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ELECTRICAL
PANELS
GCP/GCE/
GCPC/GCEC/
GCV/TSF1
2 ASSEMBLY AND
MAIN INSTRUCTIONS
FOR USE AND
MAINTENANCE
This publication cancels and replaces any previous edition and revision.
We reserve the right to implement modifications without notice.
This catalogue cannot be reproduced, even partially, without prior written consent by the Manufacturer.
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INDEX
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TABLE OF CONTENTS
1.0 INTRODUCTION.......................................................................................................................................1
1.1 Disclaimers.........................................................................................................................................1
1.2 Symbols: meaning and use................................................................................................................1
1.3 General features................................................................................................................................2
1.4 Lifting and shipment...........................................................................................................................3
1.5 Shipping, storage and dismantling.....................................................................................................3
2.0 INSTALLATION........................................................................................................................................4
2.1 Safety distances.................................................................................................................................7
2.2 Emergency stop ...............................................................................................................................7
2.3 Protection degree...............................................................................................................................9
2.4 Safety switches..................................................................................................................................9
2.5 Technical data..................................................................................................................................10
3.0 COMMISSIONING.................................................................................................................................. 11
4.0 USE AND SETTINGS.............................................................................................................................12
4.1 Use and settings..............................................................................................................................12
4.2 Manual cycle....................................................................................................................................16
4.3 Automatic cycle................................................................................................................................17
4.4 Alerts................................................................................................................................................19
4.5 Led panel indicators.........................................................................................................................22
5.0 MAINTENANCE......................................................................................................................................23
5.1 Qualification of the employees.........................................................................................................24
5.2 Trouble-shooting............................................................................................................................. 25
6.0 MAINTENANCE REGISTER...................................................................................................................32
A ATTACHMENTS......................................................................................................................................33
A1 Electric layout...................................................................................................................................33
A2 Declaration of conformity................................................................................................................ 116
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1.0 INTRODUCTION
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1.1 Disclaimers
This manual contains symbols meant to recall the user's attention as regards the safety regulations in force
and maintenance operations. Meaning of he symbols:
Danger - Warning
This symbol is used in the safety warnings or instructions, or in any case when there is a potential
hazard likely to cause injury.
Caution
This symbol is used for safety-related warnings or precautions meant to prevent damage to the control
panel or other important messages to the operator.
Important
This symbol is used in safety-related warnings and compels the user to carefully read this manual.
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1.0 INTRODUCTION
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The electrical panel is intended for use by properly trained personnel: the installation must be designed and
carried out only by qualified technicians.
Caution
Inaccurate installation or use can cause serious damage to the electrical panel, to the user and to the
persons involved.
Please be reminded that the regulations in force in the country of installation are compulsory; in case of several
legal indications, always refer to the more binding requirements.
The product has been designed and manufactured in compliance with safety regulations, for use in ordinary,
unclassified environments.
To avoid damage to property and persons, it is recommended to use all the necessary precautions and adhere
to the highest professional standards.
The dimensions of the panel for the estimation of the thermal power loss have been calculated assuming there
are no other heat sources nearby.
If installed in a space where other panels have been installed, ensure a sufficient distance that allows heat
dissipation.
The control panel has to be used only for the intended purpose, all other uses are considered improper and
therefore dangerous.
Caution
The manual shall be kept in a place accessible to operators and it has to be well preserved.
Before operating or carrying out maintenance operations on the machine, the operator shall carefully read
the manual, paying attention to the messages highlighted by the danger warning symbol: these contains the
instructions necessary for a correct use of the machine in maximum safety conditions.
Moreover, this allows verifying the regularity and frequency of the checkings carried out.
Caution
The manufacturer is not liable for the improper functioning of the panel or any damage caused by it,
in case it is tampered with, modified, if operated improperly or inconsistently with other provisions
contained by the present manual.
The Manufacturer shall not be held responsible for possible inaccuracies contained in this instruction manual,
if due to printing or transcription errors. The Manufacturer reserves the right to bring necessary or useful modi-
fications to the product, without affecting its basic features.
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1.0 INTRODUCTION
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On storing, do not stack other items on top of the device, to avoid damaging it as well as the risk of accidental
falls.
Ensure the integrity of mechanical and electrical engineering parts of the control panel during shipping.
The weight and overall dimensions are indicated on the ID plate of the panel and inside the documentation
enclosed to it.
