Precision Automatic Vacuum Control (PAVC+)

USER GUIDE UGE105-1216 www.conairgroup.com Precision Automatic Vacuum Control (PAVC+) Corporate Office: 724.584.5500 l Instant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.6861

Please record your equipment s model and serial number(s) and the date you received it in the spaces provided. It s a good idea to record the model and serial number(s) of your equipment and the date you received it in the User Guide. Our service department uses this information, along with the manual number, to provide help for the specific equipment you installed. Please keep this User Guide and all manuals, engineering prints, and parts lists together for documentation of your equipment. Date: Manual Number: UGE105-1216 Serial Number(s): Model Number(s): DISCLAIMER: Conair shall not be liable for errors contained in this User Guide or for incidental, consequential damages in connection with the furnishing, performance or use of this information. Conair makes no warranty of any kind with regard to this information, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. Copyright 2016 l Conair l All rights reserved

Table of Contents 1-1 Introduction Purpose of the User Guide... 1-2 How the Guide is Organized... 1-2 Your Responsibility as a User... 1-2 ATTENTION: Read This So No One Gets Hurt... 1-3 How to Use the Lockout Device... 1-4 2-1 Description Introduction... 2-2 3-1 Installation Vacuum... 3-2 Electrical... 3-2 Remote Communications... 3-2 Calibration... 3-3 4-1 Operation Manual Mode - Initial Mode... 4-2 A Automatic Mode... 4-2 Appendix Customer Service Information... A-1 B Warranty Information... A-2 Appendix PAVC+ Screens and Operation... B-1 Table of Contents I i

ii I Table of Contents

Introduction SECTION 1 1 Introduction Purpose of the User Guide... 1-2 How the Guide is Organized... 1-2 Your Responsibility as a User... 1-2 ATTENTION: Read This So No One Gets Hurt... 1-3 How to Use the Lockout Device... 1-4 Introduction I 1-1

Purpose of the User Guide This user guide describes the Conair Precision Automatic Vacuum Control (PAVC+) and explains step-by-step how to install, operate, maintain and repair this equipment. Before installing this product, please take a few moments to read the user guide and review the diagrams and safety information in the instruction packet. You should also review manuals covering associated equipment in your system. This review won t take long, and it could save you valuable installation and operating time later. How the Guide is Organized Symbols have been used to help organize the User Guide and call your attention to important information regarding safe installation and operation. Symbols within triangles warn of conditions that could be hazardous to users or could damage equipment. Read and take precautions before proceeding. 1 u r Numbers indicate tasks or steps to be performed by the user. A diamond indicates the equipment s response to an action performed by the user or a situation. An open box marks items in a checklist. A circle marks items in a list. 2 Indicates a tip. A tip is used to provide you with a suggestion that will help you with the maintenance and the operation of this equipment. Indicates a note. A note is used to provide additional information about the steps you are following throughout the manual. 0 Your Responsibility as a User You must be familiar with all safety procedures concerning installation, operation, and maintenance of this equipment. Responsible safety procedures include: Thorough view of this User Guide, paying particular attention to hazard warnings, appendices, and related diagrams. Thorough review of the equipment itself, with careful attention to voltage sources, intended use, and warning labels. Thorough review of instruction manuals for associated equipment. Step-by-step adherence to instructions outlined in this User Guide. 1-2 I Introduction

ATTENTION: Read This So No One Gets Hurt We design equipment with the user s safety in mind. You can avoid the potential hazards identified on this machine by following the procedures outlined below and elsewhere in the User Guide. WARNING: Improper installation, operation, or servicing may result in equipment damage or personal injury. 1 Introduction This equipment should be installed, adjusted, and serviced by qualified technical personnel who are familiar with the construction, operation, and potential hazards of this type of machine. All wiring, disconnects, and fuses should be installed by qualified electrical technicians in accordance with electrical codes in your region. Always maintain a safe ground. Do not operate the equipment at power levels other than what is specified on the machine serial tag and data plate. WARNING: Voltage hazard This equipment is powered by three-phase alternating current, as specified on the machine serial tag and data plate. A properly sized conductive ground wire from the incoming power supply must be connected to the chassis ground terminal inside the electrical enclosure. Improper grounding can result in severe personal injury and erratic machine operation. Always disconnect and lock out the incoming main power source before opening the electrical enclosure or performing non-standard operating procedures, such as routine maintenance. Only qualified personnel should perform troubleshooting procedures that require access to the electrical enclosure while power is on. Introduction I 1-3

