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Sterling XXX10-80 User's Manual

1. or c Touch Next P to go to the Pump n 1 Setup screen 10 Pump 80 Station Controller Chapter 3 Installation 44 d Touch Goto and enter a pump number to go to that pump s setup screen 5 To save or restore settings go to the System Setup screen and touch Save Restore on the right side of the screen Naming Pumps 3 To name a station go to the Pump Status screen Touch the icon for the pump you want to name and hold it for several seconds The Pump n Operator Settings screen for the selected pump appears Touch Pump Setup atthe Pump n Operator Settings screen The Pump n Setup screen appears Press Pump Name at the bottom of the Pump n Setup screen A keypad will pop up You can enter a name of up to eight 8 alpha numeric characters Use lt to erase any mistakes Use to enter the value Note Make sure to choose different names as the system does not recognize duplicate names 6 You can scroll through the pumps by scrolling through Back and Next at the top of the screen Copying Settings from One Pump to Others If other pumps at your facility will use the same settings as a pump you have already set up you can copy the settings from this pump to the others The station name will not be copied To copy settings from one pump to others l At the Pump n Setup screen for the pump you want to copy from touch Copy in the screen s upper right The Pump Copy screen appears showing the pump
2. 2 Touch Return The Pump n Setup screen appears 3 Touch Pumps The Pump Status screen appears 4 Put the standby pump online by briefly touching its icon The icon changes color to show the new status and the system begins using the pump In addition all Station n Operator and Setup screens show the new pump assignment When the failed pump is operational again you can repeat this process this time using the standby pump s number as the setting for Source Pump the repaired pump s number as the setting for Standby Pump 10 Pump 80 Station Controller Chapter 4 Operation 60 3 5 Alarms Reviewing Alarms At the Station Status or Pump Status screen 1 TouchAlarms The Alarm Log screen appears with the newest alarm listed first Alarm Summary To scroll up and down through the list e Touch A and VY at the bottom of the list Silencing Alarms Whenever a new alarm occurs your controller sounds the horn and turns on the strobe light at each central alarm If the alarm is for a specific station or pump and if the station or pump has a local alarm the controller also turns on the local alarm light In addition a banner appears on the touch screen displaying an alarm message anda Push To Silence button To silence the alarm 1 Touch Push to Silence on the alarm banner The horns and lights at the central alarms turn off The local alarm light stays on The banner will close Your controller has separate co
3. Name Servers IP Address F1 F2 Fig 28 37 Press the IP Address F2 button 10 Pump 80 Station Controller Chapter 8 Appendix 108 38 The IP Address screen will appear Fig 29 IP Address IP Address Use DHCP 192 168 10 1 F4 a Pa Fig 29 39 Press the IP Address F1 button 10 Pump 80 Station Controller Chapter 8 Appendix 109 x Fig 30 41 Enter the appropriate IP Address for the display you are setting up e Remote Display 1 Enter 192 168 10 2 via the keyboard e Remote Display 2 Enter 192 168 10 3 via the keyboard e Remote Display 3 Enter 192 168 10 4 via the keyboard e Remote Display 4 Enter 192 168 10 5 via the keyboard 42 Press the Enter key to close the keyboard 43 The IP Address Screen Fig 29 will appear 44 Press the OK F7 button 10 Pump 80 Station Controller Chapter 8 Appendix 110 45 After a short delay the Adapters Screen Fig 3 will appear Fig 31 46 Press the OK F7 button 47 The Network Adaptors Screen will appear Fig 28 48 Press the Close F8 button 49 The Network Connections Menu will appear Fig 27 50 Press the Close F8 button 51 The Network and Communications Menu will appear Fig 26 52 Press the Close F8 button 53 The Terminal Settings Menu will appear Fig 23 54 Press the Close F8 button 55 The RSView ME Station Screen will appear Fig 1
4. 2 ccseeeeeeteteeeeectneeeeteeeneeeeetseeeeeeteas 14 Terminating Cable FIG rs chez taps eo coec a setee se tisbee aves Pyane Pants sae tenansaaenes wav shceieie cnkattcendee 15 Addressing and Installing ArmorBlocks aaaasnessnnnnnnnneeesinnnnnnnnesesrnnrnnnnneeene 17 Installing KwikLink Connectors ccccecescccceesseceeeeeeeeeeeeeseaeeeeeseaaaeeseessaaeeeeesaaes 20 Connecting the Controller to the N tWOPK ccsccccceeeseeeeeeeeeeeeeeeeeeeeeeeenaeeeenenaaes 21 Connecting the Power Supply Enclosure to the N twOrk ccccccccesssseesseees 23 Connecting Vacuum Receivers to the N tWOrk cscccccccceseeceeeesteeeeteeseeeeeeesaaees 25 Connecting Vacuum Pumps and Filter Chambers to the Network 00000 27 Connecting Central Alarms to the Network cccccccesceeeseeseeeeeeeneeeeeesseeeeeesaaes 33 SO i0 o AEE E ET E E vend oeded oi gaat E E 35 Setting UD ANE System prsesia e aani oaa bt Bhagat eee IS 36 Setting Up Stations nenea a A E aa 40 10 Pump 80 Station Controller Chapter 1 Safety 3 Setting Up PUMPS rssh cay ceva ous aten cg aeaerg cane soencnetoadutaaan tan aiGea eawhalyaladcadan seceasuenteecunans 43 Finishing Setup Setting Up Passwords ccccccsceeeceteteeeeeeeteeeeeeeeneeeetteeneeeeeeees 47 DAVE FICSIOLS SOU Saimen ss Yel acne tes tsia e e a As ue etna 48 3 6 NAUTILUS ca tac cana a SO A a apace alee cag eee loaned gi 49 CHAPTER 4 OPERATION eenia ainor anian atona un
5. 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 matter 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 e Loss ofa skilled operator temporarily or permanently e Breakdown of shop morale e Costly damage to equipment e 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 an
6. SCC 10 Pump 80 Station Controller Part Number 882 00585 01 Bulletin Number CV3 660 Effective 8 7 07 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 DCN No Copyright 2008 All rights reserved 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 wi
7. 1 above disabled disabled Enable this option if and only if your facility has enabled installed a miscellaneous alarm on the input for Pump Fault 2 for this pump Filter Cleaning Options Blow back When this option is enabled the controller disabled disabled periodically sends compressed air backward enabled through the pump s air filter to dislodge accumulated dust and debris Enable this option if and only if the pump has the equipment for compressed air filter cleaning Every n loads Number of conveying cycles to stations between 1 99 5 filter cleanings Adjust this setting based on experience The more dust and debris in your material line the smaller this number needs to be 10 Pump 80 Station Controller Chapter 6 Configurable Settings 68 Off time Implosion with Seal Valve Implosion without Seal Valve Every n Loads Pulse s Number of pulses of compressed air sent through the pump s filter during cleaning If blowback is not working as desired the service department may ask you to change this setting Number of seconds that the air compressor remains on for each pulse during filter cleaning If blowback is not working as desired the service department may ask you to change this setting Number of seconds between air pulses during 0 5 99 9 sec filter cleaning If blowback is not working as desired the service department may ask you to change this setting When this option is enabled the