On receiving the control panel, carry out a visual inspection to ensure no damages have occurred during ship-
ping and that the data on the plate correspond to those present on the acknowledgement of order.
If the panel is not to be immediately installed but it has to be stored, take the necessary some precautions not
to damage the outer casing and the internal electrical components.
Caution
Store the panel packed, indoor, covered and protected from atmospheric agents and animals; the rec-
ommended moisture level should be between 30 and 75% and the temperature between - 25 °C and +
55 °C.
Caution
At the end of it life or in the case of demolition, the device shall be disposed of according to the laws
in force in the country of destination.
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Danger - Warning
It is forbidden carrying out commissioning, maintenance operations, repairs or modifications unless
entrusted to specialized personnel, under precise instructions.
It is recommended to verify the integrity of the control panel during unpacking; do not use it in case of any
doubts.
Before starting the installation make sure the following piece of information were checked and followed:
a) All installation operations are carried out by qualified personnel and the safety standards of the country of
installation were observed;
b) Make sure that the data contained on the ID plate placed on the panel match to the plant to which it is inte-
grated; check the power, voltage, current and frequency;
c) For the electrical connection follow the wiring diagram;
d) Check and provide the recommended cross section values of the power supply lines;
e) Make sure the earthing is always connected to the distribution system and consistent with the regulations
in force in the country of use;
f) Make sure that the cables are correctly connected the auxiliary circuit; check the proper connection of the
phase conductors and of the neutral;
g) Proper wiring of the buttons /emergency buttons.
Provide therefore two lines of NC contacts. The first line represents the 24Vdc chain that carries the enabling
signal to the PLC. The second line represents the 24Vac chain that carries the enabling signal to the PLC.
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+24 V DC
+24 V AC
SHARED +24 V AC
Push- PLC OUTPUTS
button
Push-
button
Thermal
Gates
Mobile
REMOTE
Thermal
CONTROL
SWITCH
Gates
Mobile
Ref Vac
INPUTS
PLC I4 I6 I7
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Caution
A wrong or missing connection of the neutral conductor can cause serious damage to the control
panel and to the distribution installations connected.
Danger - Warning
Prior to use, check the direction of rotation of all equipments and ensure the safety of personnel dur-
ing the examination.
Install the control panel on the basis of the protection degree; it is recommended to use cable having the same
features in order to avoid a downgrading of the protection.
Danger - Warning
The control panels must be perfectly installed; any flow, modification made to the initial project, the
intervention of external agents such as plants, animals, dust, mould or so must be removed; then re-
stored to the default values.
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Danger - Warning
The control panel shall be placed at a safe distance from sources of heat, fuel depots, from flammable
materials, chemicals.
In order to limit potentially dangerous situations, isolate the area surrounding the control panel and
preclude the possibility that unauthorized persons approaches the area.
Although the devices are manufactured in compliance with the regulations on electromagnetic com-
patibility, it is recommended to NOT install the panel near equipments which represent a sources of
emissions.
Particular attention must be paid during assembly phase of the control panel to avoid the falling external ele-
ments, such as metal shavings or other materials that could damage or block the movement of the electric
components.
Danger - Warning
An incorrect installation and electrical connection can cause serious damage to persons, the device,
the electrical installations and to the plant.
Important
The installer must issue a declaration of conformity regarding the installation of the control panel at
the end of the installation operations.
Important
The control panel (located to the left) must be equipped with suitable red mushroom-shaped, stay-put
Emergency button to enable the shut-down when completely pushed.
The emergency stop has to be used only in case of danger conditions and therefore the machine must be im-
mediately shut down.
Pushing one of the emergency stop buttons causes the hardware cutting of the controls and the flashing of the
red EMERGENCY led.
In case thee is no safety control unit, in order to start back the plant correctly in the automatic mode, it is suf-
ficient to reset the emergency button and press the button to start the cycle.
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Operations to be performed in order to start back the plant in case the emergency stop button has
been pressed or the inspection hatch is open(if provided with safety micro) - if the safety unit option is
available.
In order to restore the plant functionality, it is possible to proceed in two different ways:
1) Option:
- Remove power from the control panel via the appropriate switch;
- Eliminate the causes that led to the actuation of the emergency stop button;
- Reset the emergency push down or close inspection hatch;
- Supply power to the control panel via the appropriate switch.
2) Option:
A) In case of emergency button pressed:
- Open one of the inspection covers, protected by a safety micro;
- Close the inspection hatch mentioned above;
- Reset the pushed emergency stop button;
- Press again start to reactivate the cycle in automatic mode.
