AEC 1-Pump 1-Station Controller User Manual

1-Pump 1-Station Controller

Part Number: 882.00212.00

Bulletin Number: CV3-600

Effective: 10/27/05

Write Down Your Serial Numbers Here For Future Reference:

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We are committed to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change without notice.

DCN No. ____________
© Copyright 2004
All rights reserved.

Please note that our address and phone information has changed.
Please reference this page for updated contact information.

These manuals are obsolete and are provided only for their technical information, data and capacities.
Portions of these manuals detailing procedures or precautions in the operation, inspection, maintenance
and repair of the products may be inadequate, inaccurate, and/or incomplete and shouldn’t be relied
upon. Please contact the ACS Group for more current information about these manuals and their
warnings and precautions.

Parts and Service Department

The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering
design specifications, which will maximize your equipment’s performance and efficiency. To assist in expediting your phone
or fax order, please have the model and serial number of your unit when you contact us. A customer replacement parts list
is included in this manual for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to
providing excellent customer service.

For immediate assistance, please contact:

• North, Central and South America, 8am – 5pm CST [phone] for drying, conveying, heating and cooling
and automation. For size reduction: [phone].
North America, emergencies after 5pm CST [phone]

North America email: [e-mail]

• Mexico, Central & South America
Email: [e-mail]

• Europe, Middle East & Africa [phone]

Email: [e-mail]

• India [phone]

Email: [e-mail]

• Asia/Australia [phone]

Email: [e-mail]

Sales and Contracting Department

Our products are sold by a worldwide network of independent sales representatives. Contact our Sales Department for the
name of the sales representative nearest you.

Let us install your system. The Contract Department offers any or all of these services: project planning; system packages
including drawings; equipment, labor, and construction materials; and union or non-union installations.

For assistance with your sales or system contracting needs please Call:

North, Central and South America [phone] or [phone] Monday–Friday, 8am–5pm CST

Europe/Middle East/Africa [phone]
India [phone]
Asia/Australia [phone]

Facilities:

ACS offers facilities around the world to service you no matter where you are located. For more information, please visit us at
www.acscorporate.com

United States:

ACS Schaumburg – Corporate Offices

1100 E. Woodfield Road
Suite 588
Schaumburg, IL 60173
Phone: + 1 847 273 7700
Fax: + 1 847 273 7804

ACS New Berlin – Manufacturing Facility

2900 S. 160th Street
New Berlin, WI 53151
Phone : [phone]
Fax: + 1 262 641 8653

Asia/Australia:

ACS Suzhou

109 Xingpu Road SIP
Suzhou, China 215126
Phone: + 86 8717 1919
Fax: [phone]

Europe/Middle East/Africa:

ACS Warsaw

Ul. Działkowa 115
02-234 Warszawa
Phone: + 48 22 390 9720
Fax: [phone]

India

ACS India

Gat No. 191/1, Sandbhor Complex
Mhalunge, Chakan, Tal Khed,
Dist. Pune 410501, India
Phone: [phone]
Fax: + 91 20 40147576

Shipping Information

Unpacking and Inspection

You should inspect your equipment for possible shipping damage. Thoroughly check the
equipment for any damage that might have occurred in transit, such as broken or loose wiring
and components, loose hardware and mounting screws, etc.

In the Event of Shipping Damage

According to the contract terms and conditions of the Carrier, the responsibility of the
Shipper ends at the time and place of shipment.

Notify the transportation company’s local agent if you discover damage

Hold the damaged goods and packing material for the examining agent’s inspection. Do not
return any goods before the transportation company’s inspection and authorization.

File a claim with the transportation company. Substantiate the claim by referring to the
agent’s report. A certified copy of our invoice is available upon request. The original Bill of
Lading is attached to our original invoice. If the shipment was prepaid, write us for a
receipted transportation bill.

Advise customer service regarding your wish for assistance and to obtain an RMA (return
material authorization) number.

If the Shipment is Not Complete

Check the packing list as back-ordered items are noted on the packing list. In addition to the
equipment itself, you should have:

; Bill of lading

; Packing list

; Operating and Installation packet

; Electrical schematic and panel layout drawings

; Component instruction manuals (if applicable)

Re-inspect the container and packing material to see if you missed any smaller items during
unpacking.

If the Shipment is Not Correct

If the shipment is not what you ordered, contact the shipping department immediately. For
shipments in the United States and Canada, call 1 [phone]; for all other countries, call
our international desk at [phone]. Have the order number and item number available.
Hold the items until you receive shipping instructions.

Returns

Do not return any damaged or incorrect items until you receive shipping instructions from the
shipping department.

1 –Pump 1-Station Controller Chapter 1: Safety ii

Table of Contents

CHAPTER 1: SAFETY ................................................................V

1-1 How to Use This Manual ............................................................................................. v

Safety Symbols Used in this Manual..................................................................... v

1-2 Warnings and Precautions ......................................................................................... vi

1-3 Responsibility .............................................................................................................vii

General Responsibility......................................................................................... vii

Operator Responsibility .......................................................................................viii

Maintenance Responsibility.................................................................................viii

Reporting a Safety Defect ...................................................................................viii

CHAPTER 2: FUNCTIONAL DESCRIPTION.............................. 9

2-1 Models Covered in This Manual..................................................................................9

2-2 General Description..................................................................................................... 9

2-3 Standard Features....................................................................................................... 9

Mechanical Features .............................................................................................9

2-4 Optional Features......................................................................................................10

2-5 Safety Devices and Interlocks ................................................................................... 10

Safety Circuit Standards...................................................................................... 10

Fail Safe Operation .............................................................................................10

Safety Device Lock-Outs.....................................................................................11

CHAPTER 3: INSTALLATION .................................................. 12

3-1 Uncrating ................................................................................................................... 12

3-2 Mounting the Control Panel.......................................................................................12

3-3 Electrical Connections............................................................................................... 12

Making Control Panel Power Drop Wiring Connections......................................12

Connecting the Control Panel to Vacuum Receivers .......................................... 13

