Sterling 882.00249.00 User Manual

SCC 2-Pump 12-Station Controllers

Part Number: 882.00249.00

Bulletin Number: CV3-650

Effective: 10/25/05

Write Down Your Serial Numbers Here For Future Reference:

_________________________ _________________________

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

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 +1 (800) 483-3919 for drying, conveying, heating and cooling and automation. For size reduction: +1 (800) 229-2919. North America, emergencies after 5pm CST (847) 439-5855

North America email: acsuscanadacustserv@corpemail.com

• Mexico, Central & South America Email: acslatinamericacustserv@corpemail.com

• Europe, Middle East & Africa +48 22 390 9720

Email: acseuropecustserv@corpemail.com

• India +91 21 35329112

Email: acsindiacustserv@corpemail.com

• Asia/Australia +86 512 8717 1919

Email: acsasiacustserv@corpemail.com

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 +1 (262) 641-8600 or +1 (847) 273-7700 Monday–Friday, 8am–5pm CST

Europe/Middle East/Africa +48 22 390 9720 India +91 21 35329112 Asia/Australia +86 512 8717 1919

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 : +1 262 641 8600 Fax: + 1 262 641 8653

Asia/Australia:

ACS Suzhou

109 Xingpu Road SIP Suzhou, China 215126 Phone: + 86 8717 1919 Fax: +86 512 8717 1916

Europe/Middle East/Africa:

ACS Warsaw

Ul. Działkowa 115 02-234 Warszawa Phone: + 48 22 390 9720 Fax: +48 22 390 9724

India

ACS India

Gat No. 191/1, Sandbhor Complex Mhalunge, Chakan, Tal Khed, Dist. Pune 410501, India Phone: +91 21 35329112 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 (630) 595-1060; for all other countries, call our international desk at (630) 595-1060. Have the order number and item number available. Hold the items until you receive shipping instructions.

2–Pump 12-Station Controllers Chapter 1: Safety 2

Returns

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

Credit Returns

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

Prior 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 RMS

Prior 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.

2–Pump 12-Station Controllers Chapter 1: Safety 3

Table of Contents

CHAPTER 1: SAFETY ................................................................ 6

1-1 How to Use This Manual ............................................................................................. 6

Safety Symbols Used in this Manual.....................................................................6

1-2 Warnings and Precautions .......................................................................................... 7

1-3 Responsibility ..............................................................................................................8

General Responsibility...........................................................................................8

Operator Responsibility .........................................................................................9

Maintenance Responsibility................................................................................... 9

Reporting a Safety Defect ..................................................................................... 9

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 .................................................. 14

3-1 Uncrating ................................................................................................................... 14

3-2 Mounting the Control Panel.......................................................................................14

3-3 Electrical Connections............................................................................................... 14

Making Control Panel Power Drop Wiring Connections......................................14

Connecting the Control Panel to Vacuum Hoppers............................................. 15

Connecting the Control Panel to the Pump Package ..........................................15

Main Power .........................................................................................................17

3-4 Setup ......................................................................................................................... 17

Gaining Access to the Menu System...................................................................18

Station Settings Menu .........................................................................................19

Pump Settings Menu ...........................................................................................27

System Settings Menu ........................................................................................32

Service Settings Menu ........................................................................................33

Saving Controller Settings to Flash Memory .......................................................33

3-5 Initial Startup .............................................................................................................33

CHAPTER 4: OPERATION ........................................................ 34

4-1 Startup.......................................................................................................................34

Setting Load Times .............................................................................................34

Enabling and Disabling Individual Stations..........................................................35

2–Pump 12-Station Controllers Chapter 1: Safety 4

4-2 Controller Description and Operation ........................................................................ 35

Text Area.............................................................................................................35

Station Icons........................................................................................................ 37

Status Indicators.................................................................................................. 38

Controller Keypad................................................................................................ 39

4-3 Operation ..................................................................................................................... 40

Operation States .................................................................................................40

4-4 Shut-Down................................................................................................................. 42

CHAPTER 5: MAINTENANCE ................................................... 43

Updating BIOS Software .....................................................................................43

CHAPTER 6: TROUBLESHOOTING ......................................... 46

6-1 General Troubleshooting...........................................................................................46

Controller Recovery using Flash Memory Technology........................................ 48

CHAPTER 7: APPENDIX .......................................................... 49

7-1 Warranty....................................................................................................................49

Warranty Specifications....................................................................................... 49

Warranty Restrictions ..........................................................................................49

Warranty Liabilities ..............................................................................................50

Customer Responsibilities...................................................................................50

7-2 Drawings and Diagrams ............................................................................................ 51

7-3 Spare Parts List.........................................................................................................52

7-4 Controller Identification (Serial Number) Tag ............................................................ 56

7-5 Technical Assistance (Contact Information).............................................................. 56

Parts Department ................................................................................................ 56

Service Department............................................................................................. 56

Sales Department................................................................................................ 56