B) In the case of inspection hatch (protected by a safety micro) open:
- By pressing one of the emergency buttons;
- Close the inspection hatch which has caused the alarm;
- Reset the pushed emergency stop button;
- Press again start to reactivate the cycle in automatic mode.
Operations to be performed in order to start back the plant in case the emergency stop button has been
pressed or the inspection hatch is open (if provided with safety micro) - if the safety unit option is not available.
The absence of the option safety controller involves the automatic start-up of the machine once restored this'
that has resulted in the state of alarm: the emergency button pressed or opening of the micro contact for the
closing of the inspection hatches).
N.B.: In order to avoid a restart in automatic mode, after having restored the cause of alarms, proceed ad fol-
lows:
- Disconnect the electrical panel using the disconnecter before restoring the fault.
- Place the selector switch to manual operation (selector MAN /AUTO positioned on MAN), before re-
storing the fault.
Caution
Evaluate if further emergency buttons are required near the utilities.
It is recommended to include at least one emergency stop button with safety key to be used during machine
maintenance.
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In order to protect the control panel from indirect contact, overload and short circuit, it is the responsibility of
the installer to provide a protection device upstream the line, having the features and values suitable to the
installation point.
In order for the properly sizing of the protection device to check the value expressed in kA found in the docu-
mentation of the framework.
Caution
It is the installer's responsibility to make sure the electrical load connected and the current values do
not exceed the designed value of the control panel
It is recommended to provide the appropriate devices for the protection of circuits fed directly from the line
voltage from overvoltage due to lightning or other particular events.
Important
Never exceed the wires length over 50 m between the control panel and end user.
Caution
When required by the nature of the equipment connected to the control panel, it is necessary to pro-
vide specific safety switches.
On opening a safety device, all dangerous movements of the equipment need to be stopped and the equip-
ment must be prevented from accidentally getting restarted.
If so, no safety device can be by-passed or tampered with.
Some applications require the movable guards to remain blocked during a hazardous production cycle.
Caution
On choosing the number and features of the switches to be provided (magnetic sensors, mechanical
interlocks, ..) take into account the environment in which the machine operates as the switch have to
ensure an appropriate protection degree (IP).
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Danger - Warning
Make sure the micro-switches are correctly positioned and locked.
Check that the electrical drawing regards the components on which the operations are carried out.
Check that the voltage matches the one envisaged for the operation.
Important
Check that the voltage value of the motors stays between ranges +/- 10% of the nominal value.
Check that the movements matches the indications on the related buttons.
Caution
Provide the necessary protection from lightning during operation and the related devices to ground
any electrical discharge.
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3.0 COMMISSIONING
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Danger - Warning
A wrong or missing connection of the neutral conductor can cause serious damage to the control
panel and to the distribution installations connected.
It is forbidden carrying out commissioning, maintenance operations, repairs or modifications unless
entrusted to specialized personnel, under precise instructions. Always use suitable work clothing for
all operations, that is personal protection devices (shoes, gloves, goggles, etc.) in accordance with
the safety regulations.
Caution
Do not disassemble or force electrical components when the panel is powered.
Danger - Warning
Check the suitability of the supporting plane as well as the support structures on which the control
panel is to be installed.
Check the suitability of manoeuvring space, paths, corridors, passageways and escape routes around
the equipment to avoid situations that could lead to falling hazards.
Important
Checking of the suitability and the proper functioning of the electrical system: supply line, plug, distri-
bution board, safety switches that has to cut off the power short circuit current, section, power, length
of the power supply cable and of the earthing system according to EN 60204 -1.
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Main
Switch
PLC panel
Scada interface
Stop
Start
Auto/Man
4.1.1 START-UP
Start the machine up by means of the main switch, located on the control panel; switch it from position 0 to
position 1 (refer to the safety instructions before performing this operation).
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Only trained personnel authorized by WAM can access the setting menu.
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The working hours view refers to the electric motors installed on the plant. The maintenance operator can reset
the working hours by pushing on the related digits.
On the same page, the motor maintenance can also be set by setting the remaining working hours countdown
of the related motor on the SET column.
On the next two pages there can be set the delay time of the devices the plant is provided with. The timing
values can be filled in by means of the numeric keyboard. On the first page of the settings menu it is possible
setting the working temperature of the heater.
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Push SAVE button on the last page of the menu to save de modifications.