8. Touch System Setup at the Station Status or Pump Status screen The System Setup screen appears System Setup Save Restore amp Date Stations 13 47 6 23 2005 Pumps Password Not Active Help Note Touching Help in the lower right of this screen gives you a menu of online help for the choices in this screen 2 Touch Stations Present in the upper left of the System Setup screen 3 This will take you to the Stations Installed screen Stations Installed Node 1 Node 2 2 Stations s 2 Stations Node 3 Node 4 2 Stations N Ss 2 Stations Node 5 on9 Static Node 6 Statio os Next 2Stations Ni s 2 Stations s Node 7 Statio o Node atio System 2 Static ol 2 Stations 4 ations ation Setup Node 9 S S 8 Node 10 2 Stations N N 2 Stations Stations Node 11 on2 S Node 12 tion 2 Stations D si 2 Stations Installed Pumps Node 13 Sta Node 14 2 Stations o 5 2 Stations Node 15 o 01 Node 16 2 Stations S 2 Stations Node 17 Node 18 2 Stations s D 2 Stations A screen showing a list of stations appears The stations that are not installed are red The stations that are installed are green Briefly touching the icon for a station toggles between not installed and installed Briefly touching the icon for a node toggles the node s configuration between 2 stations per block and 1 station per block When configured for 2 stations per block each of the stations on the block will have one optional input and one
9. arven ve Staton Fig 25 23 Verify that the circle next to Run Current Application is filled If not press the On Startup F1 button until the Run Current Application is filled 24 Press the OK F7 button 25 The Startup Options Screen Fig 24 will appear 26 Press the Close F8 button 27 The Terminal Settings Menu Fig 23 will appear 28 Press the up arrow A button to highlight Networks and Communications 29 Press the enter 4 button to select Networks and Communications 10 Pump 80 Station Controller Chapter 8 Appendix 105 30 The Networks and Communications Menu Fig 26 will appear Networks and Gommunications KEPServer Serial Port ID s Network Connections RSLinx Enterprise Communications Fig 26 31 Press the down arrow Y button to highlight Network Connections 32 Press the enter 1 button to select Networks Connections 10 Pump 80 Station Controller Chapter 8 Appendix 106 33 The Network Connections Menu will appear Fig 2 Network Gonnections Device Name Network Adaptors Network Identification Fig 27 34 Press the down arrow Y button to highlight Network Adaptors 35 Press the enter 1 button to select Networks Adaptors 10 Pump 80 Station Controller Chapter 8 Appendix 107 36 The Network Adaptors Screen will appear Fig 28 Network Adaptors Built in Ethernet Controller
10. Chapter 6 Configurable Settings 63 Names Description CC Options Deefault__ Conveying Options o O Conveying Options Assigned to pump n Name of the pump to which this station s vacuum line is connected Special convey When this option is enabled the station s disabled disabled vacuum valve remains open for the convey enabled time even if the station is not demanding material and is indicating that it is full When disabled the station s vacuum valve opens when there is demand from the station and it remains open until the convey time has elapsed or material trips the volume fill proximity switch Enable this option if and only if the station has no flapper Closed Loop This option allows material to be conveyed and processed without being contaminated by outside influence such as dust other materials etc Alarm Options No convey When this option is enabled the controller disabled disabled issues a no convey alarm if it has repeatedly enabled attempted to convey material to the station but the flapper never opened during the dump delay The number of attempts is controlled by the next setting Usually this option should be enabled At times you may wish to disable it during operation as a stopgap measure for dealing with an alarm attempts B4 alarm Number of attempts before alarm the number of times the controller will attempt to convey material to a station before it issues a no convey a
11. VersaView Program Compact Flash Card labeled 744 00134 00 10P80S Disp Program RSView ME Station ee Load Application Run Application Application Settings F1 F3 Delete Log Files ee Before Running F5 Fig 13 8 Press the Load Application F1 button 10 Pump 80 Station Controller Chapter 8 Appendix 93 9 The Load Application Screen Fig 14 will appear Load Application Fig 14 10 Press the Source F1 button so the circle next to External Storage 1 is filled 11 Use the up and down arrows to select the VersaViewCE_LockDown mer application 12 Press the Load F2 button 10 Pump 80 Station Controller Chapter 8 Appendix 94 13 The Replace Communications Confirmation Screen Fig 15 will appear Replace Gommunications Fig 15 14 Press the Yes E7 button 15 The RSView ME Station Screen without an Exit F8 button Fig 13 will appear 16 Press the Run Application F2 button when it is no longer grayed out 10 Pump 80 Station Controller Chapter 8 Appendix 95 17 The application will start after a short time Fig 16 Reboot Fig 16 18 Press the VersaView Enable button 19 VersaView Mode Enable message will be displayed 20 Remove the VersaView Program Compact Flash Card from the display 21 Press the Reboot button 22 The display will reboot 23 If an Error Screen Fig 10 appears Press the OK F7 button
12. VersaView Program Compact Flash Card labeled 744 00134 00 10P80S Disp Program Tap the Start button in the bottom left portion of the screen Tap Windows Explorer 10 Pump 80 Station Controller Chapter 8 Appendix 98 39 A window will appear showing the contents of the My Computer folder Fig 19 PARSON TE eee K x Address My Computer o w A amp Documents My Network Program Files Storage Card Storage Temp and Settings Documents Card2 D p Windows Control Panel estat W My Computer 40 Double tap the Storage Card2 folder Fig 19 10 Pump 80 Station Controller Chapter 8 Appendix 99 41 A window will appear showing the contents of the Storage Card2 folder Fig 20 Hehea K x Address Storage Card2 w eee ee oe R Help Images PDF Rockwell Storage Card TOOLS Batch BRutil Software Launch start B Storage cara2 Fig 20 42 Double tap the BRutil icon 10 Pump 80 Station Controller Chapter 8 Appendix 100 Pe we ee h Fonts Hel z niniin E a Launch Restore system 3 start Gstorage card System Backup Rec AL Fig 21 44 Press the Restore system button DO NOT PRESS THE BACK UP SYSTEM BUTTON 10 Pump 80 Station Controller Chapter 8 Appendix 101 45 A Warming Window Fig 22 will appear Zel gt 3 xia a wx v Address Storage Card2 eee tes e a e
13. could disrupt system operation Figure 2 Side View of a Typical Power Cable and Data Cable Installation Cable tie buckle ee Vacuum tube Black power cable oy Grey data cable oe Note When approaching a node location stop the attachment process Run the cables over the node area such as a T valve and make sure you create a slight amount of slack when continuing the attachment with cable ties Doing so lets you install KwikLink connectors or ArmorBlocks with greater ease with less stress on the cable Setting Up and Installing Mounting Plates Setting Up Mounting Plates It s a good idea to get all your mounting plates set up with KwikLink connector bases or ArmorBlock cable bases before installation as your system layout determines Note ArmorBlock cable bases are installed on mounting plates perpendicular in orientation to the flat cable runs Vacuum hoppers receiver stations and vacuum pumps require 8 connector ArmorBlocks central alarm stations require 4 connector ArmorBlocks Make sure that each mounting plate has properly attached tube clamps as required Each mounting plate requires two 2 tube clamps Always use locking washers especially in high vibration environments 10 Pump 80 Station Controller Chapter 3 Installation 14 Figure 3 Side View of a Typical Mounting Plate Assembly with ArmorBlock Base a Rotate 302 to 45 downward Installing Assembled Mounting Plates After you ve set up the mo