Contract Department ...........................................................................................56

CHAPTER 8: SERVICE ONLY INFORMATION ........................57

8-1 Service Settings Menu ..............................................................................................57

Setting the Ramp Up Time ..................................................................................57

Setting the Ramp Down Time..............................................................................58

Setting the Pump Stage Time..............................................................................59

Setting the LCD Blink Delay ................................................................................60

Setting the Hi Vacuum Sensor Delay ..................................................................61

Setting the Hi Vacuum Vent Delay ......................................................................62

Setting the Hi Vacuum Load Count .....................................................................63

Using the Installation Aids Menus .......................................................................64

8-2 Other Controller Restricted Areas ............................................................................. 67

Using the OEM Service Menu .............................................................................67

Recovering Passwords........................................................................................ 68

Restoring the Controller to Factory Defaults ....................................................... 69

2–Pump 12-Station Controllers Chapter 1: Safety 5

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.

2–Pump 12-Station Controllers Chapter 1: Safety 6

Controller Safety Tags

High Voltage Inside Enclosure

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.

Read Operation and Installation Manual

; 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 extreme caution when working with your 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.

2–Pump 12-Station Controllers Chapter 1: Safety 7

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.

2–Pump 12-Station Controllers Chapter 1: Safety 8

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.

2–Pump 12-Station Controllers Chapter 1: Safety 9

Chapter 2: Functional Description

2-1 Models Covered in This Manual

This manual provides operation, installation, and maintenance instructions for 2-Pump, 12Station 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 2-Pump, 12-Station Conveying Controller is a programmable logic controller, with 24 VDC or 115 VAC control circuit, easy-to-use 16-key operator interface keypad and optional audible/visual alarm.

2-2 General Description

Our systems create vacuum for the automatic pneumatic conveying of most free-flowing, dry, pelletized, or granular materials in a central material handling system. 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.

Note: Vacuum leaks occuring anywhere in your system reduce capacity.

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.

2–Pump 12-Station Controllers Chapter 2: Functional Description 10

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

• 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.

2–Pump 12-Station Controllers Chapter 2: Functional Description 11

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 2-Pump, 12-Station Controller. Failure to do so may result in serious injury. No one but the person who installed the lockout may remove it.

2–Pump 12-Station Controllers Chapter 2: Functional Description 12

2–Pump 12-Station Controllers Chapter 2: Functional Description 13

Chapter 3: Installation

3-1 Uncrating

2-Pump, 12-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. 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

Plug the power cord supplied with your unit into a properly grounded, 3-slot, 115/1/50-60 VAC or 230/1/50-60 VAC receptacle specified on the control panel serial tag. The control enclosure draws less than five (5) amps during normal operation at 115/1/50-60 VAC.

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.

2–Pump 12-Station Controllers Chapter 3: Installation 14

Connecting the Control Panel to Vacuum Hoppers

Refer to the wiring connection diagram in Figure 1 on the next page that applies to your application.

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 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.

Note: For safety, make sure that the +24 volt line is fused. The size of the

fuse depends on the number of stations installed.

A 4 amp fuse is sufficient for a 12-station installation.

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 with blowback, wire the pump package blowback solenoid (SOL

B) to the terminal located in the control panel enclosure.

5. 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.

2–Pump 12-Station Controllers Chapter 3: Installation 15

Figure 1: Typical 24-Volt Junction Box Wiring Diagram

FROM CONTROLLER OUTPUT

FOR PUMP MOTOR STARTER

TO MOTOR

(MTR)

GRD

(NEUTRAL)/(+24VDC)

L2 L3

A09

T1 T2 T3

(115VAC)/(0VDC)

TO CONTROLLER INPUT FOR

PUMP HIGH-VACUUM

TO TERMINAL A1 (NEUTRAL)/(+24 VDC)

146T3

RESET

TEST

TRIPPED

3T2T1

FROM CONTROLLER OUTPUT

FOR VACUUM SOLENOID

ON MOTOR STARTER (M)

FROM CONTROLLER OUTPUT

FOR BLOWBACK SOLENOID

TO JUNCTION BOX

SOL A/B

KAY VALVE

LOCATED ON

PUMP

VACUUM

COMMON

BLOWBACK

TO UPPER VALVE

PROCESS AIR CONNECTION

SUBPANEL LAYOUT AND CONNECTION DIAGRAM

LEGEND

FIELD WIRING

INTERNAL WIRING

WIRE LUG

(115V AC AND 24V DC)

A0544675

GRD

(115V AC)

FROM CONTROLLER OUTPUT

FOR MOTOR STARTER

FROM CONTROLLER OUTPUT

FOR VACUUM PUMP SOLENOID

FROM CONTROLLER OUTPUT

FOR PUMP BLOWBACK SOLENOID

3 PHASE / 4 WIRE SERVICE AND FUSED DISCONNECT SWITCH TO BE PROVIDED BY CUSTOMER

DISC

CONTROL WIRING

POWER WIRING

1PS

N. O.

9596 A2 A1

1SOL

MTR

5 HP PUMP

TO CONTROLLER INPUT FOR PUMP HIGH VACUUM

(NEUTRAL)

VACUUM PUMP MOTOR STARTER

VACUUM SOLENOID ON PUMP

BLOWBACK SOLENOID ON PUMP

2–Pump 12-Station Controllers Chapter 3: Installation 16

Main Power

Your 12-station controller system can operate from a 115 VAC or 220 VAC source at 50 Hz or 60 Hz. The main power switch on the controller is located on the right side of the housing. Built into the power switch are the controller fuses. Also, the configuration of the fuse holder determines the voltage setting of the controller (115/220 VAC).

