AEC 3-Pump 33-Station Controllers User Manual

3-Pump 33-Station Controllers

Part Number: A0572879

Bulletin Number: WH2-605F.1

Effective: 8/05/04

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.

Table of Contents

CHAPTER 1: SAFETY..................................................................VI

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

Safety Symbols Used in this Manual.................................................................... vi

1-2 Warnings and Precautions ........................................................................................vii

1-3 Responsibility...........................................................................................................viii

General Responsibility........................................................................................viii

Operator Responsibility ....................................................................................... ix

Maintenance Responsibility ................................................................................. ix

Reporting a Safety Defect.................................................................................... ix

CHAPTER 2: FUNCTIONAL DESCRIPTION ............................. 10

2-1 Models Covered in This Manual ...............................................................................10

2-2 General Description ................................................................................................. 10

2-3 Standard Features ................................................................................................... 11

Mechanical Features ..........................................................................................11

Electrical Features .............................................................................................11

Controller Features.............................................................................................11

2-4 Optional Features .................................................................................................... 11

2-5 Safety Devices and Interlocks .................................................................................. 12

Safety Circuit Standards.....................................................................................12

Fail Safe Operation ............................................................................................ 12

Safety Device Lock-Outs .................................................................................... 12

CHAPTER 3: INSTALLATION .................................................... 13

3-1 Uncrating ................................................................................................................. 13

3-2 Mounting the Control Panel...................................................................................... 13

3-3 Electrical Connections.............................................................................................. 13

Making Control Panel Power Drop Wiring Connections....................................... 13

Connecting the Control Panel to Vacuum Hoppers ............................................. 14

Connecting the Control Panel to the Pump Package...........................................14

3-4 Setup....................................................................................................................... 15

Setting the Number of Stations and the Number of Pumps..................................15

Setting Up Alarm Silences..................................................................................17

Setting Up Pump Staging ................................................................................... 18

Setting Up Touch Switch Delay .......................................................................... 18

Setting Up Stations.............................................................................................19

Setting Up Pumps .............................................................................................. 23

Finishing Setup: Setting Up Passwords ..............................................................25

3-5 Initial Startup............................................................................................................ 27

CHAPTER 4: OPERATION ......................................................... 28

4-1 Overview ................................................................................................................. 28

4-2 Basic Tasks ............................................................................................................. 28

Reviewing Station Status.................................................................................... 28

Reviewing Pump Status .....................................................................................30

Logging On and Logging Off...............................................................................31

Enabling and Disabling Stations and Pumps.......................................................32

Starting and Stopping the System....................................................................... 32

Reviewing and Adjusting Basic Station Settings..................................................33

Navigating among the Station Operator Screens ................................................ 33

Adjusting Convey Time and Dump Delay............................................................34

Activating and Stopping Priority Convey for a Station.......................................... 35

4-3 Adjusting Advanced Settings.................................................................................... 36

Reviewing and Resetting a Pump Hour Meter..................................................... 36

Transferring Stations to a Standby Pump............................................................37

4-3 Alarms ..................................................................................................................... 39

Reviewing Alarms ..............................................................................................39

Silencing Alarms ................................................................................................40

CHAPTER 5: MAINTENANCE.................................................... 41

CHAPTER 6: CONFIGURABLE SETTINGS .............................. 42

6-1 Options for Station Setup ......................................................................................... 42

6-2 Options for Pump Setup ........................................................................................... 44

CHAPTER 7: TROUBLESHOOTING.......................................... 45

7-1 General Troubleshooting.......................................................................................... 45

7-2 Alarms........................................................................................................................46

Station Alarms.................................................................................................... 46

Pump Alarms .....................................................................................................46

System Alarms...................................................................................................46

CHAPTER 8: APPENDIX ............................................................ 47

1-1 Warranty.................................................................................................................. 47

Warranty Specifications..........................................Error! Bookmark not defined.

Warranty Restrictions .............................................Error! Bookmark not defined.

Warranty Liabilities.................................................Error! Bookmark not defined.

Customer Responsibilities ......................................Error! Bookmark not defined.

8-2 Optional Components .............................................................................................. 47

8-3 Drawings and Diagrams ........................................................................................... 48

8-4 Spare Parts List ....................................................................................................... 49

AC Voltage.........................................................................................................49

DC Voltage ........................................................................................................ 49

8-5 Returned Material Policy .......................................................................................... 49

Credit Returns....................................................................................................49

Warranty Returns ...............................................................................................50

8-6 Safety Tag Information............................................................................................. 50

Controller Safety Tags........................................................................................50

8-7 Controller Identification (Serial Number) Tag ............................................................ 50

8-8 Technical Assistance (Contact Information).............................................................. 51

Parts Department ...............................................................................................51

Service Department............................................................................................51

Sales Department ..............................................................................................51

Contract Department ..........................................................................................51

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.

1-2 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.

˛ 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.

1-3 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.

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, 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.

3 –Pump 33-Station Controllers Chapter 2: Functional Description 10 of 51

Chapter 2: Functional Description

2-1 Models Covered in This Manual

This manual provides operation, installation, and maintenance instructions for 3-Pump, 33­Station 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 3-Pump, 33-Station Conveying Controller is a programmable logic controller, with 24
VDC or 115 VAC control circuit, easy-to-use touchscreen operator interface terminal and
optional audible/visual alarm.