Connecting the Control Panel to the Pump/Blower Package ..............................13

3-4 Setup ........................................................................................................................... 14

Setting Conveying Times ....................................................................................14

Setting the Material Receiver Selector Switch (Optional).................................... 15

Using and Adjusting the Auto-Shutdown Timer (1TMR)......................................16

Vacuum Switch Operation (1VS)......................................................................... 16

Mechanical High Vacuum Relief..........................................................................16

CHAPTER 4: OPERATION ....................................................... 17

4-1 Overview ...................................................................................................................17

4-2 Startup.......................................................................................................................17

Pre-Startup Checks .............................................................................................17

Starting the System .............................................................................................18

4-3 Control Panel Components ....................................................................................... 18

Material Receiver Selector Switch (Optional)......................................................18

Control Power Indicator Light ..............................................................................18

Control Power Toggle Switch ..............................................................................18

1 –Pump 1-Station Controller Chapter 1: Safety iii

4-4 Operation Sequence .................................................................................................19

4-5 Shutting Down the System ........................................................................................ 19

CHAPTER 5: MAINTENANCE .................................................. 20

CHAPTER 6: TROUBLESHOOTING ........................................ 21

6-1 General Troubleshooting...........................................................................................21

CHAPTER 7: APPENDIX .......................................................... 24

7-1 Warranty....................................................................................................................24

Warranty Specifications....................................................................................... 24

Warranty Restrictions ..........................................................................................24

Warranty Liabilities ..............................................................................................25

Customer Responsibilities...................................................................................25

7-2 Optional Components................................................................................................ 25

7-3 Drawings and Diagrams ............................................................................................ 26

7-4 Spare Parts List.........................................................................................................28

7-5 Returned Material Policy ........................................................................................... 29

Credit Returns ..................................................................................................... 29

Warranty Returns ................................................................................................ 29

7-6 Safety Tag Information .............................................................................................. 29

Controller Safety Tags......................................................................................... 29

7-7 Controller Identification (Serial Number) Tag ............................................................ 30

7-8 Technical Assistance (Contact Information).............................................................. 30

Parts Department ................................................................................................ 30

Service Department............................................................................................. 30

Sales Department................................................................................................ 30

Contract Department ...........................................................................................30

1 –Pump 1-Station Controller Chapter 1: Safety iv

Chapter 1: Safety

1-1 How to Use This Manual

Use this manual as a guide and reference for installing, operating, and maintaining your
equipment. The purpose is to assist you in applying efficient, proven techniques that enhance
equipment productivity.

This manual covers only light corrective maintenance. No other maintenance should be
undertaken without first contacting a service engineer.

The Functional Description section outlines models covered, standard features, and optional
features. Additional sections within the manual provide instructions for installation, pre­operational procedures, operation, preventive maintenance, and corrective maintenance.

The Installation chapter includes required data for receiving, unpacking, inspecting, and setup
of the equipment. We can also provide the assistance of a factory-trained technician to help
train your operator(s) for a nominal charge. This section includes instructions, checks, and
adjustments that should be followed before commencing with operation of the equipment.
These instructions are intended to supplement standard shop procedures performed at shift,
daily, and weekly intervals.

The Operation chapter includes a description of electrical and mechanical controls, in
addition to information for operating the equipment safely and efficiently.

The Maintenance chapter is intended to serve as a source of detailed assembly and
disassembly instructions for those areas of the equipment requiring service. Preventive
maintenance sections are included to ensure that your equipment provides excellent, long
service.

The Troubleshooting chapter serves as a guide for identification of most common problems.
Potential problems are listed, along with possible causes and related solutions.

The Appendix contains technical specifications, drawings, schematics, and parts lists. A
spare parts list with part numbers specific to your machine is provided with your shipping
paperwork package. Refer to this section for a listing of spare parts for purchase. Have your
serial number and model number ready when ordering.

Safety Symbols Used in this Manual

The following safety alert symbols are used to alert you to potential personal injury hazards.
Obey all safety messages that follow these symbols to avoid possible injury or death.

Danger! DANGER indicates an imminently hazardous situation which, if not

avoided, will result in death or serious injury.

Warning! WARNING indicates a potentially hazardous situation or practice which,

if not avoided, could result in death or serious injury.

Caution! CAUTION indicates a potentially hazardous situation or practice which, if

not avoided, may result in minor or moderate injury or in property
damage.

1 –Pump 1-Station Controller Chapter 1: Safety v

1-2 Warnings and Precautions

Our equipment is designed to provide safe and reliable operation when installed and operated
within design specifications, following national and local safety codes. This may include, but
is not limited to OSHA, NEC, CSA, SPI, and any other local, national and international
regulations.

To avoid possible personal injury or equipment damage when installing, operating, or
maintaining this equipment, use good judgment and follow these safe practices:

; Read and follow these operation and installation instructions when installing,

operating, and maintaining this equipment. If these instructions become damaged or
unreadable, additional copies are available from the manufacturer.

; Follow all SAFETY CODES.

; Wear SAFETY GLASSES and WORK GLOVES.

; Work only with approved tools and devices.

; Disconnect and/or lock out power before servicing or maintaining the equipment.

; Use care when LOADING, UNLOADING, RIGGING, or MOVING this equipment.

; Operate this equipment within design specifications.

; OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment. You

should remove the fuses and carry them with you.

; Make sure the equipment and components are properly GROUNDED before you

switch on power.

; Use EXTEREME CAUTION when working with conveying system. HIGH

VACUUM can be dangerous. Keep body parts, tools, clothing, and debris away from
vacuum inlets.

; When welding or brazing in or around this equipment, make sure VENTILATION is

ADEQUATE. PROTECT adjacent materials from flame or sparks by shielding with
sheet metal. An approved FIRE EXTINGUISHER should be close at hand and ready
for use if needed.

; Do not restore power until you remove all tools, test equipment, etc., and the

equipment and related components are fully reassembled.

; Only PROPERLY TRAINED personnel familiar with the information in this manual

should work on this equipment.