After saving the panel will restart. Do not unplug the panel during these operations.
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When the AUTO/MAN switch is positioned to MAN, all components installed can be managed through the
control panel (after the start-up, with no alerts enabled, the panel will show the manual operation view).
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For automatic cycle of the equipment position the switch AUTO/MAN on AUTO position. Now, the automatic
mode view is available with cycle stop.
To start-up the plant, if no alerts are enabled, it is necessary for the machine to detect the external consent.
Subsequently, the operator can proceed by pressing the green START CYCLE button. At this point, the RUN-
NING status will be displayed. On each component side there will be displayed the remaining time to the
restart or the running time set.
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When the components are managed in automatic mode, the use can check the maintenance status and select
the language Only trained personnel authorized by WAM can access the maintenance and settings menu.
If the level of the screw screen is lower than the minimum, the plant will go stand by. On reaching a level in be-
tween the minimum and the maximum value (min. lev alert on, during loading or discharging), the entire plant
gets on with the cycle type previously set. To avoid problems in case of abnormalities of the minimum sensor,
there has been provided a delay timer at the start-up and at the shut-down (paragraph 4.1.4).
Once the maximum allowed level has been reached, the machine will work in continuous operation to allow the
emptying of the screen in the shortest possible time.
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When the empty tank level has been once again reached, the screw screen and the washings will go into OFF
mode. To avoid problems in case of abnormalities of the minimum sensor, there has been provided a delay
timer at the start-up and at the shut-down (paragraph 4.1.4).
4.4 Alerts
In case of alerts enabled, the control panel view changes from green to red and on the top of the display there
will be given the alert type code. The software allows 7 different alarm views.
The alert banner can be moved on the bottom of the display by means of the arrow placed on the side of the
error message.
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The led panel indicators are placed near the control panel and it indicates the working conditions of the plant
according to the table below.
RED
LIGHT MEAN
XLT
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Each control panel require the proper and suitable maintenance to be carried out by specialized personnel
only; this will ensure a constant and proper operation of the plant under due safety conditions .
Danger - Warning
All maintenance operations have to be carried out exclusively by trained, authorized personnel.
All maintenance operations and checkings must be carried out only after the panel has been discon-
nected from the power supply.
Important
For carrying out the operation is necessary to remove the guards; refit the guards in their position
before re-starting the plant.
Disconnect from all power supplies and shut down the plant in case of abnormal working or failure.
Caution
It is forbidden modifying parts of the control panel or changing the position of the mechanical or elec-
trical components.
Failure to follow the given indications could cause a low safety operation conditions of the panel and
the decay of the warranty. The responsibility deriving from any potential intervention will fall on the
executioner as in fact it becomes the manufacturer.
Caution
It is recommended to include at least one emergency stop button with safety key to be used during
machine maintenance.
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Optimizing prevention is based on having a knowledge of the experimental data measured on plant compo-
nents having similar features.
The prevention is necessary in case components meant to ensure the safety of the operators involved.
It is therefore recommended to register:
1) the specific electrical parameters during normal operation;
2) the electrical parameters measured during abnormal operation;
3) pieces of information provided by the manufacturer and the maintenance rate.
The proper knowledge of the factors previously indicated allow creating a maintenance schedule which re-
duces to minimum the possible hitches, it ensures the necessary plant safety and optimizes the cost/benefits
ratio related to maintenance.
The automatic switches and the main plant devices are supplied by the most qualified manufacturers, which
had their products already tested, to provide the proper operation of the machines during their life time dura-
tion.
Training the maintenance technicians is fundamental in view of the correct and effective maintenance of the
entire electrical plant and, particularly, of the switches.
The necessary skilfulness and know-how can be reached only by practising along with acquiring the suitable
theoretical knowledge.
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5.2 Trouble-shooting
The personnel authorized to intervene in most of failure cases or in those cases not otherwise indicated, is
represented by an expert maintenance operator or authorized and specially trained in regard to mechanical,
electrical and electronic parts.
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CAUSES/
SCENARIO CORRECTIVE ACTIONS
CONDITION
Make sure that water is present before the solenoid valves.
Make sure that the system is performing the countdown for the timed
activation of the wash and, if too long, it intervenes on time settings
(see manual).
Ensure that the coil of the solenoid valve is energized.
Ensure that the voltage of the coil matches supply voltage.