Marked on the faceplate of the fuse holder shows the configuration for the desired voltage. Using a small screwdriver, remove the fuse holder. To select the operating voltage, align the arrow marker on the holder and the switch as shown in the following section.

The 12 station controller has a standard IEC power cord. Plug the cord into any standard 115 VAC outlet. If you selected the 220 VAC option, remove the end connector and install a standard 220 VAC plug. Doing so does NOT effect the controllers warranty.

DC Controller Power Sources

Although main controller power is 115/220 VAC, control power is actually unregulated 24 VDC. The 24 VDC control power supplies the power for all solenoids, sensors, and the controller itself. The unregulated supply can deliver up to five (5) amps of continuous current to drive a very large system.

Inputs

• Station connections

Outputs

3-4 Setup

This section provides the procedures for configuring your 2-pump, 12-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.

To help you set up the controller quickly, this section walks you through the setup using the menu system. This procedure will work for most applications, but you may need to perform some minor adjustments afterwards to achieve the best conveying performance.

• High vacuum connections

• System error connections

• Station connections

• Pump/blowback

• Spare

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

described in this section and in the Mechanical Components manual.

Note: The controller must be in Offline mode to permit access to the menu

system.

2–Pump 12-Station Controllers Chapter 3: Installation 17

Gaining Access to the Menu System

To enter the menu system, make sure that the controller is in the OFFLINE state. Press the MENU key to initiate the menu system.

The menu has three (3) top level menus:

1. Station Settings

2. Pump Settings

3. System Settings

Press the CLEAR key in the menu system to bring you up one level.

Figure 2: Menu Tree Structure

2–Pump 12-Station Controllers Chapter 3: Installation 18

Station Settings Menu

To access the Station Settings menu, place the controller in the OFFLINE state:

1. Press the ENTER/MENU key to enter the menu system.

2. Continue to press the ENTER/MENU key until the following screen displays:

STATION SETTINGS? NO/YES

To enter the Station settings menu:

• Press the YES key.

To bring you up one level within any menu:

• Press the CLEAR key.

Operation Mode, Station Settings Menu

In most applications, each loading station can use different types of hoppers. The two common types are standard hoppers and sight glass loaders. You’ll need to set up your controller for the type of hopper you are using for each of the 12 loading stations.

The first submenu in the Station Settings menu is the Operation Mode.

To enter the Operation Mode submenu:

• Press the YES key at the following screen prompt.

OPERATION MODE? NO/YES

Each station in the conveying system can be a standard configuration or a sight glass configuration. Each hopper design operates in a slightly different manner.

In Standard mode, a flapper sensor detects a demand on the system. The volume fill sensor senses when the hopper is filled with material. These two (2) sensors are wired in series and a single input of the controller reads them. The controller determines the difference in the signals, depending on load sequence timing.

In Sight Glass mode, only one single sensor detects demand. This mode has no volume fill operation, and you’ll need to disable that function. Properly setting the operation mode lets the controller correctly sequence station loading.

Upon entering the Operation Mode menu, the controller prompts you to set all 12 stations to Normal (default) mode.

2–Pump 12-Station Controllers Chapter 3: Installation 19

To set all the stations to Normal mode and return to the Station Settings menu:

• Press the YES key at the following screen prompt.

ALL NORMAL MODE? NO/YES

This function lets you use the fast setup feature of the controller. Normal mode is the factory default, so if no sight glass loaders are on your system, you won’t need to alter this setting.

Pressing the NO key moves to the All Sight Glass Mode screen. Again, this function lets you quickly change all stations to Sight Glass mode if all stations have sight glass loaders.

ALL SIGHTGLASS MODE? NO/YES

To move on to the individual settings screen:

• Press the NO key.

The following screen displays.

STATION: 1 NORMAL Y=NORMAL N=SIGHTGLS

Starting with Hopper 1, the controller now lets you individually set the operation mode of each station.

1. Press the YES key to set the station to Normal mode.

2. Press the NO key to set the station to the Sight Glass mode.

3. Press the SET key to save the new setting into controller memory and increment to

the next station in sequence.

4. Press the CLEAR key to exit to the Station Settings menu.

2–Pump 12-Station Controllers Chapter 3: Installation 20

+ 49 hidden pages