We have long recognized the importance of safety and have designed and manufactured our
equipment with operator safety as a prime consideration. We expect you, as a user, to abide
by the foregoing recommendations in order to make operator safety a reality.

1 –Pump 1-Station Controller Chapter 1: Safety vi

1-3 Responsibility

These machines are constructed for maximum operator safety when used under standard
operating conditions and when recommended instructions are followed in the maintenance
and operation of the machine.

All personnel engaged in the use of the machine should become familiar with its operation as
described in this manual.

Proper operation of the machine promotes safety for the operator and all workers in its
vicinity.

Each individual must take responsibility for observing the prescribed safety rules as outlined.
All warning and danger signs must be observed and obeyed. All actual or potential danger
areas must be reported to your immediate supervisor.

General Responsibility

No mater who you are, safety is important. Owners, operators and maintenance personnel
must realize that every day, safety is a vital part of their jobs.

If your main concern is loss of productivity, remember that production is always affected in a
negative way following an accident. The following are some of the ways that accidents can
affect your production:

• Loss of a skilled operator (temporarily or permanently)

• Breakdown of shop morale

• Costly damage to equipment

• Downtime

An effective safety program is responsible and economically sound.

Organize a safety committee or group, and hold regular meetings. Promote this group from
the management level. Through this group, the safety program can be continually reviewed,
maintained, and improved. Keep minutes or a record of the meetings.

Hold daily equipment inspections in addition to regular maintenance checks. You will keep
your equipment safe for production and exhibit your commitment to safety.

Please read and use this manual as a guide to equipment safety. This manual contains safety
warnings throughout, specific to each function and point of operation.

1 –Pump 1-Station Controller Chapter 1: Safety vii

Operator Responsibility

The operator’s responsibility does not end with efficient production. The operator usually has
the most daily contact with the equipment and intimately knows its capabilities and
limitations.

Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates, or
through a casual attitude toward machinery formed over a period of months or years. Your
employer probably has established a set of safety rules in your workplace. Those rules, this
manual, or any other safety information will not keep you from being injured while operating
your equipment.

Learn and always use safe operation. Cooperate with co-workers to promote safe practices.
Immediately report any potentially dangerous situation to your supervisor or appropriate
person.

Maintenance Responsibility

Proper maintenance is essential to safety. If you are a maintenance worker, you must make
safety a priority to effectively repair and maintain equipment.

Before removing, adjusting, or replacing parts on a machine, remember to turn off all electric
supplies and all accessory equipment at the machine, and disconnect and lockout electrical
power. Attach warning tags to the disconnect switch.

Be sure that all non-current carrying parts are correctly connected to earth ground with an
electrical conductor that complies with current codes. Install in accordance with national and
local codes.

When you have completed the repair or maintenance procedure, check your work and remove
your tools, rigging, and handling equipment.

Reporting a Safety Defect

If you believe that your equipment has a defect that could cause injury, you should
immediately discontinue its use and inform the manufacturer.

The principle factors that can result in injury are failure to follow proper operating procedures
(i.e. lockout/tagout), or failure to maintain a clean and safe working environment.

1 –Pump 1-Station Controller Chapter 1: Safety viii

Chapter 2: Functional Description

2-1 Models Covered in This Manual

This manual provides operation, installation, and maintenance instructions for 1-Pump, 1­Station Conveying Controllers. Model numbers are listed on the serial tag. Make sure you
know the model and serial number of your equipment before contacting the manufacturer for
parts or service.

The 1-Pump, 1-Station Conveying Controller is an integrated system composed of a control
panel that sends and receives signals to and from a vacuum pump and a material receiver.

2-2 General Description

Our material conveying systems create vacuum for the automatic conveying of most free­flowing, dry, pelletized, or granular materials in central material handling systems. Material
characteristics determine the type of equipment needed to convey the material.

A typical use for our equipment is an in-plant distribution system for plastic processing
plants, loading silos and bulk storage containers.

Our central vacuum systems are as varied as the applications they service. The tubing and
equipment furnished in our system is designed to convey the material(s) specified at the time
of purchase at specific rates and distances.

We can advise you on your system capabilities based on system makeup, distance, material,
and conveying rates you want.

System capacity is directly affected by the pressure drop in the overall system, such as
number of material line bends, pipe length, Y-tubes, T-tubes, etc.

Use the minimum effective amount of vinyl flex hose to maximize material line efficiency.
Keep material lines as straight as possible. Refer to Vacuum Pump Product manual (Part No.
A0536580) for installation recommendations.

Note: Vacuum leaks occuring in your system reduce capacity.

2-3 Standard Features

Mechanical Features

Sensor-Driven Automatic Machine Bin Filling

• If the machine bin is full, the single-station system does not convey. The system

automatically resumes conveying when the material level drops in the machine bin.

Efficient Design Conveying

• Adjustable timer-driven hopper filling.

• Single-station controller systems can be adapted for silo-fill and surge bin applications.

• Ideal for minimum inventory applications.

1 –Pump 1-Station Controller Chapter 2: Functional Description 9 of 30

2-4 Optional Features

Options marked with “*” indicate options that can be factory installed or retrofitted in the
field.

Rotary Switch for High Level Selection. A ten (10) – position single- or double-pole
switch allows you to select from multiple material receivers.

115/1/60 or 24VDC Operation. Required to operate with a 115/1/60 or 24VDC supply
voltage.

2-5 Safety Devices and Interlocks

This section includes information on safety devices and procedures that are inherent to the
Controller. This manual is not intended to supersede or alter safety standards established by
the user of this equipment. Instead, the material contained in this section is recommended to
supplement these procedures in order to provide a safer working environment.

At the completion of this section, the operator and maintenance personnel will be able to do
the following:

• Identify and locate specific safety devices.

• Understand the proper use of the safety devices provided.

• Describe the function of the safety device.

Safety Circuit Standards

Safety circuits used in industrial systems protect the operator and maintenance personnel
from dangerous energy. They also provide a means of locking out or isolating the energy for
servicing equipment.

