B390L+B450L_electrical_manual_en_V2

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B450L + B390L
- ELECTRICAL INSTRUCTION MANUAL -

Wiring instruction manual B450L+B390L-en.doc


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- ELECTRICAL INSTRUCTION MANUAL -
B390L+B450L
with Siemens S7-1200

Wiring diagram file Keypad Description


4074-01A-* Batterie_Vxx.zip SIMATIC KP400 Two-beater opener with speed
control and B450L cage
Last update Print date
16/06/2013 06/05/2019

CONTENTS

I – LIST OF INPUTS AND OUTPUTS .................................................. 3


II – MENU STRUCTURE ......................................................................... 4
III – CONNECTIONS AND EMERGENCIES ...................................... 5
IV – DEFAULT PARAMETER ACQUISITION ................................... 5
V – MANUAL CONTROLS ..................................................................... 5
VII – VARIABLE MACHINE PARAMETERS..................................... 7
VIII – MAINTENANCE............................................................................ 9
IX – B390L CONTROL PANEL ............................................................ 10
X – SIMATIC KP400 TERMINAL ........................................................ 11
XI – WASTE ANALYSIS PROCEDURE ............................................. 12
XII – DISPLAY ........................................................................................ 13
XIII – EMERGENCY AND WARNING MESSAGES ........................ 14
XIV – INVERTER PARAMETERS ...................................................... 17
XV – Door safety anti-tamper check ..…………………………………18

Wiring instruction manual B450L+B390L-en.doc


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I – LIST OF INPUTS AND OUTPUTS
Digital inputs on the CPU 1214C – Byte 0
HSC1 - SE02801 SPEED CONTROL BEATER 1
%I0.1 - SQ01001 LEFT DOOR CONTROL
HSC2 - SE02802 SPEED CONTROL BEATER 2
%I0.3 - SQ01002 RIGHT DOOR CONTROL
%I0.4 - SQ01201 B450L CAGE DOORS CLOSED
%I0.5 - SB02801 START BUTTON
%I0.6 - SB02802 STOP BUTTON
%I0.7 - KM01201 KM01201 CONTROL (LINE ACTIVATED)

Digital inputs on the CPU 1214C – Byte 1


%I1.0 - KM03401-5 POWER CONTACTORS CONTROL
%I1.1 - SE03001 IN DOOR CONTROL
%I1.2 - SE03002 OUT DOOR CONTROL
%I1.3 - SQ01003 ELECTRICAL BOX
%I1.4 - --- SPARE INPUT
%I1.5 - QM02201-3 MOTOR THERMAL RELAY ALARM

Digital inputs on the module SM1221 – Byte 2


%I2.0 - R02001 BRAKING CHOPPER TEMPERATURE ALARM
%I2.1 - SA03001 MATERIAL FLOW ON/OFF SELECTOR
%I2.2 - SB01001 EMERGENCY BUTTON
%I2.3 - E01401 BEATER STOP CHECK
%I2.4 - ST03201 BOX OVERTEMPERATURE ALARM
%I2.5 - U02001 INVERTER BLOCK ALARM
%I2.6 - RM1 BLEND 1 REQUEST
%I2.7 - RM2 BLEND 2 REQUEST

Digital outputs on the CPU 1214C – Byte 0


%Q0.0 - KA03401 LINE ACTIVATION ENABLE
%Q0.1 - KA03402 EXTERNAL SIGNAL
%Q0.2 - KA03403 START BEATERS
%Q0.3 - KA03405 START WASTE GEARMOTOR
%Q0.4 - KA03406 START CAGE CYLINDER
%Q0.5 - KA03407 START CAGE FAN
%Q0.6 - KA03408 START SILO FAN
%Q0.7 - KA03409 RESET INVERTER ALARM

Digital outputs on the CPU 1214C – Byte 1


%Q1.0 - KA03601 BLEND 1 MATERIAL REQUEST
%Q1.1 - KA03603 BLEND 2 MATERIAL REQUEST

Digital outputs on the module SM1222 – Byte 2


%Q2.0 - H03601 GREEN LIGHT - ON
%Q2.1 - H03601 RED LIGHT – STOP/EMERGENCY
%Q2.1 - --- OUTPUT AVAILABLE
%Q2.2 - --- OUTPUT AVAILABLE

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II – MENU STRUCTURE

N.B. Tree menus are used here, as with Windows. Each menu is arranged in hierarchical order, with
branches and sub-branches on various levels. When you have reached the page you need, you have
to return to the top to conduct a new search. If a page is displayed for five minutes without any
changes being made, you return automatically to the start-up page.