How to Use the Lockout Device CAUTION: Before performing maintenance or repairs on this product, you should disconnect and lockout electrical power sources to prevent injury from unexpected energization or start-up. A lockable device has been provided to isolate this product from potentially hazardous electricity. Lockout is the preferred method of isolating machines or equipment from energy sources. Your Conair product is equipped with the lockout device pictured below. To use the lockout device: 1 Stop or turn off the equipment. 2 Isolate the equipment from the electric power. Turn the rotary disconnect switch to the OFF, or O position. 3 Secure the device with an assigned lock or tag. Insert a lock or tag in the holes to prevent movement. 4 The equipment is now locked out. WARNING: Before removing lockout devices and returning switches to the ON position, make sure that all personnel are clear of the machine, tools have been removed and all safety guards reinstalled. To restore power to the device, turn the rotary disconnect back to the ON position: 1 Remove the lock or tag. 2 Turn the rotary disconnect switch to the ON or I position. 1-4 I Introduction

2SECTION Description Introduction... 2-2 2 Description Description I 2-1

Introduction The PAVC+ is used with high technology vacuum water tanks to maintain a constant and precise vacuum pressure. Connections are provided for automatic feedback control of the setpoint by use of X/Y laser scanners that monitor the profile. The PAVC+ provides recirculation and vacuum pump Start and Stop, with input conditioning. Setpoint adjustment is via the control panel. The local setpoint can also be adjusted externally by Raise and Lower contacts or ethernet communications. The Vacuum Level actual and setpoint values are displayed on the HMI. A wide pressure range is possible as the PAVC+ controls a Vent Valve and the vacuum pump RPM. 2-2 I Description

3SECTION Installation Vacuum... 3-2 Electrical... 3-2 Remote Communications... 3-2 3 Installation Calibration... 3-3 Installation I 3-1

Vacuum Vacuum Port Vacum Sensor port 14 NPT male, sensor mounted in the vacuum reservoir tanks. Electrical DC Supply - 24 Volts, 12 Watts, DC Supply Version 24 volts DC supply. Two terminals are provided labeled 101 (24 VDC) and 102 (0V). Ground Label 102 (0V) should be connected to ground). Remote Communications Ethernet IP and Modbus 70P/IP are used to communicate with remove devices. IP: 192.168.1.20 Refer to Appendix B for addressing 3-2 I Installation

Calibration The vacuum sensor is calibrated for the manufacturer: 14.5-0 PSI and sends an analog signal to the controller. 4.5 PSI = 10 VDC 0 PSI = 0 VDC The analog input is scale in the HMI. 3 Installation Installation I 3-3

3-4 I Installation

4SECTION Operation Manual Mode - Initial Mode... 4-2 Automatic Mode... 4-2 4 Operation Operation I 4-1

Manual Mode - Initial Mode Starting the vacuum pump initially places the PAVC+ in Manual mode and sets the setpoint to zero. The operator should then use the Up and Down keys to adjust the vacuum. The vacuum pump RPM change in response to the adjustments. The operator should be visually monitoring the extruded product at this time. The display shows the actual vacuum pressure. External scroll inputs are disabled. NOTE: To change the amount that the up and down key increment the setpoint, go to the Settings screen. Each press of the Up key will cause an approximate increase of 0.1 in. {2.54 mm} of water. Each press of the Fine Edit Down key will cause an approximate decrease of 0.1 in. {2.54 mm} of water. Automatic Mode The vacuum pressure is initially set using Manual mode. Once the product dimensions are correct (or close), the Auto/Manual key should be pressed to toggle to the Automatic mode. A bump-less transition is made as the setpoint is forced to the Actual value. The system will now use automatic correction of the vacuum pump RPM in order to keep the actual pressure steady. External Raise and Lower scroll inputs become active so that external systems (X/Y Scanners) may make fine adjustments to the setpoint. Each press of the Up key causes an increase of 0.1 in. {2.54 mm} of water. The setpoint will appear in the display. Any further presses of the key pad will cause the whole display to count up (0.1 in. {2.54 mm} of water for each press). The display will show an actual sensed value after a short delay. The Down key complements the Up key and will cause a decrease of 0.1 in. {2.54 mm} of water. The Info/Settings key allows the operator to view and change the PAVC+ settings. The power key turns the PAVC+ vacuum on or off. 4-2 I Operation

We re Here to Help Conair has made the largest investment in customer support in the plastics industry. Our service experts are available to help with any problem you might have installing and operating your equipment. Your Conair sales representative also can help analyze the nature of your problem, assuring that it did not result from misapplication or improper use. How to Contact Customer Service To contact Customer Service personnel, call: Additional manuals and prints for your Conair equipment may be ordered through the Customer Service or Parts Department for a nominal fee. Most manuals can be downloaded free of charge from the product section of the Conair website. www.conairgroup.com NOTE: Normal operating hours are 8:00 am - 5:00 pm EST. After hours emergency service is available at the same phone number. From outside the United States, call: 814-437-6861 You can commission Conair service personnel to provide on-site service by contacting the Customer Service Department. Standard rates include an on-site hourly rate, with a oneday minimum plus expenses. 0 Before You Call... If you do have a problem, please complete the following checklist before calling Conair: UU UU UU UU UU Make sure you have all model, control type from the serial tag, and parts list numbers for your particular equipment. Service personnel will need this information to assist you. Make sure power is supplied to the equipment. Make sure that all connectors and wires within and between control systems and related components have been installed correctly. Check the troubleshooting guide of this manual for a solution. Thoroughly examine the instruction manual(s) for associated equipment, especially controls. Each manual may have its own troubleshooting guide to help you. Appendix I A-1