Various agencies have contributed to the establishment of safety standards that apply to the
design and manufacture of automated equipment. The Occupational Safety and Health
Administration (OSHA) and the Joint Industrial council (JIC) are just a few of the
organizations that have joined with the plastics industry to develop safety standards.

Every effort has been made to incorporate these standards into the design of the conveying
system; however, it is the responsibility of the personnel operating and maintaining the
equipment to familiarize themselves with the safety procedures and the proper use of any
safety devices.

Fail Safe Operation

If a safety device or circuit should fail, the design must be such that the failure causes a
“Safe” condition. As an example, a safety switch must be a normally open switch. The switch
must be held closed with the device it is to protect. If the switch fails, it will go to the open
condition, tripping out the safety circuit.

At no time should the safety device fail and allow the operation to continue for example, if a
safety switch is guarding a motor, and the safety switch fails, the motor should not be able to
run.

1 –Pump 1-Station Controller Chapter 2: Functional Description 10 of 30

Safety Device Lock-Outs

Some safety devices disconnect electrical energy from a circuit. The safety devices that are
used in this Controller are primarily concerned with electrical power disconnection.

WARNING! Always disconnect and lockout all electrical power and pneumatic (i.e. compressed air)

sources prior to servicing the 1-Pump, 1-Station Controller. Failure to do so may
result in serious injury. No one but the person who installed the lockout may remove
it.

1 –Pump 1-Station Controller Chapter 2: Functional Description 11 of 30

Chapter 3: Installation

3-1 Uncrating

1-Pump, 1-Station Controllers are shipped mounted on a skid, enclosed in a plastic
wrapper, and contained in a cardboard box.

1. Pry the crating away from the skid.

Note: Remove the nails holding the box to the skid and lift the box off carefully;

avoiding staples in the 1’ x 4’ wood supports. Cut the steel banding.

2. Use a pry bar to remove the blocks securing the unit to the skid.

3. Lift unit from sides. Use a pry bar if necessary to carefully remove the

skid from the unit.

4. Lower slowly.

3-2 Mounting the Control Panel

Note: Before you mount the panel, consider how you run wiring to the vacuum

hoppers, the filter chamber atmospheric valve (if so equipped) and the pump
motor starter(s), vacuum switch(es), and vent valve(s).

Mount the panel on a flat, vertical area. It should be a visible area that gives your
operator access to the control. The panel requires a low voltage power drop as listed on
the serial tag.

3-3 Electrical Connections

Refer to local electrical codes, the schematic and connection diagrams supplied with this
unit and the serial tag for wiring considerations. Run all wiring in conduit if codes require
it.

Making Control Panel Power Drop Wiring Connections

Connect the control panel to a grounded 115 VAC duplex outlet, as indicated on the
serial tag. The control enclosure draws less than two (2) amps during operation at 115
VAC.

1 –Pump 1-Station Controller Chapter 3: Installation 12 of 30

Connecting the Control Panel to Vacuum Receivers

The receiver bin-full sensor is already wired into inputs on a terminal block in the control
panel. Refer to the electrical schematic supplied in the information package.

A station bypass switch can be wired into the bin-full sensor circuit as shown in Figure 1
shown below. Mount the switch near the receiver and use it to simulate a bin-full
condition. When the switch opens, the control finishes the current cycle then goes into
AutoSutdown mode.

Close the switch to restart the conveying sequence.

Note: This step is useful when servicing the receiver, clearing obstructions, or

changing materials or machine bin/silo.

Figure 1: Station Bypass Switch Diagram

Wiring without Station Bypass Switch

A B

Bin-Full switch (LS)

Wiring with Station Bypass Switch

Station Bypass switch

(TS)

A

Off
On

(normally open, held closed)

Connecting the Control Panel to the Pump/Blower Package

Wire your single-station control panel to the motor starter coil, vaccum switch, and vent
valve on the vacuum pump or blower package. Refer to the electrical schematic enclosed
with the unit for more information.

If you purchased the optional rotary/selector switch, connect each receiver bin-full sensor
to a terminal block in the control panel. Only one material receiver can be selected at a
time. To select a receiver, turn the switch to the receiver number you want, and make the
connection to the appropriate vacuum receiver. This method is useful when filling silos
one at a time.

Bin-Full switch

(LS)

A1

N. O.

B

1 –Pump 1-Station Controller Chapter 3: Installation 13 of 30

3-4 Setup

This section provides the procedures for configuring your 1-pump, 1-station controller.

Configuration of your controller includes setting conveying times, . We recommend that you
carry out these procedures in the order given here.

Note: Before carrying out these procedures, install all equipment as described in this

section and in the Conveying Systems manual.

Setting Conveying Times

DANGER! Disconnect power BEFORE opening the control enclosure!

Electric current, capable of causing injury or death may be present in the control
enclosure during these procedures. Make sure that all adjustments performed in this
chapter are done only by qualified, safety-conscious personnel.

Adjust the vacuum conveying cycle duration by setting the DIP switches in the control
enclosure.

Choose the best conveying time for your process by starting with a medium length time
setting. Begin to convey material, and note how long it takes to fill the material receiver. The
sound of the pump or blower changes and the conveying rate drops off as the receiver fills.

Select a conveying time that is slightly longer than the time it takes to fill the material
receiver. The dump delay time is a function of the conveying time you selected and is not
independently adjustable.

Note: Verify the program number on the EPROM before you refer to Figure 2 or 3!

Figure 2: DIP Switch Chart for Adjusting Vacuum Time, Program A0538928

Dump delay

7 seconds

10 seconds

20 seconds 25 seconds 30 seconds 35 seconds

1234

OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF

OPEN

1234

ON ON ON ON ON ON ON ON

OPEN

60 seconds 70 seconds 90 seconds 110 seconds

1234 1234 1234 1234

ON ON ON ON ON ON ON ON

OPEN

1234

ON ON ON ON ON ON ON ON ON ON ON ON

OPEN OPEN

1234 1234 1234

OFF

OPEN

1234 1234 1234

OPEN

OPEN

1234 1234 1234

OFFOFFOFF

OPEN

OFFOFFOFFOFFOFFOFFOFF

OPEN

OFFOFFOFFOFFOFFOFFOFF

OPEN

OFF

OPEN

ONONONON

OPEN

55 seconds50 seconds45 seconds40 seconds

OFF

OPEN

OFF

OPEN

190 seconds170 seconds150 seconds130 seconds

OPEN

PROGRAM # A0538928

Note: Figure 2 contains two (2) different programs (7 and 10 second dump delay).