The washing The system is
Check the connection between the coil and the control panel.
system is not in an automatic
working. RUN mode. Make sure that the power relay of the coil is energized, check the
proper connection of the relay and the possible malfunction of the
relay contacts.
Make sure that the relevant output of the PLC is energized.
If the coil is energized, the water is present and the washing is not
activated, check the operation of the solenoid valve and replace it, if
necessary.
The display is red
and an error mes- Open the control panel and check which thermal protection intervened.
sage appears.
CHECK THE
If the 60FR10 thermal protection has intervened, make the following
THERMAL MO-
checks to the motor screw screen:
TOR RELAY
Ensure that the setting of the thermal protection absorption is consist-
ent with the absorption of the motor.
Check whether the rotational direction of the motor is correct (if neces-
sary, invert the phases).
Frequent
Ensure that all 3 phases are present on the motor. If necessary, check
interventions
the electrical connections to the remote control switch.
of the mo-
tors’ thermal Ensure that there are no mechanical obstructions that make the motor
protections. The led panel absorb more than expected.
indicators emit a Ensure that there is no actual motor overheating and replace where
solid red light and
appropriate.
the siren sounds.
Reset the thermal protection that intervened.
If the 61FR50 thermal protection has intervened, make the following
checks:
Check the correct connection of heating cables in the appropriate box.
Verify the integrity and proper operation of the heating cables, as de-
scribed by the Wam procedures.
Reset the thermal protection that intervened.
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SCE- CAUSES/CONDI-
CORRECTIVE ACTIONS
NARIO TION
Stop the plant.
The Make sure there are no mechanical obstructions, wear or blockages
screw due to which the motor is drawing too much power. If necessary, inter-
screen vene with maintenance according to the manual.
continual-
ly revers- Check whether the “normal” rotational direction of the screw screen is
The system is in correct (if necessary, invert the phases).
es to the
an automatic RUN
rotational Ensure that all three phases reach the motor.
mode.
direction Check the motor absorption with another tool.
and sub-
sequently If the absorption is not greater than the plate absorption, check the set-
goes into ting of the autoreverse parameter in order to release the screw screen
alarm. (may be set too low); increase the value, if necessary.
Restart the system.
Emergency buttons Keep away from the plant all operators who are not in charge with the
pushed. reactivation of the push-button.
An error message
is displayed on the Eliminate all obstacles and solve the problem that prompted an opera-
panel with red back- tor to press the push-button.
ground:
VERIFY THE EMER-
If the emergency stop button remains blocked by means of the special
GENCY STOP BUT-
key, refer to the maintenance operator in charge.
TON.
Ensure no personnel remains in the hazardous area before restoring
the normal operation of the plant.
FOR PLANT WITH NO SAFETY CONTROLLER.
Set to manual the auto/manual selector.
Immedi-
ate inter- Reset the pushed emergency button/s.
ruption of Set to automatic the auto/manual selector.
all system Press start cycle.
functions.
FOR PLANT WITH SAFETY CONTROLLER.
The led panel indica- Open the safety guard (see procedure on Wam manual).
tors emit a solid red
Close the guard.
light and the siren
sounds. Reset the pushed emergency button/s.
Press start cycle.
PLANT WITH SAFETY CONTROLLER IN CASE OF SHUT DOWN
FOR SEVERE REASONS.
Shut down the equipment.
Solve the problem that prompted an operator to press the push-button.
Reset the pushed emergency button/s.
Stop the plant.
Perform the start up procedure.
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A1 Electric layout
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A2 Declaration of conformity
The manufacturer:
WAMGROUP S.p.A.
located in
Strada degli Schiocchi, 12 - I-41124 Modena - Italy
under its own responsibility declares that:
the machinery series GCP/GCE/GCPC/GCEC/TSF1 provided with a control panel cod: 044001099
EC DECLARATION OF CONFORMITY OF THE MACHINERY Annex II A 2006/42/CE Directive
EU DECLARATION OF CONFORMITY
complies with the requirements imposed by the following directives:
Directive 2006/42/EC of the European Parliament and the Council of 17 May 2006 on machinery and amending Directive
95/16/EC;
Directive 2014/30/EU of the European Parliament and the Council of 26 February 2014 on the harmonisation of the laws of
the Member States relating to electromagnetic compatibility;
Directive 2014/35/EU of the European Parliament and the Council of 26 February 2014 on the harmonisation of the laws of
the Member States relating to the making available on the market of electrical equipment designed for use within certain voltage
limits.
116