14. for use on a Sterling 10 Pump 80 Station Convey Control 1 Remove the compact flash card from the VersaView if one is installed by pressing the Eject Button Fig 9 Compact Flash Card Slot Fig 9 2 Ifyou are setting up a Remote Display disconnect the Ethernet cable connecting the VersaView to the network If you are setting up the Primary Display leave the Ethernet cable connected 3 Cycle power on the VersaView 10 Pump 80 Station Controller Chapter 8 Appendix 89 4 Ifyou are upgrading a VersaView that has been configured to work with 10 Pump 80 Station control an Error screen Fig 10 will appear Press the OK F7 button to close the screen Fig 10 10 Pump 80 Station Controller Chapter 8 Appendix 90 5 PDF Viewer J gs Remote Desktop 4 td Internet Explorer Fig 11 10 Pump 80 Station Controller Chapter 8 Appendix 91 6 Ifthe VersaView boots to the RSView ME Station screen with an Exit F8 button Fig 12 press the Exit F8 button to bring up the Windows CE desktop Fig 11 Skip to step 26 RSView ME Station SEES Load Application Run Application Application Settings F1 F3 Delete Log Files Before Running F5 Terminal Settings F4 2 Start BijRsview ME Station Fig 12 10 Pump 80 Station Controller Chapter 8 Appendix 92 7 Ifthe VersaView boots to the RSView ME Station screen without an Exit F8 button Fig 13 insert the
15. number for the pump you are copying from Source Pump Pump 1 1 Copy to on To Pees Single bess Pump Pump 2 Tay Copy to First Last Pump Range of hi 5 Pumps Pump 2 Pump 5 Password Copy to Not Active All Pumps Help 2 Follow the directions below to copy settings to one other pump a range of pumps or all pumps 10 Pump 80 Station Controller Chapter 3 Installation 45 To copy the selected pump s settings to one other pump l Touch the gray Copy to Pump button next to the green Copy To Single Pump button The keypad pops up Enter the pump number for the pump you are copying to Use lt to erase any mistakes Use J to enter the value The keypad disappears and the Pump Copy screen shows the pump number you entered under Copy to Pump Touch the green Copy To Single Pump button Copy Complete briefly appears at the top of the screen As appropriate either continue copying to other pumps or touch Pump Setup to go back to the Pump n Setup screen To copy the selected pump s settings to a range of other pumps l Touch First Pump next to the green button labeled Copy To Range of Pumps button The keypad pops up Enter the number for the pump at the lower end of the range you are copying to Use lt to erase any mistakes Use to enter the value The keypad disappears and the Pump Copy screen shows the pump number you entered under First Pump Touch Last Pump next to t
16. optional output If more optional equipment needs to be used with a station for example if a station requires an RPV and a Slide Gate the block should be configured for 1 station per block When configured for 1 station per block the station on the block will have three optional inputs and three optional outputs This will allow more optional equipment to be used with a single station than the 2 stations per block allows Each station block configured in this manner will reduce the number of stations the control can support by one 10 Pump 80 Station Controller Chapter 3 Installation 36 4 Press System Setup to return to the System Setup screen 5 Touch Pumps Present in the upper part of the System Setup screen 6 This will take you to the Pumps Installed screen The screen shows a list of pumps The pumps that are not installed are red The pumps that are installed are green Briefly touching the icon for a pump toggles between not installed and installed 7 Press System Setup to return to the System Setup screen 8 The new setting appears under System Parameters on the System Setup screen Setting the Date Time You can set the current date and time by going to the System Setup screen and pressing Set Time amp Date 1 To set the time touch Hour A keypad will pop up and you will be able to enter the current hour The controller uses military time You can repeat this process for the minutes by pressing Minute 2 To s
17. p 54 A button to start and stop the system is located in the lower right of the Station Status Pump Status and Alarm Log screens When the system is off the button is red and reads Push to Start System When the system is on the button is green and reads Push to Stop System Depending on the setup at your facility the system may prompt for a password when you touch this button If conveying does not begin when you start the system check to make sure that all needed pumps are enabled If they are check that all needed stations are enabled 10 Pump 80 Station Controller Chapter 4 Operation 50 4 3 Basic Tasks This section covers tasks that can be carried out with no password or with an operator s password Reviewing Station Status The starting point for all operations is the Station Status screen To reach this screen from any other screen 1 Touch Stations The Station Status screen appears Depending on which model you have your screen will appear as one of the following EEEE EEEE See TET PEC RTE a l DEMET Pumps Alarms The status of each station is color coded as summarized in the upper right of the screen You can see an explanation of each status by using the online help To do so from this screen 2 Touch anywhere in the rectangle in the upper right of the screen or the Help button on the lower right side of the screen The Help Menu appears 3 Inthe section of the Help Menu labeled Scre
18. products Sales Department Call 262 641 8610 Monday Friday 8am 5pm CST 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 Contract Department Call 262 641 8610 Monday Friday 8am 5pm CST 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 10 Pump 80 Station Controller Chapter 8 Appendix 79 10 Pump 80 Station Convey Control Hardware Setup and Upgrade Instructions 10 Pump 80 Station Controller Chapter 8 Appendix 80 Table of Contents CompactLogix L35E Setup Brand New Processor ccccceeceneee een eenees 82 CompactLogix L35E Upgrade cccccccccsccssecessecesscecssecessecesseseessecesseeeeeees 86 VersaView CE 1000H Setup 00 00 ccc ccc ccc ccc cece cence eee ene e neat ees 89 Remote Display 00 0 c cece cece cece eee cent eee eee cease eaten aetna 102 10 Pump 80 Station Controller Chapter 8 Appendix 81 CompactLogix L35E Setup Use this procedure to setup a new CompactLogix PLC for use on a 10 Pump 80 Station Convey Control 1 Verify that the control is powered down and the PLC CPU key switch is in the RUN position 2 Insert the configuration compact flash card conta
19. there are any inaccuracies in the proportions the mix will contain more Material A and less Material B To change the mixture for the remote proportioning valve 1 Go to the Station n Operator screen as described on page 55 or go to the Station n Setup screen 2 Touch RPV Material B A keypad pops up 3 Enter the desired percentage for the additive material Use lt to erase any mistakes Use to enter the value The new setting appears under RPV Material B 10 Pump 80 Station Controller Chapter 4 Operation 57 4 4 Advanced Tasks This section describes the procedures carried out during operation that are normally reserved for setup personnel These procedures require use of the setup password if your facility has defined one The procedure for logging on with the setup password is the same as for logging on with the operator password see page 45 Logging off is also the same except that operators can log off only at the Station n Operator screen while most screens accessible to setup personnel offer Log Off as an option You can also change the setup for stations pumps and the system during operation See Chapter 4 System Setup for information on the procedures and options Reviewing and Resetting a Pump Hour Meter The controller keeps two meters for the length of time a pump has run One like a car s odometer keeps a running total and cannot be reset The other like a car s trip odometer counts the r