1 –Pump 1-Station Controller Chapter 3: Installation 14 of 30

Figure 3: DIP Switch Chart for Adjusting Vacuum Time, Program A0541578

Dump delay

15 seconds

18 seconds

1.5 seconds 3.0 seconds 4.0 seconds 6.0 seconds

1234

OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF

OPEN

1234

ON ON ON ON ON ON ON ON

OPEN

20 seconds 25 seconds 30 seconds 35 seconds

1234 1234 1234 1234

ON ON ON ON ON ON ON ON

OPEN

1234

ON ON ON ON ON ON ON ON ON ON ON ON

OPEN OPEN

1234 1234 1234

ONONONON

OFF

OPEN

1234 1234 1234

OPEN

OPEN

1234 1234 1234

OFFOFFOFF

OFF

OPEN

OPEN

OPEN

OPEN

OPEN

18 seconds15 seconds12 seconds9 seconds

OFFOFFOFFOFFOFFOFFOFF

OPEN

OFFOFFOFFOFFOFFOFFOFF

OPEN

55 seconds50 seconds45 seconds40 seconds

OPEN

PROGRAM # A0541578

OFF

OFF

Note: Figure 3 contains two (2) different programs (15 second and 18 second dump

delay).

Setting the Material Receiver Selector Switch (Optional)

1. Connect all proper material and vacuum lines before

switching material receivers.

2. Select the material receiver you want. The controller senses the bin-full sensor on the

material receiver.

Caution! Setting the selector to the wrong material receiver can cause a silo to over-

fill!

Do not turn on the pump/blower package until you make all connections
and select the proper material receiver.

3. The selector switch allows material to convey only when the controller receives a bin

full signal. You must make all other required connections manually.

An optional double pole rotary switch is also available. You can use the additional contact to
control a solenoid coil output of the same voltage as the controller, and direct airflow to the
material receiver. The primary contact monitors the material receiver bin-full sensor.

1 –Pump 1-Station Controller Chapter 3: Installation 15 of 30

Using and Adjusting the Auto-Shutdown Timer (1TMR)

The Auto-Shutdown timer in the control enclosure is factory-set to shut down the vacuum
pump package if no material demand is sensed within approximately thirty (30) seconds. A
no-material-demand condition occurs if the bin-full sensor on the material receiver trips. The
timer starts at the beginning of the dump-delay sequence. Automatic operation resumes when
the material level drops in the machine bin or silo below the material receiver and creates a
material demand condition.

You can adjust the Auto-Shutdown timer between 0 and 100 seconds. To change the timer
setting, locate 1TMR in the control enclosure. Turn the knob clockwise (within the 270°
range) to increase the time period that the pump package remains on after the controller
senses a no-material-demand condition. Turn the knob counterclockwise to decrease this
time.

Note: The thirty-second (30 sec.) setting is ideal for most conditions.

Vacuum Switch Operation (1VS)

The vacuum switch is mounted in the pump package junction box. It protects the motor and
pump from damaging high vacuum conditions.

Note: The vacuum switch is preset at the factory for the maximum capacity of the

motor and pump, and must not be adjusted!

Allowing the vacuum switch to be tampered with voids your warranty!

During operation, the power unit draws a vacuum of less than 5” Hg (169 millibars) when
only air is pulled into the system; it draws a vacuum of 5” to 10” Hg (169 to 339 millibars)
when material conveys. If the vacuum reaches 12” Hg (407 millibars), it indicates an
obstruction in the system. The vacuum switch closes and a dump delay sequence starts. This
sequence repeats until you clear the obstruction.

Note: Vacuum draw depends on pump size.

Mechanical High Vacuum Relief

The regulated vent valve provides a backup mechanical safety that protects the system from
damaging high vacuum conditions if the vacuum switch fails. It prevents vacuum from
exceeding 14” Hg (475 millibars) by regulating the supply air pressure to the vacuum air
cylinder.

Caution! Do not adjust the air regulator on the vent valve to trip at a point higher

than 14” Hg (475 millibars).

This point is the maximum safe vacuum that the pump package can
operate.

1 –Pump 1-Station Controller Chapter 3: Installation 16 of 30

Chapter 4: Operation

4-1 Overview

Your 1-pump, 1-station controller sends a control shift signal to a compressed air-operated
valve. The valve directs airflow for material conveying, material dumping, and idle position.
A vacuum switch and a mechanical vacuum relief valve can be used to protect the vacuum
pump and motor from high amp draw damage.

The conveying cycle is determined by signals from a sensor mounted in the vacuum receivers
and interpreted by the controller. The controller monitors current system status and sends the
convey signal to the system until material levels send a signal to the controller to stop
conveying.

This section provides the procedures necessary for using your controller.

Note: Before you carry out any of the procedures in this chapter, the system must

be set up as described in Chapter 3.

4-2 Startup

Pre-Startup Checks

Before operating the single-station controller or any other part of your conveying system,
check these items:

1. Verify that all components in the system are installed securely and ready to operate.

Refer to the instructions supplied with auxiliary equipment for specific checks.

2. Make sure that couplers, fittings, attachments, and flexible lines are securely attached

and are vacuum-tight.

3. Verify that all electrical and compressed air connections to the vacuum pump/blower

package are complete, tight, and safe.

4. Fill the vacuum pump blower gearbox with oil, based on the manufacturer’s

instructions included in your Customer Information Packet.

Caution! Do not overfill the geabox. Too much oil can damage the blower.

5. If you haven’t already done so, remove the plastic plug from the air inlet.

WARNING! KEEP HANDS AWAY FROM THE OPEN AIR INLET TO AVOID INJURY!

