Dekker OnDek Controller User Manual

Dekker Controller Manual Rev: Feb 18 2016

 Overview__________________________________ __ 2
 Battery_______________________________________3
 Controller Input/Output Layout___________________4
 Current Input/Output Assignments__________ _____5
 Entering Password____________________________ 6
 Changing Vacuum Units______________________ _ 7
 Changing Vac CutIn and CutOut_________________ 8

 Multimachine Setup________________________ ___ 9
 Temperature Warnings And Faults_______________10
 Setting Date And Time_________________________11
 Entering Keycodes____________________________13
 Cooling Fan__________________________________15
 Rotation_____________________________________16
 Scavenger Output_____________________________17
 Faults and Fault Logs__________________________18
 Autostart____________________________________ 21
 Maintenance Schedules________________________ 22
 Reset Maintenance Schedule Hours_______________25
 DPInlet_______________________________________26
 Remote Start/Stop______________________________27
 Network Options_______________________________28

 Key Code List 28

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4 line LCD Display

ESCAPE BUTTON RETURNS TO
RUN/STANDBY/STOPPED SCREEN

PROGRAM BUTTON PROGRAM MENU
FOR SETPOINTS, CLOCK, UNITS

MAINT BUTTON MENU FOR: SPARE
PARTS LIST MAINTENANCE SCHEDULES
SERVICE HISTORY

LOG BUTTON FAULT HISTORY LOG
MENU

RESET BUTTON RESETS FAULTS

RUN STATUS LED GREEN = SYSTEM
RUNNING ORANGE = STANDBY/AUTO
MODE RED = SYSTEM STOPPED

OFF LED RED = SYSTEM STOPPED

OFF BUTTON STOPS SYSTEM

ON BUTTON STARTS SYSTEM

GREEN= SYSTEM RUNNING

POWER ON BUTTON
TURNS CONTROLLER ON
AND OFF

POWER ON LED
RED=CONTROLLER

HAND/AUTO
BUTTON
ALTERNATES
BETWEEN
HAND AND
AUTO
MODES

HAND/AUTO
LED
ORANGE=HAND
GREEN=AUTO

ENTER
BUTTON
SELECT
MENU ITEMS
MENUS AND
VALUES

UP / DOWN – ARROW/ - BUTTON
NAVIGATE MENUS AND CHANGE
VALUES

DEKKER CONTROLLER OVERVIEW

Dekker’s Controller is standard on the Vmax models. The Dekker Controller provides for system control
as well as monitoring of system status. Service functions include display of spare parts list, maintenance
schedules, and service history, along with logging of fault conditions.
The Dekker Controller includes a 4-line large-font liquid crystal display, a durable Lexan membrane
keypad, and multiple status LEDs. Communication between controllers is via RS-485 for multi-machine
systems. An Ethernet port provides for remote monitoring and control via TCP/IP protocols and can be

enhanced with the use of Dekker’s OnDek Software (optional and purchased separately). Input and

output (I/O) includes 9 digital (24VDC) inputs and 7 dry relay contact outputs. Analog I/O includes 2 RTD
(Resistance Temperature Detectors) inputs, four 0-10VDC/4-20mA inputs, one 0-10VDC output, and one
4-20mA output. Power input to the controller is 24VDC.

DEKKER CONTROLLER KEYPAD

The Dekker Controller text display, buttons, and LEDs are described below. Refer to the diagram below
that shows this information.

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Battery

The OnDek Dekker Controller

Battery

The Dekker Controller is shipped from supplier with a battery protector placed between the battery clip
and the surface of the battery, it may be a rubber sleeve around the clip or a small plastic insulator
between the clip and battery. This must be removed before applying power to the controller. If not
removed the controller will not retain Date, Time and other values that are written to the controller for
setup. The controller cannot be flashed with new firmware until this is removed. To remove use a pair of
needle nose pliers and pull from clip.