20. to close the screen 24 The RSView ME Station Screen with an Exit F8 button Fig 12 will appear 25 Press the Exit F8 button to bring up the Windows CE desktop Fig 11 26 Insert the VersaView Firmware Upgrade Compact Flash Card into the display 10 Pump 80 Station Controller Chapter 8 Appendix 96 27 The Firmware Upgrade Card Window Fig 17 will appear My y Firmware Upgrade Card Computer PDF Viewer i 3 Start Frmware Upgrade Card AF om a Fig 17 28 When prompted to upgrade firmware press the Upgrade F7 button 29 The firmware upgrade process will begin and after a short time the display will reboot 10 Pump 80 Station Controller Chapter 8 Appendix 97 30 31 32 33 34 35 36 Tap Programs 38 When the calibration screen Fig 18 appears follow the on screen instructions use a pencil eraser pen cap or other dull pointing device Carefully press and briefly hold stylus on the center of the target Repeat as the target moves around the screen Fig 18 When the firmware upgrade complete window appears remove the VersaView Firmware Upgrade Compact Flash Card from the display by pressing the Eject Button Press the Exit F8 button If the VersaView boots to the RSView ME Station screen Fig 12 press the Exit F8 button to bring up the Windows CE desktop Fig 11 The Windows CE Desktop Fig 11 will appear Insert the new
21. with PLC control if you will be adjusting the mix from the controller s touch screen Enable this option with local control if the station operator will be adjusting the mix using a timer box at the station RPV material B Percentage of the additive material to be 0 100 30 included in the mix This setting applies only when RPV is enabled with PLC control The system is set up so that if there are any inaccuracies in the proportions the mix will contain more Material A and less Material B than specified here Number of Cycles of depositing Material A and 1 100 Material B during the convey time This setting applies only when RPV is enabled with PLC control and Material Purge is not enabled Example If you set convey time to 30 seconds RPV Cycles to 3 and Material B to 30 so Material A is 70 the system will convey as follows Material A for 7 seconds Material B for 3 seconds End Cycle 1 Material A for 7 seconds Material B for 3 seconds End Cycle 2 Material A for 7 seconds Material B for 3 seconds End Cycle 3 In a volume fill station a cycle will be truncated before completion if the station becomes full 10 Pump 80 Station Controller Chapter 6 Configurable Settings 67 6 3 Options for Pump Setup Several of the items in this screen are not setup options but are instead intended for use during operation These items hour meter and transferring stations to a standby pump are described in Chapter 4 O
22. you have kept your finger on the screen too long Touch Stations or Pumps to return to the Status screen and try again 10 Pump 80 Station Controller Chapter 4 Operation 54 Reviewing and Adjusting Basic Station Settings Reaching and Reading the Station Operator Screens The 10 80 Controller has a Station Operator Settings screen for each station as shown below This screen enables you to review and adjust all basic settings for the station To reach the Station n Operator screen 1 Go to the Station Status screen if needed To reach this screen from any other screen touch Stations on the right hand side of the screen 2 Touch and hold the icon for the station until the controller either prompts for the password or displays the Station n Operator screen Once you have entered the password if needed the Station n Operator screen appears Stations Convey Time 20 Sec Pumps Station Setup Priority Convey Activate Settings in the box labeled Convey the red Priority Convey Activate button and the menu controls on the right hand side of the screen appear for all stations The other options in this screen appear if and only if the station has these features enabled Buttons in light gray are settings that you can adjust at this screen Boxes in dark gray are for display only If a pump assignment or purge setting needs to be changed this must be done at the Station n Setup screen Navigating
23. 0 keyed edge is Tx toward the latch latch 2 Making sure that the cable is completely straight carefully close the hinged assembly and apply firm even pressure until the first latch locks into place Note Make sure that the flat cable is completely straight before continuing The latch has two catches the first loosely holds the connector on the cable the second requires more pressure to close the connector tightly The cable must be in the correct position for the connector to close properly 3 Drive the two screws at the center points about halfway down first on the latch side then the hinge side 4 Continue to tighten the screws a little at a time until fully tightened no more than 15 inch pounds 5 6 Nem of torque Note You can only pierce the cable once Once pierced the KwikLink connector must not be removed This insures that the inner conductors are not exposed to the elements Connecting the Controller to the Network To connect the controller to the network make sure that the KwikLink connector is properly installed on the flat grey data cable To connect 1 Attach the keyed round connector to the terminal of the controller marked DeviceNet Tighten the cord grip ring until snug 2 Align the square connector of the grey drop cable so the cable leads down from the connector Evenly press the square connector onto the top of the KwikLink connector It should make two audible snaps when properly seat
24. 2 56 Press the Reset F7 button 10 Pump 80 Station Controller Chapter 8 Appendix 111 57 A Reset Confirmation screen will appear Fig 32 Reset Gonfirmation Fig 32 58 Press the Yes F7 button 59 After a short delay the screen will reboot 60 While the VersaView is rebooting plug the Ethernet cable back in 61 The Windows CE desktop will appear for a short time The VersaView will then launch the Remote Display program 10 Pump 80 Station Controller Chapter 8 Appendix 112
25. AP DROP api es eee call ACS PART No AOSSS195 c2 CORDS ARE REQUIRED Connecting Vacuum Receivers to the Network Make sure that all previous installation steps have been done first before starting this task To connect a vacuum receiver to the network 1 Attach patch cord from vacuum hopper junction box station demand to appropriate input connector See Figures 10 and 11 connection is shown on first hopper on the block only for clarity 2 Dress the excess patch cord cable with cable ties so it does not interfere with operation and gives a pleasing appearance 10 Pump 80 Station Controller Chapter 3 Installation 25 Figure 10 10 80 4 Connector ArmorBlock Connections Station ArmorBlock 2 Stations Block Configuration Inputs Outputs Station 1 Sequence Valve Station 1 Demand Station 1 Option Station 1 Option Station 2 Station 2 Demand Sequence Valve Station 2 Option Station 2 Option 4in 4out ArmorBlock A0558296 ArmorBlock Base A0555191 Press to Close Note 1 The block shown is addressed 01 for the first 2 two hoppers The block addressed 02 would have the connections for 3 4 etc Note 2 If a hopper does not have an optional input or optional output the T connector is not required Connect the patchcord directly to the connector on the ArmorBlock 10 Pump 80 Station Controller Chapter 3 Installation 26 Figure 11 Proper Vacuum Receiver Connections 4 IN