Wiring instruction manual B450L+B390L-en.doc


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III – CONNECTIONS AND EMERGENCIES
Connect the production line to the electrical box in accordance with EN60204-1(4.3.2) and IEC
364-3(TT-312.2.2).
The inverter line has a filter in compliance with European Directive EMC 89/336 with 230V
leakage current and phase to earth less than 40mA.
Make the connections according to the wiring diagram and check the line and the auxiliary voltages,
initially disconnecting the terminal blocks.
With magneto-thermal switches QM in position 0, press the buttons and limit switches on the
machine to check all the inputs.
Check that the emergency button SB01001 on the control panel, the safety guard limit switches and
overrun devices cut off power to the control circuits.
If you press the blue line button SB01201 on the keypad with the guards closed, line contactor
KM01201 must activate.
If you open a guard or press the emergency button SB01001, contactor KM01201 must de-activate
and cut off powers to the motors and inverters.

IV – DEFAULT PARAMETER ACQUISITION


This procedure is performed from the second page in the Machine menu by selecting the
ACQ.VAR.DEF. function. The standard values determined during programme development will be
loaded.

V – MANUAL CONTROLS
To test motor rotation and the basic movements of the machine, we have created some manual
control pages from which you can check all the functions without the machine running
automatically. Clearly the line must be activated by pressing the blue line button before carrying out
any tests. This programming area can only be accessed from the second page in the Machine menu
– F2=COMMANDS.
!!! IMPORTANT !!!

N.B. THE SAFETY DEVICES ARE NOT ACTIVE!


THESE TESTS MUST ONLY BE PERFORMED BY TRAINED ELECTRICIANS
(IEV 826-09-01 modified)

 Caution

DANGER
Risk of personal injury

Wiring instruction manual B450L+B390L-en.doc


5/18
VI – PRODUCTION CYCLE
A - STARTING UP
1. Check that the working speed values of beater 1 of the B390L are set according to the
characteristics and requirements of the system. The number of revolutions of beater 2 is
determined automatically by the pole-motor ratio. All speeds are expressed in rpm (revolutions
per minute).

2 . Check that grids 1 and 2 are open and analyse the percentage of waste to get the desired value.
If necessary, adjust the position of the baffles if it is not suitable, following the instructions
provided.

3. Press the start button SB02801 to start up all the motors automatically in sequence.

B- STOPPING

EMERGENCY STOP
An emergency stop can be generated by any of the following:
1. Pressing the emergency button SB01001
2. Opening any of the doors or guards with the machine running
3. Activation of the thermal relays
4. Inverter shutdown
5. Alarm
6. Intervention of safe operation controls

The power supply to the motors and inverters is cut off instantly.

NORMAL STOP:
If you press button SB02802 on the control panel, or the stop button on the B95 central
control unit, the machine cycle is interrupted.
The beaters of the B390L and material request from the previous machine stop instantly.

C – CYCLE ALARM
The following malfunctions are signalled by an intermittent alarm and an error message.

- Motor thermal relay activation


- Beaters clogged
- Doors open
- Contactors faulty
- Box overheating
- Resistance overheating
- Beaters jammed
- Inverter block

Wiring instruction manual B450L+B390L-en.doc


6/18
VII – VARIABLE MACHINE PARAMETERS
A - ACCESS CODE SETTING
The programme has four access levels and associated passwords. Once an access level has been
established, it remains enabled until a new code is entered or you exit the Password page
(PASSWORD). Important: if the panel is not used for five consecutive minutes, the user is
disconnected automatically and the level resets to the one below.

➢ Level 0 : No authorisation required → This gives access to the parameter display


and setting page (read only). A higher level
is required to change the values.