6. Verify that no loose parts, tools, or foreign materials are in or near the unit or other

system components.

7. Turn off the compressed air supply, switch on the power at the external fuse box or

disconnect, and move the main power on the control enclosure to the ON position.

8. Using the ON/OFF switch, turn on the pump just long enough to verify that the motor

is rotating in the proper direction.

1 –Pump 1-Station Controller Chapter 4: Operation 17 of 30

Changing Motor Rotation Direction

If the motor is rotating in the wrong direction, do the following:

1. Disconnect the power at the external disconnect.

2. Switch any two incoming power leads on the main power supply.

Caution! Do not change wiring at the motor starter!

Starting the System

After you completely install the conveying system and make all pre-startup checks, perform
the following procedure to operate the system.

1. Turn on compressed air to the power unit solenoid valve and set the supply regulator

at 80 psi (551.6 kPa/5.52 bars).

2. Close the disconnect switch on the electric supply circuit and on the vacuum pump

package.

3. Move the ON/OFF switch in the ON position.

Note: The pump does not turn on until the first dump delay is complete. Conveying

then begins.

4-3 Control Panel Components

Once the controller has been configured according to the instructions listed in Section 3-4,
The only procedure necessary to begin conveying, is to turn on the controller using the Power
toggle switch described below. If the controller is equipped with the Optional Material
Receiver Selector Switch, then the operator will need to select the material receiver to convey
to before turning on the Power toggle switch on the controller.

Material Receiver Selector Switch (Optional)

The MATERIAL RECEIVER SELECTOR switch (Shown in Figure 4 on Page 19) allows
you to select the material receiver from multiple material receivers for time-filling. It is
typically used in railcar unloading processes.

Control Power Indicator Light

The CONTROL POWER indicator light illuminates when the control panel energizes.

Control Power Toggle Switch

The CONTROL POWER switch starts or stops the conveying cycle. If you selected a
material receiver with a material demand condition, the cycle begins. This switch also lets
you turn the vacuum pump or blower on and off.

1 –Pump 1-Station Controller Chapter 4: Operation 18 of 30

Figure 4: Control Panel Components

MATERIAL RECEIVER

SELECTOR

10

9

8

7

65

CONTROL POWER

ON

OFF

SINGLE STATION TIME-FILL

1

2

3

4

Optional material receiver
selector switch

Power On
indicator light

Power On/Off
toggle switch

4-4 Operation Sequence

Once the controller has been energized, the following will occur:

1. The dump delay/blowback sequence occurs.

2. The vacuum pump/blower motor starts and the pump vent valve directs vacuum

through the material receiver.

3. The material discharge valve seals under the vacuum.

4. The material receiver fills until the DIP switch-set vacuum timer times out.

5. The vent valve shifts, breaking vacuum.

6. The dump delay blowback sequence begins. The material discharge valve opens and

the material leaves the receiver.

If the switch on the material discharge valve senses a full machine bin, the vacuum pump
motor shuts down, based on an adjustable auto-shutdown time. When the controller senses a
need for material, it restarts the cycle after Step 1.

4-5 Shutting Down the System

1. Move the power switch on the control box to the OFF position.

2. Disconnect main power to the pump package at the disconnect switch in the junction

box.

3. For maintenance or long-term shut-down, unplug the control panel from the power

source, disconnect main power to the vacuum pump motor, and turn off compressed
air.

1 –Pump 1-Station Controller Chapter 4: Operation 19 of 30

Chapter 5: Maintenance

Our conveying systems require periodic maintenance to provide long, dependable
service. For maintaining mechanical components in your conveying system, see the
Conveying System Mechanical Components manual (Part No. A0536580) for more
information.

Caution! Keep the electrical panel closed securely to prevent contaminating the

components with material and to prevent electrical shock.

Don’t defeat the disconnect!

1 –Pump 1-Station Controller Chapter 5: Maintenance 20 of 30

Chapter 6: Troubleshooting

6-1 General Troubleshooting

Note: For more information on troubleshooting your conveying system, see the

Conveying System Mechanical Components manual (Part No. A0536580).

Problem Possible cause Solution

A pump/blower package
doesn’t run.

A material receiver is
being by-passed in the
loading cycle.

Problem Possible cause Solution

control box.
Power switch is off. Turn ON the control box.
Power switch has failed. Replace the switch.
Fuse is blown. Replace the fuse.
The machine bin is full. The hopper operates after the

The high level switch has failed. Replace the switch.
The discharge valve is blocked. Remove the obstruction and

Loose control wiring. Secure all terminal connections.
Motor connections are loose. Reattach blowback and motor

The motor overload has tripped. Reset the overload and check

The circuit board has failed. Replace the circuit board.
Main fuse in power drop or
optional fused disconnect has
blown.
The relay has failed. Replace the relay.
The Auto-Shutdown timer has
failed.
The noise suppressor has failed. Replace the suppressor.
The bin below it is full if its
amber indicator light is off.

The hopper is off line. Using the controller, place the

The convey time for the hopper
is set to zero.
The field-installed station bypass
switch is simulating a Bin Full
condition.
The field-installed station bypass
switch is bad or mis-wired.

Plug in the power cord. No power to the
Check the main disconnect.

material level drops.

check for free movement of the
flapper assembly.

connections.

the motor for the proper amp
draw on tag.

Replace the fuse.

Replace the timer.

Normal operation. When the
level drops, the hopper is
conveyed to.

hopper on line.
Using the controller, enter a
reasonable convey time.
Normal operation. Set the
switch so the hopper is back in
the loading sequence.
Repair, replace, or rewire.

1 –Pump 1-Station Controller Chapter 6: Troubleshooting 21 of 30

The material receiver does
not completely fill.

The POWER light does
not illuminate.

The power light doesn’t
light when the ON/OFF
switch is in the ON
position and the
unit won’t run.

Hopper over-fills
repeatedly.

High vacuum condition.

POWER light on, but
pump/ blower motor
doesn’t run.

Pressure present at the
vacuum unit.

Unit shifts into blowback
cycle repeatedly.