Equipment Guarantee Conair guarantees the machinery and equipment on this order, for a period as defined in the quotation from date of shipment, against defects in material and workmanship under the normal use and service for which it was recommended (except for parts that are typically replaced after normal usage, such as filters, liner plates, etc.). Conair s guarantee is limited to replacing, at our option, the part or parts determined by us to be defective after examination. The customer assumes the cost of transportation of the part or parts to and from the factory. Performance Warranty Conair warrants that this equipment will perform at or above the ratings stated in specific quotations covering the equipment or as detailed in engineering specifications, provided the equipment is applied, installed, operated, and maintained in the recommended manner as outlined in our quotation or specifications. Should performance not meet warranted levels, Conair at its discretion will exercise one of the following options: Inspect the equipment and perform alterations or adjustments to satisfy performance claims. (Charges for such inspections and corrections will be waived unless failure to meet warranty is due to misapplication, improper installation, poor maintenance practices, or improper operation.) Replace the original equipment with other Conair equipment that will meet original performance claims at no extra cost to the customer. Refund the invoiced cost to the customer. Credit is subject to prior notice by the customer at which time a Return Goods Authorization Number (RGA) will be issued by Conair s Service Department. Returned equipment must be well crated and in proper operating condition, including all parts. Returns must be prepaid. Purchaser must notify Conair in writing of any claim and provide a customer receipt and other evidence that a claim is being made. Warranty Limitations Except for the Equipment Guarantee and Performance Warranty stated above, Conair disclaims all other warranties with respect to the equipment, express or implied, arising by operation of law, course of dealing, usage of trade or otherwise, including but not limited to the implied warranties of merchantability and fitness for a particular purpose. A-2 I Appendix

PAVC+ Screens and Operation Home Manual/Auto Switch Manual Mode Starting the vacuum pump initially places the PAVC+ in Manual mode and sets the setpoint to zero. The operator should use the Up and Down Scroll Keys to adjust the vacuum pump RPM. The operator should be visually monitoring the extruded product at this time. The display shows the actual vacuum pressure. Automatic Mode The vacuum pressure is initially set using Manual mode. Once the product dimensions are correct (or close), the Manual/Auto switch should be pressed to toggle to the Automatic mode. A bump-less transition is made as the setpoint is forced to the Actual value. The system will now use automatic correction of the vacuum pump RPM in order to keep the actual pressure steady. Each press of the Small Scroll button will cause an approximate increase/decrease of blower (%) in manual or vacuum (InH 2 O) in automatic in the Small increments set on the Local Scrolls screen. Setpoint display and manual input of setpoint. Display of mode: Manual or Auto. Display of actual blower (%) in manual or vacuum (InH 2 O) in automatic Recirc and Vacuum Pump mode switches used to toggle the pump s On/Off mode. (Continued) Appendix I B-1

PAVC+ Screens and Operation (continued) Pressing the Information button will take the operator to the PAVC Menu screen. PAVC+ Menu This screen allows the operator to navigate to the PAVC+ System screens. Local Scrolls This screen allows the operator to set the Small and Large scroll increments for the scroll buttons on the Home and PAVC+ Main screens. B-2 I Appendix (Continued)

PAVC+ Screens and Operation (continued) Remote Scrolls This screen allows the operator to set the Remote scroll increment for the Remote scroll Increase/Decrease inputs. PAVC+ Inputs This screen allows the operator to monitor the PAVC+ system inputs. (Continued) Appendix I B-3

PAVC+ Screens and Operation (continued) PAVC+ Outputs This screen allows the operator to monitor the PAVC+ system Outputs. PAVC+ Temperature Control B-4 I Appendix This screen allows the operator to set the High and Low temp limits for controlling the Temp Control Output. (Continued)

PAVC+ Screens and Operation (continued) PAVC+ Units This screen allows the operator to set the units for Vacuum and Temperature. PAVC+ Diagnostics This screen allows the operator to set/monitor the PAVC+ PID parameters. (Continued) Appendix I B-5

PAVC+ Screens and Operation (continued) PAVC+ Ethernet This screen allows the operator to monitor the PAVC+ Ethernet communication. B-6 I Appendix