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987654321

Digital Inputs
Relay Outputs C1 - C7

RTD1

RTD2

Analog In 4

Analog In 3

Analog In 2

Analog In 1

NC C7 NO | NC C6 NO

NC C5 NO | NC C4 NO

C3 NO | C2 NO | C1 NO

RS232 Port

4-20MA Calibration Switches

Controller Input/Output Layout

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Current Input/Output Assignments

Digital Inputs Analog Inputs

1. E-Stop 1. Vacuum

2. Overloads 2. Backpressure

3. Aux Contact Vac Pump 3. Circ Pump Pressure

4. Low Fluid Level 4. Diff Pressure

5. High Fluid Level

6. Remote Start RTD Inputs

7. Remote Stop RTD1 – Aux Temp

8. Circ Pump Overload RTD2 – Discharge Temp

9. External Warning

(Note: External warning is used to give a warning on the screen from an external device.)
(Analog input 4 is a 0-15 psia transducer used in conjunction with Analog input 1 transducer to
measure the difference in vacuum across the inlet filter)

Relay Outputs

 C1/NO = Vac Pump Motor Starter
 C2/NO = Local Lag Light
 C3/NO = Horn Output
 C4/NO = Remote Lag Light
 C5/NO = AllFault Out
 C6/N0 = Scavender Valve Out
 C7/NO = Cooling Fan

All inputs and outputs are 24VDC

Analog inputs are 0-10 Vdc by default, but configurable for 4-20ma

C5 Allfault output is used to for a remote indicator for any shutdown fault.

C6/NO Scavenger only10 Minute Run times were changed to a minium of 30 Minutes and adjustable to
90 Minutes in firmware version 1.12d all prior versions were 0 - 10 applies to firmware versions prior to
v 1.12d

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ESC button

Password 0

MAINT

ENTER

Entering Password

Press and hold ESC button until Password 0 appears at bottom of screen.

Press MAINT button twice which enters the password 33 Then press ENTER

You now have access to change Controller settings.

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PROG

Changing Vacuum Units

Enter Password

If current screen is STOPPED or RUNNING press PROG once to view Setpoints screen. If HgV is already
set for vacuum units you will see Vac CutIn and Vac CutOut in HgV units.

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DOWN

Vacuum Unit

PROG

To change to another Unit use DOWN arrow to scroll to Vacuum Unit Then press ENTER.

Once you press ENTER use UP arrow to change unit, you will have a choice of TORR, HgV or Millibars.

Once selection is made you must press ENTER again to save.

Changing Vac CutIn and CutOut

Enter Password

If current screen is STOPPED or RUNNING Press PROG once to view Setpoints screen.

Press UP or DOWN button if necessary to select Vac CutIn then press ENTER

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Once ENTER is pressed use UP or DOWN arrows to change value then press ENTER to save. Using
UP/DOWN arrows repeat for Vac CutOut and save again by pressing ENTER

NOTE: When set up for multimachine, controller must be in STOPPED mode when changing Setpoints.

Multimachine Setup

Multimachine allows two or more Controllers to communicate and rotate Lead and Lag pumps based on
hours Run. When rotation occurs the pump with the least hours will rotate to Lead if the hours are
imbalanced. This keeps from putting all the run hours on one pump. To set up for multimachine CAT5
Ethernet cables are run from the RS485 jack mounted inside the panel. The cable is plugged into the jack
in the first panel, then routed to the second panel and plugged in. Each panel has two jacks so that you
can run cables to each machine if more than two. Cables must be run before setting the Controller up
for multimachine. Once cables are run go to first Controller and Enter Password.

Now press PROG button twice to view System Options Screen
Press DOWN arrow until Multimachine is selected.
Press ENTER.
Even though multimachine may already be set for 1 use UP button to move to 2 then back to 1

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And press ENTER. Controller will reboot.

Go to second Controller Enter Password and follow same steps above only change multimachine to 2
and press ENTER.

