitions
The following error messages will appear on the SCC ULTIMA Display at different
times during the operation of the system.
There are three types of error messages involved for each piece of equipment con-
nected to the display.
Information messages
Shutdown errors
Safety errors
In most cases the error message will have an arrow following the message which
indicates right (*) or left (*) side. Error messages from either side will report to the
screen selected.
INFORMATION MESSAGES
These messages are normal and can occur in all modes. They do not cause a shut-
down. Examples of these messages are:
"BAG IN POSITION" - is displayed after completion of the film setup function and
an eyespot was detected.
"EYESPOT NOT DETECTED" - is displayed after completion of the film setup func-
tion and an eyespot was not detected.
"OUT OF REGISTRATION" - is displayed while running in the filled bags mode
and an eyespot was not detected within the registration window. In the empty bag
mode, this message will appear without any shutdown. If in the filled bags mode,
the message may prompt a shutdown if registration cannot be restored by the bag-
maker without operator intervention.
15-13 11/93
SCC ULTIMA CONTROL SYSTEM
Error Message Definitions con't.
"REGISTRATION RESTORED" - is displayed while running in the filled bags
mode. The eyespot was detected in the window following an out of registration con-
dition.
NOTE: When a filled cycle goes out of registration, the bagmaker will cancel the
endseal operation display "OUT OF REGISTRATION" and go immediately into a
film setup. If an eyespot is detected, the film will be pulled into position, a backseal
made, the error message cancelled, and operations will continue normally. A bag of
about 2-1/2 times normal length with a double charge will be produced in the
process.
If registration cannot be restored, the scale will be disabled, bagmaker stopped, and
the "OUT OF REGISTRATION" error will remain displayed.
"JAM DETECTED - ULTIMA" - is displayed when the jaws are jammed, (the jaws
did not close in the time allotted). This message is only displayed for the first jam. ^~"
second consecutive jam would shut the system down.
"UNDEFINED COMMAND -CC" - means the ULTIMA received a command from
the display that was not defined in the Protocol.
"DEFECTIVE OUTPUT K/F **-ULTIMA"- means output did not turn OFF or ON as
commanded by processor. The possible causes for this error include:
defective output module K**
defective fuse
broken wire to the load or loose terminal
defective load
** = the I/O board number of the output with the error.
"DEFECTIVE HTR OUTPUT Z*- ULTIMA" - means one of the heaters did not turn
OFF or ON as commanded by the processor.
Possible causes for the problem include:
defective output module Z*
circuit breaker tripped in zone Z* ^.
broken wire to the load or loose terminal
defective load
* = the heat zone with the error.
15-14 11/93
SCC ULTIMA CONTROL SYSTEM
Error Message Definitions con't.
"PREMODULE FAULT P*:B*MJLTIMA" - an output did not turn either OFF or ON
as commanded by the processor and the error occurred before the output module.
P* = the output port with the error
B** = the bit number within that port
The cause of this type message is usually a defective board mounted device such as a
driver, latch/ etc., and will generally not be field reparable.
"DEFECTIVE INPUT **-ULTIMA" - an input used in the safety string is reporting
it's down, but the MASTER RELAY is still up.
This message would appear if the wiring to the external switch were defective going
to the processor.
"******** TEMP IS TOO LOW -ULTIMA" - means the actual temperature is below the
set value (from 5 to 20) for that temperature zone.
********
= the specific zone.
This message will appear on startup in a continuous bags mode. It notifies you that
bagmaker will not cycle because one or more heating zones are not at the proper
operation temperature.
*********'
TEMP IS TOO HIGH-ULTIMA" - means the actual temperature is above
the set value (from 5 to 20 degrees) for that temperature zone.
********
= the specific zone.
NOTE: The above temperature messages are only displayed for the single cycle and
any continuous cycle in progress. (The +/- 5 to 20 degrees depends on the setup of
the proportioning band).
"********'
1 1 = represents JAW FRONT / JAW REAR / PLATEN / AUX. zones.
1 5-1 5 1 1 /93
SCC ULTIMA CONTROL SYSTEM
Error Message Definitions con't.
CONTROLLED SHUTDOWN ERRORS
These errors cause a controlled shutdown. Your system will stop upon completing
the present function. Examples of these errors are:
"TERMINAL COUNT - ULTIMA" - is displayed in filled bags mode when the termi-
nal count (bag stop) = 0.
"FEED RATE EXCEEDS ULTIMA SPEED" - is displayed in filled bags mode when
the feed system dumps the product faster than the ULTIMA is making bags.
"LOW FILM - ULTIMA" - means the low film switch was activated (only displayed
while running filled bags). The shutdown will occur to keep the film from being
pulled through the bagmaker which would make it much more difficult to change
rolls of film.