26. CPU by pressing the retaining clip to the right and pulling the compact flash card straight out Fig 5 Fig 5 4 Insert the configuration compact flash card containing the new version of the software labeled PLC Configure 744 00130 00 into the PLC CPU 10 Pump 80 Station Controller Chapter 8 Appendix 86 5 Go to the System Setup Screen Fig 6 by pressing the System Setup button on any screen System Setup SYSTEM PARAMETERS Stations Pumps Present Present Save 1 1 Restore DeviceNet Nodes Alarm Strobe Alarm Horn Name Se g amp Date Stations uppression Silence Purge Vlv A Material n 6 23 2005 Pumps Operator Password Operator Password Setup Not Active Password Duration Password 5 Min Help Fig 6 6 Go to the Save Restore Screen Fig 7 by pressing the Save Restore button on the right side of the screen Save Restore Settings SAVE SETTINGS System Setup DeviceNet Nodes Stations Saved at Pumps 8 57 Jun 24 2005 Password Not Active Fig 7 Save Settings by pressing the yellow Save Settings button Wait for the Save Complete message This message is only displayed for 10 seconds Turn off power to the control enclosure Wait 5 seconds Turn on power 0 Wait for the Run LED on the top front of the CPU to turn solid green and for the I O LED to stop blinking Fig 8 for 30 seconds Ifa firmware upgrade is not required this will only take me OTA 10 Pump 80 Station Controller Chapt
27. Installation 40 Station Setup 1 Back Next lt gt Goto Copy Stations Pumps Station Service System Setup Password Not Active Help 3 Touching Help in the lower right of this screen gives you a menu of online help for the choices in this screen 4 Adjust settings as required Touching any box that appears in red for disabled toggles it to green for enabled Many boxes have more than one embedded state Touching any box that appears in light gray gives you a keypad to enter a new value Keypad entry works as with many ATM machines the first digit you enter initially appears in the rightmost column and moves to the left as you enter more digits Use lt to erase any mistakes Use J to enter the value The keypad disappears and the Station n Setup screen shows the new value in the selected gray box Touching Reset To Defaults in the lower right of the screen changes all settings for this station back to their factory defaults See pp 63 67 for details on the options and their default settings 4 As appropriate a Copy this station s settings to one or more other stations as described below or b Touch Back lt to go to the Station n 1 Setup screen or c Touch Next P to go to the Station n 1 Setup screen or d Touch Goto and enter a station number to go to that station s setup screen 5 To save or restore settings go to the System Setup screen and touch Save Restore on the r
28. K VACUUM PIPE NETWORK FLAT CABLE GREY PATCH CORD 20FT 6M YELLOW ACS PART A0555190 2 CORDS ARE REQUIRED 4 INPUT 4 OUTPUT ARMORBLOCK ACS PART 40558296 ARMORBLOCK BASE ACS PART 40555191 VACUUM PUMP DENOTES INCLUDED IN VACUUM PUMP DISTRIBUTIVE I O KIT 10 Pump 80 Station Controller Chapter 3 Installation ARMORBLOCK MOUNTING PLATE KIT ACS PART 40556696 NOTE EACH MOUNTING BLOCK REQUIRES 2 CLAMPS SPECIFIC TO THE PARTICULAR SIZE OF CONVEY PIPE USED SEE DWG 40563626 FOR CLAMP SIZING REQUIREMENTS i ma A 2 29 Figure 14 Proper Vacuum Pump Connections XPDB Pump T CONNECTOR INCLUDED WITH LOCAL ALARM KIT ACS PART 40555169 POWER FLAT CABLE BLACK VACUUM PIPE NETWORK FLAT CABLE GREY ARMORBLOCK MOUNTING PLATE KIT ACS PART 40556696 4 INPUT 4 OUTPUT ARMORBLOCK ACS PART 0558296 NOTE EACH MOUNTING BLOCK REQUIRES 2 CLAMPS SPECIFIC TO THE PARTICULAR SIZE OF CONVEY PIPE USED SEE DWG A0563626 FOR CLAMP SIZING REQUIREMENTS ARMORBLOCK BASE ACS PART A0555191 PATCH CORD 20FT 6M YELLOW ACS PART A0555190 3 CORDS ARE REQUIRED VTPB PUMP DENOTES INCLUDED IN DISTRIBUTIVE I O KIT Connecting Filter Chambers Make sure that all previous installation steps have been done first before starting this task To connect a filter chamber to the network 1 Attach patch cords from vacuum pump filter chamber to the appropriate connector s See Fi
29. P SIZING REQUIREMENTS NETWORK FLAT CABLE CREY 7 POWER OR NETWORK TAP CABLE DROP ACS PART A0555195 1 CORD IS REQUIRED amp IS CONNECTED AS SHOWN TO THE NETWORK FLAT CABLE GREY MAIN TOUCH SCREEN CONTROL DISPLAY CATS ETHERNET CABLE o o 1 CABLE IS NEEDED PER DISPLAY AS SHOWN N ee CONNECTED TO ANYD TERMINAL OF THE ETHERNET SWITCH ETHERNET SWITCH REMOTE TOUCH SCREEN are CONTROL DISPLAY Connecting the Power Supply Enclosure to the Network The power supply provides electrical power to make the system work Some network layouts require more than one power supply Location is also an important consideration when locating power supply enclosures on your network Contact the factory for determining how many power supply enclosures your system needs as well as where they need to be installed After you ve mounted the power supply enclosure s you can connect them to your network To connect a power supply to the network 10 Pump 80 Station Controller Chapter 3 Installation 23 1 Attach a KwikLink connector included in the bag with power cables to the flat cables One connector is used for the network grey cable and one connector is used for the auxiliary power black cable 2 Align the square connector of the grey drop cable so the cable leads down from the connector Evenly press the square connector onto the top of the bottom KwikLi
30. PUT 4 OUTPUT ARMORBLOCK ACS PART 0558296 ARMORBLOCK BASE ACS PART A0555191 OUTPUT POWER FLAT CABLE BLACK VACUUM PIPE NETWORK FLAT CABLE GREY ARMORBLOCK MOUNTING PLATE KIT ACS PART A0556696 NOTE EACH MOUNTING PLATE REQUIRES 2 TUBING CLAMPS SIZED FOR THE CONVEYING SYSTEM VACUUM LINE PATCH CARD 20FT 6M YELLOW ACS PART A0555190 SEE DWG A0563626 FOR CLAMP SIZING INFORMATION VACUUM HOPPER VOLUME FILL PROXIMITY SWITCH OPTIONAL JUNCTION BOX DC MICRO RECEPTACLE ACS PART A0555194 Connecting Vacuum Pumps and Filter Chambers to the Network Connecting Vacuum Pumps Make sure that all previous installation steps have been done first before starting this task To connect a vacuum pump to the network 1 Attach patchcords from vacuum pump junction boxes to the appropriate ArmorBlock connectors See Figures 12 13 and 14 Figure 12 Vacuum Pump ArmorBlock Connections 10 Pump 80 Station Controller Chapter 3 Installation 27 Note 1 The block shown is addressed 41 for the first pumps The block addressed 42 would have connectors for pumps etc Note 2 If a pump does not have Pump Fault 2 or a local pump alarm light the T connector is not required Connect the patchcord directly to the connector on the ArmorBlock 10 Pump 80 Station Controller Chapter 3 Installation 28 Figure 13 Proper Vacuum Pump Connections Standard XPD XPC Pumps POWER FLAT CABLE BLAC