➢ Level 1 : Authorised user → This gives access to all the pages dedicated
to automatic operation of the machine (read
and write). The user can view and change
the parameters. This level password is
reserved for authorised personnel.

➢ Level 2 : Expert user → This gives access to all the pages for
automatic and manual operation. Since the
machine can be operated manually, when
some of the safety devices are not active,
this level password is reserved for IEV 826-
09-01 mod. trained personnel.

➢ Level 9 : Marzoli personnel → This gives access to all fields (read and
write) and pages. It is the only level
allowing software updating. Only Marzoli
personnel know this password.

There are two different ways of setting an access level.


➢ From the System page:
a) Go to the System page and select F2=SET PASSWORD.
b) The Password page is displayed.
c) Select F1=LOGIN.
d) Type in the password and press ENTER to confirm.
e) You can now access all the pages and fields requiring an access level equal to or
below that associated with the password.

➢ From an attempt to access


a) Select a password-protected field or page.
b) The Password page is displayed.
c) Enter a password of the desired level and press ENTER to confirm.
d) You can now access all the pages and fields requiring an access level equal to or
below that associated with the password.

Wiring instruction manual B450L+B390L-en.doc


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B - MACHINE SETTINGS
On the MACHINE SETTINGS page, there are two options:
CHOOSE MACHINE MODEL - F1 (Marzoli personnel only)
ANALOGUE PRESSURE SWITCH – F2

The function is enabled if an asterisk is displayed next to the script when you press F2. It is
disabled by pressing F2 again.

C – WASTE ANALYSIS
Refer to Section XI below.

D - WORK PARAMETER SETTINGS


The MAIN MENU gives access to pages for setting the following:

➢ Machine settings
➢ Times
➢ Pressures
➢ Speeds

It also has links for enabling manual commands (see section V) and acquiring default
parameters (see section IV).

F – ACCESS PASSWORD SETTING


See Section VII.

G – SUPERVISION NETWORK
Within the intranet Profinet network, each machine can be identified by a node number and a
machine number. Both these parameters can be entered in the programme loaded in the
machine. They must be set according to the Marzoli layout indications. This can be done on
panel KP400, which has a dedicated page.

H – SOFTWARE UPDATE AND RELEASE


This page shows the date of the last modification made to the and keypad software.
The information on this page cannot be modified by the user.

Wiring instruction manual B450L+B390L-en.doc


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VIII – MAINTENANCE
Efficient operation of the machine depends on correct maintenance by SPECIALISED
PERSONNEL according to the rules of GOOD PRACTICE.
The maintenance frequencies are detailed below.

A. ONCE A WEEK Press the EMERGENCY BUTTON to check the power


contactors.

B. ONCE A FORTNIGHT Clean the ELECTRICAL BOXES thoroughly, suctioning up


any dust and fibre deposits on the components.

C. EVERY TWO MONTHS


1. Check the locking screws on the auxiliary cables and the power screws on the
components in the electrical boxes (contactors, thermal relays, terminals, etc.).
2. Check the electrical connections on the motors (wire clamping screws).
3. Clean the motors thoroughly to ensure correct cooling.
4. Check the limit switches and sensors on the machine.
5. Check the 24Vdc supply voltage to the PLC.

D. ONCE A YEAR Thorough motor overhaul, with greasing or precautionary replacement


of the bearings.

If any of the electrical parts malfunctions, ALWAYS check carefully what message is displayed on
the screen.

• INVERTER ALARM Check whether the problem is due to overheating or


overcurrent. Make sure the motor absorbs current that is below
the rated values and balanced on the three phases.

• THERMAL SAFETIES Check the settings of the thermal safety devices, input currents,
three-phase voltages and contactor contacts.

• OPERATIONS INTERRUPTED Check the inputs and outputs to ensure correct


operation of the command. Check for short-circuits or
component interruptions.

CYCLIC CONTROL OF THE LIMIT SWITCHES.


Check before start-up of production that all the fixed covers are in the right positions and properly
blocked with all screws in position and locked.
From time to time, it will appear on the operator panel the request to check the proper operation of
the protections (doors or covers) equipped with interblocks. This is a safety procedure and it is
imperative to perform it.