Problem Possible cause Solution

Vacuum time is too short. Lengthen vacuum time.
Material supply is too low. Refill material supply.
Material probe is not positioned
correctly in material supply.
Material probe is not adjusted to
the characteristics of the
material.
Obstructions in the supply line. Clear all obstructions in the line.
The filter is dirty. Clean or replace the filter.
A terminal connection is loose. Secure terminal connections on

The light is burned out. Replace the light (1LT).
The disconnect switch on the

unit or in the power drop is
open.
The fuse(s) in the power drop
disconnect switch is (are) open.
Fuse(s) 1FU has/have opened. Replace the fuse(s).

Vacuum time is too long. Decrease vacuum time.

Material line obstruction. Clear the material line.
Material probe obstruction. Reposition or clear the probe.
Railcar air intake is blocked. Clean or clear the filter.
Vacuum switch failed. Replace the vacuum switch.
Wiring fault in the vacuum
switch.
Machine bin is filled with an
adequate material supply.

The motor overload (10L) has
tripped and taken the motor off
line.
The motor starter (10L) has
failed.

Improper blower rotation. Switch any two wires at the

Vacuum switch (1VS) detects
a high vacuum condition.

Adjust the material probe at the
pickup point.
Adjust the material probe to
compensate for flow
characteristics.

the terminal board.

Close the switch.

Replace the fuse(s).

Check connections.

Normal operation. The unit
resumes operation when the bin
level drops.
Reset the overload and check
the motor for the proper amp
draw as listed on the nameplate.
Repair or replace the motor
starter as needed.

incoming power mains on the
disconnect.

A material line is plugged.
Filter chamber needs cleaning.
Switch may be mis-wired
(initial startup).

1 –Pump 1-Station Controller Chapter 6: Troubleshooting 22 of 30

Vacuum conveying rates
decline.

Vacuum leak in the system. Find the leak and repair it.
Filter in filter chamber is plugged. Clean thoroughly; replace if

worn.

Material receiver filter is plugged. Clean thoroughly; replace if

worn.

Blower is dead-headed. Check the blower inlet for

obstructions.
Valve(s) not seating properly. Service valve(s).
Low air pressure. Verify minimum of 80 psi

(551.6 kPa/5.52 bars) supply air

pressure.

1 –Pump 1-Station Controller Chapter 6: Troubleshooting 23 of 30

Chapter 7: Appendix

7-1 Warranty

Unless otherwise specified, this product includes a Standard ONE YEAR PARTS AND
LABOR WARRANTY.

Warranty Specifications

The manufacturer hereby expressly warrants all equipment manufactured by it to be free from
defects in workmanship and material when used under recommended conditions, as set forth
in the operating manuals for such equipment. THE FOREGOING EXPRESS WARRANTY
IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, GUARANTIEES,
AGREEMENTS, AND SIMILAR OBLIGATIONS OF THE COMPANY AND/OR
MANUFACTURER (UNLESS OTHERWISE SPECIFIED IN THE SPECIFIC PRICE
PAGE OR LIMITED BY THE MANUFACTURERS’ WARRANTY FOR PARTS). The
Company’s obligation is limited to repair or replace FOB the factory any parts that are
returned, prepaid, within one year of equipment shipment to the original purchaser, and
which in the Company’s opinion, are defective. Any replacement part assumes the unused
portion of this warranty.

Warranty Restrictions

This parts warranty does not cover any labor charges for replacement of parts, adjustment
repairs, or any other work. This warranty does not apply to any equipment which, in the
Company’s opinion, has been subjected to misuse, negligence, or operation in excess of
recommended limits, including freezing or which has been repaired or altered without the
Company’s express authorization. If the serial number has been defaced or removed from the
component, the warranty on that component is void. Defective parts become the property of
the warrantor and are to be returned immediately, without any further use or handling.

1 –Pump 1-Station Controller Chapter 7: Appendix 24 of 30

Warranty Liabilities

THE COMPANY EXPRESSLY DISCLAIMS ANY AND ALL LIABILITY FOR ANY
SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES OR EXPENSES THAT
RESULT FROM THE USE OF THIS PRODUCT. Some states do not allow the exclusion or
limitation of special, consequential or incidental damages, so the above limitation may not
apply to you. The Company’s obligation for parts not furnished as components of its
manufactured equipment is limited to the warranty of the manufacturers of said parts. The
company neither assumes nor authorizes any other persons to assume for it any liability in
connection with the sale of its equipment not expressed in this warranty. No person, agent,
manufacturer, distributor, dealer, installer or company is authorized to change, modify or
extend the terms of this warranty in any manner whatsoever.

The time within which an action must be commenced to enforce any obligation of the
Company’s arising under this warranty, or under any statute or law of the United States or
any state thereof, is hereby limited to the duration of this warranty. Some states do not permit
this limitation, so the above may not apply to you. This warranty gives you specific legal
rights and you may also have other rights which vary from state to state. For transactions
involving the potential applicability of international law or that of a foreign country,
this warranty policy and the procedures hereunder shall be governed by
applicable federal and state law, but not by the United Nations Convention on Contracts for
the Sale of Goods.

Customer Responsibilities

Any sales, use, or other tax incident to the replacement of parts under this warranty is the
responsibility of the purchaser.

7-2 Optional Components

The following is a list of options that your controller may be equipped with:

Rotary Switch for High Level Selection. A ten (10) – position single- or double-pole
switch allows you to select from multiple material receivers.

115/1/60 or 24VDC Operation. Required to operate with a 115/1/60 or 24VDC supply
voltage.