31. a head start by conveying a few loads to it and then stopping the priority convey No more than one station for a given pump can be in priority convey at once To activate priority convey Go to the Station n Operator screen as described on p 55 or go to the Station n Setup screen Touch Priority Convey Activate 10 Pump 80 Station Controller Chapter 4 Operation 56 The button changes to Priority Convey Active and blinks until the station s demand has been satisfied or you stop the priority convey The controller begins filling the chosen station only after finishing any convey already in progress To stop a priority convey before the station is completely full Touch the blinking Priority Convey Active The button changes to Priority Convey Activate and stops blinking The controller finishes the current convey if any and resumes normal operation Changing the Mixture for a Remote Proportioning Valve A remote proportioning valve RPV mixes two different materials typically virgin and regrind materials during a convey cycle If present this valve may be set up so that you control the mix with a timer at the station or it may be set up so that you control the mix with the controller s touch screen The instructions here apply only for controlling the mixture from the touch screen The controller refers to the two materials as Material A primary and Material B additive The system is set up so that if
32. able For the inside KwikLink connector next to the outside end on the grey cable mount a separately packaged blank cap on it instead of the standard resistor cap in the KwikLink connector kit 10 Pump 80 Station Controller Chapter 3 Installation 15 Discard the standard resistor cap to eliminate confusion 5 Mount the mounting plate assembly on the vacuum line at the end of the cable run See Page 14 for more information 6 Using the straight blade cable cutter carefully trim each flat cable so it sticks out past the final KwikLink connector by to 3 Place a dust cap over the end of the trimmed cable 7 Lay the dust cap and cable into the KwikLink connector so the dust cap tabs engage in the connector slots The dust cap tabs should fit into the connector slots perfectly Left 8 Lay the cable in the hinged base noting the correct keyed profile flat edge toward the hinge keyed edge toward the latch Make sure that the cable and dust cap are properly seated inside 9 Making sure that the cable is completely straight carefully close the hinged assembly and apply firm even pressure until the first latch locks into place Note Make sure that the flat cable is completely straight before continuing The latch has two catches the first loosely holds the connector on the cable the second requires more pressure to close the connector tightly The cable must be in the correct position for the connector to clo
33. among the Station Operator Screens The controls in the upper right hand corner of the screen enable you to move among the Station Operator screens 1 To display the screen for the next lower numbered station for example to move from the screen for Station 15 to the screen for Station 14 touch lt Back 2 To display the screen for the next higher numbered station for example to move from the screen for Station 15 to the screen for Station 16 touch Next P 3 To display the screen for a specific station touch Goto A keypad pops up Enter the number for the desired station Use lt to erase any mistakes Use to enter the value 4 To exit to the Station Status or Pump Status screen touch Stations or Pumps 10 Pump 80 Station Controller Chapter 4 Operation 55 Adjusting Convey Time and Dump Delay Convey time is the length of time the station s vacuum valve remains open to allow material to be drawn in For a volume fill station the valve closes when material covers the station s volume fill proximity sensor or this time elapses whichever comes first Dump delay is the length of time allowed for material to drain from the station into its receiver During this time the controller does not attempt to deliver any more material to the station The settings for convey time and dump delay should match the times actually required to fill and empty the station The following problems may occur if these settings are
34. and change settings for all pump options Operator Password If you define a password for operators then a password will be required to carry out any function other than reviewing station and pump status silencing alarms reviewing the alarm log and looking at help screens Entering the operator s password will give the user access to the functions at the following screens e Station Status to enable or disable a station and start or stop system e Pump Status to enable or disable a pump and start or stop system e Station n Operator to adjust a station s convey time and dump delay activate priority convey and review the station s last convey time and pump assignment depending on the options installed the screen may also enable the operator to adjust the mixture percentage for a remote proportioning valve change the purge time and purge valve and set the intended material line for manifold sharing Entering the setup password will give the user access to all functions To set or remove password protections 1 Press System Setup on the right side of the screen to go to the System Setup screen if needed The System Setup screen appears System Setup SYSTEM PARAMETERS DeviceNet Stations Pump Present Staging 1 5 Sec Nodes Alarm Strobe Alarm Hom Name Ret Time aR S s amp Date Stations Suppression Silence Purge Viv 13 47 0 Min 10 Min Material 6 23 2008 Pumps Password Not Active Save Res
35. ath 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 10 Pump 80 Station Controller Chapter 1 Safety 5 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 m A RA RAK N m v 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 thi
36. cks 10 Pump 80 Static ion 34 Figure 18 4 Connector ArmorBlock Connections for Central Alarms Alarm Silence Pushbutton A 10 Alarm Strobe Light C 00 Alarm Silence Pushbutton A I1 7 Alarm Horn C 01 Alarm Silence Pushbutton B 12 Alarm Strobe Light D 02 Alarm Silence Pushbutton B I3 Alarm Horn D 03 4input 4 Output ArmorBlock for Central Alarms 5 Dress the excess patch cord cables with cable ties so they do not interfere with operation and to give a pleasing appearance Setup This section provides the procedures for configuring your 10 Pump 80 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 Figure below gives an overview of the basic flow between the menus used in setting up the system Figure 19 Basic Menu Flow for Setup Pump Summary Station hold icon Pump na Setup System Setup DeviceNet Node Status 10 Pump 80 Station Controller Chapter 3 Installation 35 Setting Up the System Setting the Number of Stations and the Number of Pumps 1
37. connect an alarm module to the network 1 Attach one connector of the first yellow patch cord to the terminal on the alarm module Tighten the cord grip ring until snug 2 Attach the other connector to the upper right terminal of the ArmorBlock Tighten the cord grip ring until snug 10 Pump 80 Station Controller Chapter 3 Installation 33 Figure 17 Proper Central Alarm Connections PATCH CORD 20FT 6M YELLOW ACS PART ND 40555190 Ss F VACUUM PIPE POWER FLAT CABLE BLACK J NETWORK FLAT CABLE GREY Ye ye x ARMORBLOCK MOUNTING PLATE KIT ACS PART No AN556696 x NOTE EACH MOUNTING BLOCK REQUIRES 2 CLAMPS SPECIFIC TO THE PARTICULAR SIZE OF CONVEY PIPE USED SEE DRAWING A056362e6 FOR CLAMP yi INFORMATION fa f 4 INPUT 4 OUTPUT ARMORBLOCK ACS PART No A0558296 ARMORBLOCK BASE ACS PART No A0555191 x PATCH CORD eOFT lt 6M gt YELLOW Dee ACS PART NO 40555190 PUSH TO SILENCE BUTTON x ALARM ACS PART A0563822 ACS PART A0558282 3 Attach one connector of a yellow patch cord to the terminal on the alarm silence switch module Tighten the cord grip ring until snug 4 Attach the other connector to the upper left terminal of the ArmorBlock Tighten the cord grip ring until snug Note Retain the terminal caps from the ArmorBlock They may be used later Note the following illustration for 4 connector central alarm ArmorBlo