Wiring instruction manual B450L+B390L-en.doc


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IX – B390L CONTROL PANEL

SB01001 = Red emergency button SB02801 = Green start button

SB02802 = Red stop button SA03001 = ON/OFF material request

SB01201 = 400V AC line activation

Wiring instruction manual B450L+B390L-en.doc


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X – SIMATIC KP400 TERMINAL

FUNCTION KEYS

K1  Page back scroll (if a page before the current one exists, the light on the key
comes on)
K2 depends on page displayed
K3 depends on page displayed
K4  page forward scroll (if a page after the current one exists, the light on the key
comes on))
F1 depends on page displayed
F2 depends on page displayed
F3 depends on page displayed
F4 depends on page displayed
 cursor movement on map in accessible fields
 cursor movement on map in accessible fields
 cursor movement on map in accessible fields
 cursor movement on map in accessible fields

CONTROL KEYS

Shift Associated with numeric keys 1-6. Used to enter alphabetic characters
displayed next to the number, or use the Ins. function. Press once to activate
(the Shift LIGHT next to the function keys comes on) and again to
deactivate.-
Ins/Del Delete the character in the cursor position, or overwrite it if the shift function
is active.
Help On-line help for the page displayed.
Esc Cancel the value entered in the selected field.
Ack Acknowledge an alarm displayed on the operator panel.
Enter Confirm a new value entered in the selected field.

Wiring instruction manual B450L+B390L-en.doc


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XI – WASTE ANALYSIS PROCEDURE
This procedure enables you to analyse periodically the percentage quantity and type of waste
rejected by the opener, the purpose being to achieve and maintain the best degree of opening and
cleaning.

Waste analysis can take place in AUTOMATIC or MANUAL MODE.

AUTOMATIC WASTE ANALYSIS (with B175 )


1 – The machine and system must be in operation.
2 – Connect the pipe of the B175 to the deviator at the exit of the B390L.
3 – Start the fan of the B175.
4 – Regulate the fan revolutions to get the vacuum of the B175 the same as that of B390L.
5 – Switch the deviator to convey waste to the collection bin of the B175 (ON/OFF switch
on B175 panel).
6 – Return the deviator to the work position.
7 – Examine the waste in the bin.
8 – If there are problems with the waste, adjust the position of the ENTRANCE grid,
without changing the position of the exit grid, and repeat operations 6-8.
9 – When the waste analysis is satisfactory, select the value corresponding to the
presumably ideal opening of the exit grid.
10 – Repeat points 6-8 (the waste analysed now is that to be taken into consideration for
technological assessments of production output).
11 – If other problems occur, adjust the position of the exit grid and repeat points 6-8 until
the desired result if achieved.

MANUAL WASTE ANALYSIS


1 – From the start-up page, press F1 to access the main menu.
2 – From the main menu, press F1 to access the machine menu.
3 – Press K4 -> K4 -> F1 WASTE ANALYSIS (access requires a level 1 password)
4 – Enter on the map the time (in seconds, ”) considered sufficient to collect enough
material to be examined.
5 – Start the machine, which will run for the set time, keeping the waste discharge rollers
still (press F1 to start the countdown).
6 – Wait for the machine to come to a complete stop, open the doors, remove the waste
and analyse it.
7 – If the results are not satisfactory, alter the position of the entrance and exit grids and
repeat the analysis until the results are satisfactory.

Wiring instruction manual B450L+B390L-en.doc


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XII – DISPLAY
The terminal displays some parameters referring to machine operation.
To call up the page, return to the main menu and press F2.
The page presents a list of the following values, which are updated in real time:

➢ Power
➢ Material suction pressure [mmH2O]
➢ Waste suction pressure [mmH2O]
➢ Beater 1 speed [rpm]
➢ Beater 2 speed [rpm]

Wiring instruction manual B450L+B390L-en.doc


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XIII – EMERGENCY AND WARNING MESSAGES
An alarm is generated when there is a malfunction of the automation programmes. If this happens,
either the machine stops entirely, or, if the alarm is not a potential hazard to the mechanical parts,
the power supply cuts off. A warning light comes on, and a message page is displayed on the
operator panel. The message describes the current alarm and attributes it a code number, for
identification and resolution purposes.