2-2 General Description

Our material conveying systems create vacuum for the automatic conveying of most free­flowing, dry, pelletized, or granular materials. 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.

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 the Mechanical Components Product
manual (Part No. A0536580) for installation recommendations.

3–Pump 33-Station Controllers Chapter 2: Functional Description 11 of 51

2-3 Standard Features

Mechanical Features

Time-fill Capability. The length of time a station’s vacuum valve remains open to allow
material to be drawn into its receiver.

Volume-fill Capability. The length of time a station’s vacuum valve remains open to allow
material to be drawn in. The vacuum valve will close when material covers the station’s
volume-fill proximity sensor or this time elapses, whichever comes first.

Pump Blowback Filter Cleaning Outputs. When this feature is enabled, the controller
periodically sends compressed air backward through the pump’s air filter to dislodge
accumulated dust and debris.

Electrical Features

• 115/1/60 supply voltage

• 24 VDC control voltage

• Single-point power and ground connection

• Non-fused disconnect switch, lockable

• Branch circuit fusing

• Fully accessible NEMA 12-style electrical control enclosure

Controller Features

• Allen-Bradley PLC with 6” color touch screen display

• Monitors Station status and Pump status

• Allows operator to transfer stations to a standby pump when a pump fails

• Electronic time delay between pump startups to prevent an excessive power demand at

your facility

2-4 Optional Features

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

230/1/60 Operation. Required to operate with a 230/1/60 supply voltage.

Audible/visual alarm. Alarm light and horn assembly that can be remote mounted and

wired into the controller to indicate an alarm condition.

CE Package for 220/1/50 Operation. Required in Europe and other areas that need
220/1/50 supply voltage.

3–Pump 33-Station Controllers Chapter 2: Functional Description 12 of 51

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.

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 3-Pump, 33-Station Controller. Failure to do so may
result in serious injury. No one but the person who installed the lockout may remove
it.

3–Pump 33-Station Controllers Chapter 3: Installation 13 of 51

Chapter 3: Installation

3-1 Uncrating

3-Pump, 33-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, inserting forklift under the base. The forks must be equidistant

from the centerline of the unit and the unit must be balanced on the forks. Lift
slowly and only high enough to clear the skid. 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

Hardwire the input power at 110/1/50-60 VAC or 230V/1/50-60 VAC, depending on the
specifications, which are located on the Control Panel Serial Tag. The main power
switch is located on the front of the enclosure.

Caution! We recommend that you protect PLC memory by providing the control

panel with a dedicated circuit, a true earth ground, and a spike/surge
protector.

3–Pump 33-Station Controllers Chapter 3: Installation 14 of 51

Connecting the Control Panel to Vacuum Hoppers

Note: Wire size depends on control voltage, distance, number of vacuum

hoppers, and the number of wires in each raceway. Consult a qualified
electrician.

1. On 115 VAC control voltage systems, run a common hot (115 VAC) wire and

a common neutral wire from the controller to each vacuum hopper in the
system.
On 24 VDC control voltage systems, run a common +24 VDC wire and a
common 0 (zero) VDC wire from the controller to each vacuum hopper in the
system.

2. On all systems, run two wires to each vacuum hopper: one each from the

controller to the Bin-Full switch (LS) and to the Atmospheric/Sequence-T
solenoid (SOL) valve.

3. Make sure that the solenoid and the proximity switch (if supplied) on vacuum

hoppers are the same voltage (24 VDC) as the control panel voltage. Consult
the control panel serial tag and the solenoid valve nameplates.

4. Wire size depends on control voltage, distance, number of vacuum hoppers,

and the number of wires in each raceway. Consult a qualified electrician.

5. Properly ground each hopper to reduce static build up generated by material

conveying.

Connecting the Control Panel to the Pump Package

1. Wire the pump package motor starter coil (M) to the terminal provided in the

control panel enclosure.

2. Wire the pump package vacuum relief valve solenoid (SOL A) to the terminal

provided in the control panel enclosure.

3. Wire the pump package vacuum switch (VS) to the terminal located in the

control panel enclosure.

4. On vacuum pumps, wire the pump package blowback solenoid (SOL B) to the

terminal located in the control panel enclosure.

5. On 115 VAC control voltage systems, run a common hot (115 VAC) wire and

a common neutral wire from the controller to each pump package in the
system.

On 24 VDC control voltage systems, run a common +24 VDC wire and a
common 0 (zero) VDC wire from the controller to each pump package in the
system.

3–Pump 33-Station Controllers Chapter 3: Installation 15 of 51

3-4 Setup

This section provides the procedures for configuring your 3-pump, 33-station controller.

Configuration of your controller includes setting the number of stations and pumps,
setting variables such as convey time and blow-back interval, and setting up passwords.
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 Mechanical Components manual.

Setting the Number of Stations and the Number of Pumps

Figure 1: Default “Station Status” Screen Before Setup

1. At the “Station Status” screen (Figure 1) or at the “Pump Status” screen, touch the Menu

button. The “Menu” screen opens.

Figure 2: “Menu” Screen

2. At the “Menu” screen, (Figure 2), touch the System Setup button. The “System

Setup” screen opens.