-
"EXTERNAL ENABLE - ULTIMA" -is displayed in filled bags mode when the extt
nal enable input is activated.
"START DELAY TOO LONG - ULTIMA" - means the next product dump was
received and the current start delay had not timed out yet (the current bag cycle had
not started). This requires the adjustment of the start delay function to be no longer
than the time required for the bagmaking cycle.
"SHORTED RTD: ******** - ULTIMA" - means an RTD is shorted.
"OPEN RTD: ********. ULTIMA" - means an RTD is open or not connected.
"ILLEGAL ******** TEMP - ULTIMA" - means the temperature was set above a rea-
sonable number (550).
TEMP OVERRANGE - ULTIMA" - the actual temperature is above the
high limit of the temperature range (550). This would indicate a possible shorted
output module in the temperature control module and would most likely occur with
an error message concerning the output.
NOTE: For any temperature message the field "********" could represent - JAW
FRONT / JAW REAR / PLATEN / AUX. zones. _
******** _ = the specific temp zone of the error.
15-16 11/93
SCC ULTIMA CONTROL SYSTEM
Error Message Definitions con't.
SAFETY ERRORS -Immediate Shutdown
Safety errors are errors that will cause an immediate shutdown of your machine.
These are generated by the MASTER RELAY line or in componentry associated with
the safety string. Examples of these errors are:
"NO + 24V SUPPLY - ULTIMA" - indicates the ULTIMA lost its +24 volts. Possible
causes include:
blown fuse in the 120 vac source to the 24 VDC supply
blown fuse in the 24 VDC line in the power supply
external short on the 24 VDC circuitry of the system
"RIGHT DOOR OPEN -ULTIMA" - means the right door is open.
"LEFT DOOR OPEN - ULTIMA" - means the left door is open.
"LOW AIR PRESSURE - ULTIMA" - indicates the air pressure has dropped below
the limit set on the pressure switch.
"LOW OIL DETECTED - ULTIMA" - means the oil level for the pneumatic oiler is
too low.
"WATER LEVEL EXCEEDED - ULTIMA" - means the container used to collect the
water condensate from the pneumatic lines is full.
"MASTER STOP PUSHBUTTON - ULTIMA" - indicates that the emergency stop
pushbutton was pushed or is locked in.
"AUX STOP PUSHBUTTON - ULTIMA" - means the aux. stop pushbutton was
pressed.
"PRESS RESET BUTTON - CC"- means the display's MASTER RELAY has
dropped.
"MASTER RELAY - ULTIMA" - means the ULTIMA MASTER RELAY has dropped.
NOTE: The above 10 messages are displayed for safety strings faults. They all will
drop the ULTIMA MASTER RELAY. The message displayed will specify which one
caused the string to go down. When the MASTER RELAY is dropped the +24V sup-
ply and air are also dropped from the machine.
15-17 11/93
SCC ULTIMA CONTROL SYSTEM
Error Message Definitions con't.
"WATCHDOG - ULTIMA" - means the power watchdog for the ULTIMA was lost,
the CPU stopped processing. The processor will attempt to reset and restart on its
own if possible. Failure to reset will result in board replacement.
"SHUTDOWN TIMER -ULTIMA" - the ULTIMA Was left idle longer than the shut-
down time (approx. 30 minutes).
"NO ENCODER -ULTIMA" - the encoder pulses are not being detected by the
processor board. One possible cause for this error would be the transmission lever is
not engaged in either the long or short bag position.
"JAM DETECTED -ULTIMA" - the jaws were jammed for the second consecutive
cycle. The jaw closed cycle is timed each cycle. If the jaw closed proximity switch is
not detected in the amount of time required for the last cycle plus a safety factor, the
jaw closed signal is terminated for that cycle. If the situation continues for two con-
secutive cycles, the machine cycles are terminated. ^ ~
"COMMUNICATION ERROR - CC" - the display did not acknowledge one of the
commands the ULTIMA sent to it.
"CPU BLOCK ERROR *** -ULTIMA" - is displayed when one of the blocks (or
areas) of the ULTIMA control boards did not initialize properly after power up or
reset.
***
= the specific areas that had errors.
"OUCH ERROR #*** -ULTIMA" - is displayed when the control boards have a fatal
error and processing is halted.
***
= the specific type of error to cause the fault.
NOTE: If everything is hooked up properly and operating correctly, the "ZF" mes-
sages should drop the MASTER RELAY in the SCC ULTIMA Display which in turn
would drop the MASTER RELAY of the ULTIMA. Even the "ZF" errors that are not
part of the safety string will indirectly drop the ULTIMA MASTER RELAY.
15-18 11/93