When the cause of the alarm has been resolved, press the start or stop button to return to the work
pages and restart the machine as normal.

ALARM CODES

Below is a list of alarms displayed by the B390L and suggestions on how to resolve them.

Alarm 1 – Emergency button pressed


Cause: The emergency button has been pressed.

Remedies: Check whether there exist emergency conditions requiring an instant stop and remedy
the situation if required.
Release the button using the key provided.
Check button SB01001 (wire 3201, to PLC input %I2.2).

Alarm 2 – Left safeties


Cause: The set of safety devices on the left doors has been interrupted.

Remedies: Check that all the doors are closed.


Check micros YA01001 and SQ01001 (wire 2803, to PLC input %I0.1).

Alarm 3 – Right safeties


Cause: The set of safety devices on the right doors has been interrupted.

Remedies: Check that all the doors are closed.


Check micros YA01002 and SQ01002 (wire 2804, to PLC input %I0.3).

Alarm 22 – Electrical box door open


Cause: The micro on the door of the electrical box indicates incorrect closure.

Remedies: Check the door is closed.


Check micro SQ01003 (wire 3004, to PLC input %I1.3).

Alarm 4 – Exit doors


Cause: The exit door closed signal has been interrupted.

Remedies: Check that all the doors are closed.


Check micro SE03002 (wire 3003, to PLC input %I1.2).

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Alarm 5 – Entrance doors
Cause: The entrance door closed signal has been interrupted.

Remedies: Check that all the doors are closed.


Check micro SE03001 (wire 3002, to PLC input %I1.1).

Alarm 8 – Thermal relays


Cause: The series of thermal relays have been interrupted, so the machine has stopped to
prevent overheating.

Remedies: Check magnetothermal relay QM02001


Check magnetothermal relay QM02002
Check magnetothermal relay QM02201
Check magnetothermal relay QM02202
Check magnetothermal relay QM02203
Check magnetothermal relay QF00603
Check wire 3006, to PLC input %I1.5 del

Alarm 9 – Inverter
Cause: Inverter U02001 does not work. Either it has detected a thermal alarm or it is faulty.

Remedies: Check inverter U02001. If it is faulty, power off the machine and then power it on again.
Check fuses F02001
Check input %I2.5, wire 3204 (Inverter faulty).

Alarm 14 – Electrical box temperature


Cause: Thermostat ST03201 in the electrical box indicates overheating.

Remedies: Check the setting of thermostat ST03201.

Alarm 16 – Beater speed


Cause: The beaters cannot reach the desired speed in the set time.

Remedies: Check there is no clogging preventing the beaters from accelerating.


Check motor M02001.
Check the U02001 inverter parameters associated with the acceleration ramps.
Check on the beater management page that a delay compatible with the inverter
parameters has been set before acknowledging this alarm
Check sensor SE02801 (wire 2801, to PLC input %I0.0)
Check sensor SE02802 (wire 2802, to PLC input %I0.2).

Alarm 17 –24Vdc Fault


Cause: There is a short-circuit on the 24Vdc line.

Remedies: Check each of the 24Vdc lines to detect the short-circuit.

Alarm 18 – Cage door open


Cause: The door of the cage has not been closed correctly.

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Remedies: Check the door is closed correctly
Check micro SQ01101, wire 1007, plug XS7 pins 1-2
Check micro SQ01102, wire 1202, plug XS7 pins 3-4.

Alarm 19 – Braking resistor


Cause: The braking resistor temperature has exceeded the safety threshold, causing the machine
to stop

Remedies: Let the resistor cool down.

Alarm 21 – Contactors fault


Cause: With contactor KM01201 open (offline), a contactor KM03401-5 is active.
With the door open, the 400VAC mains line has not cut out.

Remedies: There is a contactor with stuck contacts. Check that the KM01201 and KM03401-5
open and close regularly.

Alarm 65 – Material suction insufficient


Cause: Suction of material is not sufficient to ensure a smooth flow of material.