38. controller builds a vacuum in the filter chamber by isolating it from the rest of the system with the sealing valve The vacuum is then released to dislodge dust and debris When this option is enabled the controller builds a vacuum in the filter chamber by isolating it from the rest of the system by closing all the station sequence valves assigned to that pump The vacuum is then released to dislodge dust and debris Number of conveying cycles to stations between filter cleanings Adjust this setting based on experience The more dust and debris in your material line the smaller this number needs to be Number of pulses of compressed air sent through the pump s filter during cleaning If blowback is not working as desired the service department may ask you to change this setting build up in the filter chamber the filter chamber to dissipate 10 Pump 80 Station Controller Chapter 6 Configurable Settings 69 Chapter 7 Troubleshooting 7 1 General Troubleshooting Problem ______ _Possible cause___ ____ Solution Thecontroler panelis noi Plug in the controller panel 4 j connected to a power source ihe co Mro er RANA Soesman Fuse circuit breaker in the power up at all p Replace reset drop is blown tripped Broken controller power switch Reset the circuit breaker and The motor circuit breaker check the motor for the proper A pump package doesn t run overload has tripped amp draw on
39. cut or disconnected Output Failure Pump disconnect is off Contactor has failed Power supply is not turned on Output Power Failure Power supply is not connected properly Critical Power supply fuse blown Pump ArmorBlock not installed properly ArmorBlock is defective Contactor is mis wired Faul Contactor is mis wired Cid PONABOE FAUN Contactor has failed i Patch cord is cut or disconnected Sealing Valve aul Solenoid has failed Too Many Stations Assigned More than 50 stations have been assigned to a pump Vent Solenoid Failure Patch cord is cut or disconnected Solenoid has failed System Alarms The alarm horn silence duration time has passed and at least one Alarm Horn Silence Expired SY alarm is still present on the system The alarm beacon suppress duration time has passed and at least AA SB ORE SUPDI Ces KOIES one alarm is still present on the system Control panel is not connected to flat cable l Control panel network cable not installed correctly peviceliet Scenes Power supply not turned on ati pp Communications Failure Power supply not connected properly Power supply fuse blown Main Control Panel Power Panel power supply fuse blown Supply Failure Panel power supply has failed Control panel is not connected to flat cable Network Power Failure Control panel network cable is not installed correctly Power supply not connected properly 10 Pump 80 Station Controller C
40. d Duration as appropriate A keypad pops up with an entry of the current setting 2 Enter the number of minutes range 2 99 Use lt to erase any mistakes Use to enter the value The keypad disappears and the new setting appears under Operator or Setup Password Duration Save Restore Settings To save settings go to the System Setup screen and touch Save Restore on the right side of the screen Touch Save Settings When the settings have been saved the controller will display Save Complete The date and time will appear under Restore Settings To restore old settings touch Save Restore TouchRestore Settings The controller will display the most recent date and time that the settings were restored 10 Pump 80 Station Controller Chapter 3 Installation 48 3 6 Initial Startup Once you have finished all the setup described above you are ready to start the system To do so 1 At any screen touch Stations on the right hand side of the screen The Station Status screen appears 2 For each station that you want to use briefly touch its icon The icon turns blue indicating that the station is ready or yellow indicating that the station needs material 3 Touch Pumps The Pump Status screen appears 4 For each pump that you want to use briefly touch its icon The icon turns blue indicating that the pump is ready 5 Touch Push to Start System in the lower right hand corner of the screen The sys
41. d 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 10 Pump 80 Station Controller Chapter 1 Safety 7 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 correct
42. dahanan an paiana anaa 50 Mat OVeErvEW Serani a A E E A E A a a ute 50 4 2 Starting and Stopping the System ssssseeeeseresssstrrrerrrntrrtntressrrrnntrtrnntestrrnseren nnee 50 A 3 e E TASKS T TT 51 Reviewing Station Status 3 eciscsseccsnseres ened yest canaisi gas cncua dab uncteanceoeneteyecd ocnoeeecae hoe 51 Reviewing Pump Status cheer cess seco an taceencdas yes teetucacvtned daanguanelgabwadece raviesanseceonacs 52 Logging On and Logging Off tases 3a caus abhor eiucs sia ecs Di tnceo ees ea set ah meat ilies aaa ees 53 Enabling and Disabling Stations and PUMPS cccccceeetceteeeeesceeeeettetseeeeetees 54 Reviewing and Adjusting Basic Station Settings cccccccccsssssssssseeeeeseeseeees 55 4 4 Advanced TASKS iit paventadeuteneneddyast netialage oin EEE EEEE EEEE aaa eee EAN 58 Reviewing and Resetting a Pump Hour Meter ccccccecceeneeeteeeeeeeeeeeenneeee 58 Transferring Stations to a Standby PUMP cccccceeteeeeeennteeeeeesneeeeteteeeeeteneaeeees 58 35 ARIGIINIS catasct aot peeshocah nytt onde tents EE Aaa Kea EREA a An a aA eana E ARA a Beet eoira 61 R viewing Alarm Serristori AEE EE EE E E EEREN 61 Silencing Aa S a eile e a a R 61 CHAPTER 5 MAINTENANCE ccssesseeeeeesseessneeeeeeneeenneeees 62 5 1 Preventative Maintenance sssssseeesssssesssssssssrrrrrrrannnrrrtrnrrnnnnnonnrnnnannnanuteeennennnne 62 CHAPTER 6 CONFIGURABLE SETTINGG ccsssesee
43. draw without picking up material for an extra period of time after conveying is finished Enable this option if and only if you are using a purge valve for this station This option cannot be used with a volume fill station Purge duration Number of seconds allowed for purging The 0 999 sec station s vacuum valve remains open for the convey time plus this time Adjust this setting to the amount of time required for material to travel from the pickup point purge valve to the station Purge valve Number address for the purge valve used with 0 not this station assigned Set this to match the number address for the purge valve that services this station If another station has the purge valve that services this station enter the number of that station range 1 50 If a central purge valve services this station enter the number address of that valve range 51 154 Material set to n Number for the material line that should be 0 150 0 not connected to this station assigned 10 Pump 80 Station Controller Chapter 6 Configurable Settings 66 Name Description RPV Remote This option allows the system to use a remote Options _ Default Proportioning Valve proportioning valve to mix two different enabled PLC materials typically virgin and regrind materials enabled local during a convey cycle Touching RPV repeatedly at the Station n Setup screen steps through the three choices Enable this option