If there are three controllers on the third set multimachine for 3. Do this for all Controllers each with a
different multimachine number starting with the first they should be, 1,2,3,4 etc.. When Controllers
power back up on each Controller it should show Units Found which will be the number of Units found
on the RS485 Bus. This should match the number of Controllers, if a Duplex 2, if a Triplex 3 etc..

Temperature Warnings And Faults

Temperature warnings and faults are factory set, It is not recommended to change these settings
without consulting with a Dekker Service Tech.

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Setting Date And Time

PROG

UP

DOWN

ENTER

Enter Password

Press PROG once to view Setpoints screen.

Using Down Arrow scroll to Date and Press ENTER key.

Use Up / Down arrows to change Date, press ENTER again to save.

Use Up / Down key to select Time.

Press Enter

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Use UP / DOWN key to change

UP

DOWN

ENTER

Press ENTER to save.

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PROG

DOWN

From STOPPED or RUNNING screen press PROG

Press PROG button once more to get to
PROG

Entering Keycodes

Keycodes are used to enable available options. Keycodes are 7 digits. All keycodes are entered with 2 leading 0s.

Enter Password

Press DOWN key to find option needed

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ENTER

ENTER

ENTER

Once selected press ENTER. Keycode will
appear with one 0

Once selected press ENTER. Keycode will
appear with two 0s

Press ENTER again then use UP/DOWN keys to enter
third digit of keycode

Press ENTER again then use UP/DOWN keys to enter
fourth digit of keycode

Press ENTER after each entry and continue until
all digits of keycode are entered

Then press ENTER one last time. The N/A will
change to Yes enabling the option chosen.

ENTER

ENTER

ENTER

.

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PROG

Cooling Fan

The Dekker Controller is equipped with a temperature control to operate a cooling fan when applicable.
This feature requires a cooling fan keycode to be entered (see entering keycodes above). Once the
cooling fan keycode is entered press the PROG button until you see the SETPOINT screen.

Use DOWN arrow to scroll to Fan CutOn and Fan CutOff. These are the setpoints to turn the fan on and
off. They can be changed by entering password, scroll back to the settings. Press ENTER then use UP /
DOWN arrows to change values. You must press ENTER again to save. Normally Open Output C7 is used
for this purpose.

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RESET

RUN HOURS

Rotation

When set up for multimachine the system will rotate pumps every 24 hours if needed. For rotation to
occur, the Lead pump must have the most run hours. When this condition is met and the time for
rotation occurs, the Lag pump will become the lead pump. If this condition is not met rotation will not
occur. If a triplex or higher system rotation for each pump will occur in order based on run hours of each
pump.

Manual Rotation

The pumps can be rotated manually, but the same condition above applies, the Lead must have the
most hours.

To rotate pumps manually, On the Lead pump, press and hold RESET button until you see the text

“Manual Transfer” appear on the screen, then release the button. Wait a few seconds and you will see

the upper text “LD” move to the opposite controller, the text “LG1” will move to where the “LD” was

previously.

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ENTER

Scavenger Output

Output 6 on the controller is used for a bleed valve. This output cycles on for 30 Secs and off for 9
minutes based on vacuum level. The vacuum level for cycling to occur is adjustable via the Setpoint
menu on the Dekker Controller.

 Enter password
 Press PROG until Setpoints screen is shown.
 Using DOWN arrow scrool to Scav Lvl
 Press ENTER
 Use UP/DOWN arrows to change value
 Press ENTER to save.

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Faults and Fault Log

If a fault occurs the fault will be displayed on the screen and recorded in the fault log. Faults include
Overload, Temperature and in some versions of firmware Back Pressure. The Temperature and Back
Pressure faults are adjustable from the setpoint screen, but it is not recommended to change these
without consulting with a Dekker Technician. Changing these values could result in pump damage.
Below is what is shown on the screen when a temperature fault occurs. The Run Status light will also
turn red and flash so you can see a fault has occurred from a distance. Faults are cleared using the Reset
button, but will not clear until the condition that caused the fault is cleared.