Remedies: Check pressure switch BP03801 (wires 3801 and 024V, brought to the analogue input
module number one, 2M and 0, respectively)
Check wiring of the analogue input module.
Replace the analogue input module.

Alarm 66 – Waste suction insufficient


Cause: Suction of waste is not sufficient to ensure correct cleaning of the machine.

Remedies: Check pressure switch BP03802 (wires 3802 and 024V, brought to the analogue input
module number one, in 2M and 1, respectively)
Check the wiring of the analogue input module.
Replace the analogue input module.

Message number 101 – Power line not connected


Cause: The power line to the machines is not connected.

Remedies: Press the run button to connect it up again.


Check KM01201 (wire 2808, at entrance %I0.7).
Check the power contactor series, entrance %I1.0 of the PLC.
➢ KM03401, wire 3010
➢ KM03402, wire 3011
➢ KM03403, wire 3012
➢ KM03404, wire 3013
➢ KM03405, wire 3001

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XIV – INVERTER PARAMETERS
Insert into the inverter these parameters:
To reset the parameters to the factory default -> P0003=1 P0010 = 30, P0970 = 1.
Par. Description Beaters
Set motor parameters, from Visual [Hz] → push M > 2sec
Select into BOP the menu “SETUP".
P100 0: Europe [kW] 50 Hz (set by default) 0
P304 1: Nord America
Nominal [hp], 60 Hz
voltage [V] 400
P305 2: Nord America
Nominal [kW], 60 Hz
current [A] 28
P307 Nominal power [kW] 15
P308 Power factor [cosΦ] 0,82
P309 Nominal efficiency [%] 91
P310 Nominal frequency [Hz] 50
P311 Speed [g/min] 1460
P1900 Identify motor 0
0: Disabilitato
Setting connection macros, push M < 2sec
2: Identificazione
Macros: di tutti
Control from i parametri
terminal NPN da fermo
/ PNP, external binary control, Cn002
potentiometer with setpoint. (Cn001=BOP Cn003=Vel. fisse)
Setting application macros, push M < 2sec
Macros: AP000=Default AP000
Setting common parameters, push M < 2sec
P1080 Minimum speed [g/min] 0
P1082 Maximin speed [g/min] 2190
P1120 Acceleration ramp [sec] 10
P1121 Deceleration ramp [sec] 10
Menu parameters, push M > 2sec → Visual → M < 2sec
P3 User access level (3=expert) 3
P702 Digital input 2 (2=invers 3=Off2 4=Off3 29=Disinser) 3
P1237 Braking 0=disab 1=5% 2=10% 3=20% 4=50% 1
P1240 Adjust Vdc (must is set to 0 for enable braking) 0
P2000 Frequency with 10V in input [rpm] (nominal+50% 1460x1,5) 2190

In the end set display r0000 (Visual) by pushing M>2sec.

Wiring instruction manual B450L+B390L-en.doc


17/18
XV – DOOR SAFETY ANTI-TAMPER CHECK
With reference to the machinery safety standard EN60204-1(4.3.2), an efficiency check is carried
out on safety devices, such as limit switches and electric locks of the doors on the machine.
The Test involves an automatic diagnostic cycle that detects the Inactivity of the door for more than
28 consecutive days, after which the level of efficiency of the checked devices will be indicated via
a specific diagnostic page.
The manager assigned by the customer must check the level of efficiency of the safety devices,
operating as described, i.e. opening/closing the doors in question and checking that the relative
safety circuit is triggered (Power OFF).
The system message that will be automatically displayed cyclically can be ignored, until the
NECESSARY checks will be carried out on the devices.
Once the check time elapses, the system will inform the operator with the following notification:
Pressing F1 will access to the screens where specifically, all the devices present will be indicated,
with the operating status of the Test :
If the red LED (Fault) = is present, it indicates that the limit switches/electric locks REQUIRE the Test.
Open the relative door and verify the efficiency of the safety circuit (power Off).
Close the door again. Grey LED (Off) = Test executed. OK !
If the grey LED(Off) = is present it indicates that the limit switches/electric locks were active
during the time covered and therefore, do NOT require the Test.
The following message will also be shown: “LAST TEST SKIPPED”, if the previous Test was not
executed.

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