1 –Pump 1-Station Controller Chapter 7: Appendix 25 of 30

7-3 Drawings and Diagrams

V

y

Figure 5: Receiver Wiring Details

Vacuum hopper - Time Fill

acuum hopper - Time Fill

(when using the proximity

switch as a Bin Full switch)

Brown

4 (115VAC)

Bin-Full

switch

(1LS)

4 (115VAC)

To Bin-Full
control relay (2CR)

13

Bin-Full

switch

(1LS)

Blue

13

or selector switch

To Bin-Full
control relay (2CR)

Figure 6: Typical Single-Station Electrical Schematic without Optional Material Receiver Selector
Switch Circuit

GRD

L2

2

1CNTL
1

2

14

45

2

18 ga
white (typical)

2

G

Power On

2

Control board

Pump high

2

vacuum switch

18 ga

red (typical)

L1

1FU

4

1A

4

4

1DISC-1

4

1S

3

1

115 VAC

1VS

N. O.

1DISC-4

1TMR

5

2 3

10

3

9

1DISC-2

11

1DISC-3

12

15

2CR

15

7

18 ga

blue

4

4

4

4

1TMR

98

N. O.

1CR

12

1LS

N. O.

8

11

12

13

8V

MOV

8

12

6

7

89 1CR

34

2SOL

8

10L

1SOL

.5 MF SUP

L3

1M

2CR

Filter chamber

2

(or pump)
blowback solenoid

Vacuum
control
panel

2

Vacuum pump
motor starter

Vacuum pump

2

vacuum/vent
(or vacuum)
solenoid

2

Pump shutdown

2

timer (OFF-DELAY)
(0-30 sec.)

2

Bin Full
control rela

1 –Pump 1-Station Controller Chapter 7: Appendix 26 of 30

Figure 7: Typical Single-Station Electrical Schematic with Optional Material Receiver Selector

Switch Circuit

L1

GRD

L2

18 ga

red (typical)

1FU

4

1A

4

4

1DISC-1

4

4

4

3

1S

1

1VS

N. O.

2CR

15

1TMR

98

N. O.

1CR

12

7

18 ga

blue

115 VAC

11

12

2

1CNTL

1

2

14

15

8

45

6

8V

MOV

7

8

89 1CR

1DISC-4

10

3

9

1DISC-2

11

1DISC-3

12

2SOL

8

34

10L

1SOL

2

18 ga
white (typical)

2

G

1M

Power On

2

Control board

2

Pump high
vacuum switch

Filter chamber

2

(or pump)
blowback solenoid

Vacuum
control
panel

Vacuum pump

2

motor starter

Vacuum pump

2

vacuum/vent
(or vacuum)
solenoid

2

.5 MF SUP

13

2CR

Pump shutdown

2

timer (OFF-DELAY)
(0-30 sec.)

2

Bin Full
control relay

4

4

Material
receiver

1SS

12

10

1TMR

12

17

18

19

20

21

22

23

24

25

26

1LS 13

N. O.

2LS 13

N. O.

3LS 13

N. O.

4LS 13

N. O.

5LS 13

N. O.

6LS 13

N. O.

7LS 13

N. O.

8LS 13

N. O.

9LS 13

N. O.

10LS 13

N. O.

1

2

3

4

5

6

7

8

9

13

5

2 3

Also, review electrical drawings supplied in the packet with the manual.

1 –Pump 1-Station Controller Chapter 7: Appendix 27 of 30

Figure 8: Auto Shutdown Timer

5

Timer

adjustment

knob

32

9 8 1

7-4 Spare Parts List

Part No. Description

A0536932 Auto Shutdown Timer
A0536546 Solid State Relay
A0539361 Control Board
A0503765 Relay

A0536646 Neon Light
W00014987 Sequence Valve Solenoid (24V)
W00014988 Sequence Valve Solenoid (115V)

1 TMR

1 –Pump 1-Station Controller Chapter 7: Appendix 28 of 30

7-5 Returned Material Policy

Credit Returns

Prior to the return of any material, authorization must be given by the manufacturer. A
RMS number will be assigned for the equipment to be returned.

Reason for requesting the return must be given.

returned material purchased from the manufacturer is subject to 15% ($75.00 minimum)

All
restocking charge.

returns are to be shipped prepaid.

All

The invoice number and date or purchase order number and date must be supplied.

No credit will be issued for material that is not within the manufacturer’s warranty period
and/or in new and unused condition, suitable for resale.

Warranty Returns

to the return of any material, authorization must be given by the manufacturer. A

Prior
RMS number will be assigned for the equipment to be returned.

Reason for requesting the return must be given.

returns are to be shipped prepaid.

All

The invoice number and date or purchase order number and date must be supplied.

After inspecting the material, a replacement or credit will be given, at the manufacturer’s
discretion, if the item is found to be defective in materials or workmanship. Purchased
components are covered under their specific warranty terms.

7-6 Safety Tag Information

Controller Safety Tags

High Voltage
Inside Enclosure

Read Operation and
Installation Manual

1 –Pump 1-Station Controller Chapter 7: Appendix 29 of 30

7-7 Controller Identification (Serial Number) Tag

r

(Located on the side of the controller box)

Street Address
Town, State Zip Code
Telephone Number
Fax Numbe

XXX CONTROL PANEL
Model No. XXX1-1 Serial No. 31K0182

115 Volt 60 Hz 1 Ph

Control Voltage 24VDC

7-8 Technical Assistance (Contact Information)

Parts Department

Call toll-free 7am–5pm CST [856] 312-9600, Fax [856] 312-9696
The ACS Customer Service Group will provide your company with genuine OEM quality parts
manufactured to engineering design specifications, which will maximize your equipment’s performance
and efficiency. To assist in expediting your phone or fax order, please have the model and serial
number of your unit when you contact us. A customer replacement parts list is included in this manual
for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to providing
excellent customer service.

Service Department

Call toll-free 8am–5pm CST [856] 312-9600
We have a qualified service department ready to help. Service contracts are available for most
products.

Sales Department

[856]

Call
Our products are sold by a world-wide network of independent sales representatives. Contact our Sales
Department for the name of the sales representative nearest you.

312-9600 Monday–Friday, 8am–5pm CST

Contract Department

[856]

Call
Let us install your system. The Contract Department offers any or all of these services: project planning;
system packages including drawings; equipment, labor, and construction materials; and union or non­union installations.

312-9600 Monday–Friday, 8am–5pm CST

1 –Pump 1-Station Controller Chapter 7: Appendix 30 of 30