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UP

DOWN

When the fault occurs it is recorded in the fault log. The fault log will record up to 10 faults. When this ir
reached the most recent fault is recorded at the top of the list and fault at the bottom of the list is
removed. To view the fault log press the Log button.

Each fault can be selected to view what values such as Vacuum, Back Pressure etc… were at the time of

the fault and up to 10 minutes prior to the fault.

To view this detail use UP or DOWN key to select the fault.

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ENTER

Then press ENTER. The first screen shows what was occurring at the time of the fault, use DOWN arrow
to view more information. Press ENTER again to view what was occurring 1 minute prior to fault. Press
again for 2 minutes prior. You can continue pressing ENTER to view up to 10 minutes prior to fault.

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UP

DOWN

ENTER

PROG

Autostart

The Dekker controller is equipped with Autostart. This feature allows automatic restart of system when
power returns from a power loss. To enable this feature press PROG button to show SETPOINTS screen.
Use DOWN arrow to select Autostart. Press ENTER. Use UP arrow to change to On. Press ENTER to save.
If system is multimachine this must be set on all controllers.

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DOWN

Maintenance Schedules

Pressing the MAINT button once will display the screen below:

This screen shows the support phone number for Dekker Vacuum along with the Serial number and
model number of the system.

Pressing the MAINT button twice will display the spare parts list for the system. This list can be used for
ordering parts if needed. Part numbers will appear in place of the Xs. These numbers are entered at the
factory. Use Down arrow to navigate through the list.

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DOWN

Pressing MAINT a third time will show the maintenance schedule intro screen. This screen also displays
the current Run Hours.

Press MAINT a fourth time to view the maintenance schedule. This list provides a recommended
maintenance schedule along with intervals. The time in hours until the maintenance is due counts down
and can be seen on the Dekker Controller LCD in this area. Proper maintenance is necessary to provide
proper performance and can prolong the life of your system. The UP and DOWN ARROW buttons can be
used to navigate through the list. Proper response and service of service due message is highly
recommended.

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Press MAINT the fifth time to view the Service History. Service history is recorded with date and time of
service each time the recommended service is completed and the maintenance schedule is reset.

Pressing MAIN again will return you to the Dekker support screen. Pressing ESC at anytime will return to
the main screen.

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DOWN

ENTER

Resetting Maintenance Schedule Hours

Enter Password

When maintenance is due you will see a warning on the screen letting you know that maintenance is
due on the system. To remove this warning you must reset the maintenance interval. Press the MAINT
button until you see the maintenance interval screen. The 0 shows the period has expired and generates
the warning on the screen. You must reset the HRS To Srv to 500 or the schedule selected. Use DOWN
key to select HRS TO SRV and press ENTER. Use UP key to reset to the correct interval (500 in this case).
Press ENTER again to save, this last press of ENTER also records the date and time this service was
completed in the Service History log.. Pressing ESC will take you back to the main screen and the
warning will be gone. Note: warnings and faults only show in run mode.

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DP Inlet

DPInlet is a differential pressure across the inlet filter to monitor the filter. When the differential
reaches the preset point a warning will show on the screen, once the filter is cleaned and the differential
is reduced the warning will go away. A keycode (See Entering Keycodes) is required to enable this
feature also an extra transducer is required.

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Remote Start Stop

To enable remote Start/Stop first the inputs must be wired. A NO momentary button is wired from the
+24VDC on one side and to Digital input 6 on the other side. A NC momentary button is wired to
+24VDC on one side and to Digital input 7 on the other. Both buttons must be momentary. Then to
enable Remote Start/Stop you must enter the keycode. (See Entering keycodes)

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Network Options

Press PROG

Continue to press PROG until Network screen appears. This screen allows for changing Static IP address,
Subnet mask and Gateway for network use. You can also turn DHCP on if a DHCP server is available to
assign the controller an IP address. This screen should only be changed by qualified personnel.

Keycode List

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