44. e next 1 Go to the System Setup screen if needed The current delay is displayed under Pump Staging 2 Touch Pump Staging A keypad pops up with the current setting 3 Enter the number of seconds range 0 99 Use lt to erase any mistakes Use to enter the value The keypad disappears and the new setting appears under Pump Staging 10 Pump 80 Station Controller Chapter 3 Installation 39 Setting Up Stations Before starting the system you must define several settings for each station such as which pump conveys material to it and whether the station has a slide gate This section first discusses how to use the controller s menu system to configure stations The table on pp 63 67 discusses the individual choices Setting Up a Single Station 1 Go to the Station Status screen if needed To reach this screen from any other screen touch Stations on the right hand side of the screen The Station Status screen appears Depending on which model you have your screen will appear as one of the following n Status Pumps Alarms 2 Touch the icon for the station you want to set up and hold it for several seconds The Station n Operator Settings screen for the selected station appears Stations Pump Station Setup System Setup Password Not Active Help Touch Station Setup at the Station n Operator Settings screen The Station n Setup screen appears 10 Pump 80 Station Controller Chapter 3
45. e 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 10 Pump 80 Station Controller Failure to do so may result in serious injury No one but the person who installed the lockout may remove it 10 Pump 80 Station Controller Chapter 2 Functional Description 11 Chapter 3 Installation 3 1 Uncrating 10 Pump 80 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 KwikLink co
46. ectrical fault occurs or if the hardware is replaced Keep in mind that this condition is extremely rare You will then need to restore saved settings or set up the controller once again with the settings you programmed in this chapter Options for Station Setup Conveying Options Convey time Length of time the station s vacuum valve 0 999 9 sec 30 sec remains open to allow material to be drawn in For a volume fill station the valve closes when material covers the station s volume fill proximity sensor or this time elapses whichever comes first Adjust this value to match the actual time needed to fill the station Last convey time Display only Length of time the station s vacuum valve was open for receiving material during the most recent convey This information is displayed for your reference when adjusting convey time and dump delay Dump delay Length of time allowed for material to drain from 3 99 sec 10 sec the station into the receiver The controller will not attempt to deliver more material to the station until this time has elapsed Adjust this value to match the actual time needed to drain the station If it is set too short the controller may attempt to refill the station before it is empty causing material to back up and or underusing the station s capacity If it is set too long the system may be unable to keep up with your equipment s demand for material 10 Pump 80 Station Controller
47. ed 3 Dress the excess cable with cable ties so it does not interfere with operation and gives a pleasing appearance Connecting the Remote Interface to the Main Controller After selecting a location and installing the remote interface connect it to the main controller 1 Install the Ethernet switch in a location safe from electrical interference and physical damage 2 Install the remote interface s in their desired locations 10 Pump 80 Station Controller Chapter 3 Installation 21 3 Run the cables from the remote interface s to the switch and the main controller neatly dressing the cable with ties so that it does not interfere with system operation and it gives a neat appearance 4 Attach RJ45 connectors at each cable end following the connector manufacturers instructions 5 The Ethernet out connection on the main controller should connect to the Ethernet in connection on the switch 6 The Ethernet out connections on the switch should connect to the Ethernet in connections on the main controller and the remote interface s 10 Pump 80 Station Controller Chapter 3 Installation 22 Figure 8 Proper Controller and Remote Interface Connections ARMORBLOCK MOUNTING PLATE KIT nen ae ACS PART 0556696 ee mee NOTE EACH MOUNTING BLOCK REQUIRES 2 CLAMPS SPECIFIC TO THE PARTICULAR SIZE OF CONVEY PIPE VACUUM PIPE ee POWER FLAT CABLE BLACK USED SEE DWG A0563626 FOR CLAM
48. ed evenly 3 Using the proper torque sequence tighten each screw a little at a time until the seal block is fully seated into the cable base Tighten to no more than 8 to 10 inch pounds 3 0 to 3 7 Nem of torque The three seat lines on the seal block should meet the cable base indicating that the seal block is fully seated The seal block clips should also click into place onto the corresponding cable base slots Installing KwikLink Connectors KwikLink connectors let you connect the controller and the power supply to the system They are also used to electronically terminate power cable and data cable runs Just like ArmorBlocks KwikLink connectors are insulation displacement connectors IDCs Caution Exercise care when installing Kwiklink connectors IDC blades on KwikLink connectors are SHARP Gently push back any protruding IDC blades before installing flat cables inside The KwikLink connector should already be attached to the mounting plate so the hinge side is down If not reinstall it with its proper alignment along the correct flat cable See the installation drawing located in your Customer Information Packet for further details To install flat cable inside KwikLink connectors 1 Lay the cable in the hinged base noting the correct keyed profile flat edge toward the hinge keyed edge toward the latch Make sure that the cable is properly seated inside 10 Pump 80 Station Controller Chapter 3 Installation 2
49. eeded 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 Note Vacuum leaks occurring anywhere in your system reduce capacity Standard Features Mechanical Features Time fill Capability The specific length of time allowed for material to convey to a station Volume fill Capability Allows for a station to be conveyed to until the prox at the top of the station detects material Vent Valve The vent valve unloads the vacuum pump motor and allows it to keep running during short periods when material conveying is not required Constantly starting and stopping the vacuum pump will damage it over time The vent valve also protects the conv
50. eeees 63 6 1 Memory Module Considerations 2 2 c cccecsesceeeeeeeeeeeeeeeeceeeeeeeeeeeeeeeneeeeeeneeeeeenneas 63 652 Options for Station Set p serach cttaetoteheceee delta scaslealishandee cael 63 6 3 Options for PUMP Setups anki tepid e e lo ARE E a E 68 CHAPTER 7 TROUBLESHOOTING nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 70 7 1 General PrOUBIGSNOOUNG auccaitcaietes i odnesied es hacetayelicneteenoiole aiedensannaboneatie dete e 70 7 2 PAVING oct iaert beatae cha e Faia tbe AEE E nena need et adem alae nanan EE eae hang 71 stelea RANEE Taaa E EE AE EA E E E E AT 71 FA EAE TAAA EEEE A a S A ois E E A A 73 S stem AlarMS tresto iernat r E E e a aa ra Er ee Ea crane aN 73 CHAPTER 8 APPENDIX amaeana ra areenaa aai screeds 74 8 1 Optional COMPOMGIS ies secon sceststee Pesikacrnntdesdsducdtenadetecnblaaa Cendauenchexeti cect aacecthamiaataceganaete 74 8 2 Drawings and DIAQKAMSs 0is 521432 cnesesperecsnyst ced nevedecasdes te Save iv enieiersgy les elem esseedeuost space 75 8 3 Main Control Panel Spare Parts List ci sccceaweriaveitiees dondteenunktiad nade 76 8 4 Returned Material Policy cc crcsedea cid tbsuec roared Mat amen 77 CREO Returns erre iea A R ota bet ed aves e AEE 77 Wa rranty Ret rnS erneer eni Se aie sat iiia da secede a E ehh kone vac Passer eee EEEE T 77 8 5 Safety Tag Winans vse ceccete sett each sdieee dceedncetvts weds sagdiet ly abet sac eeadyrnneretedenaedeeeetehactetags 78 Controller Safety Tag Si nisr
51. eiver low level When this option is enabled the controller disabled disabled issues a receiver level alarm if material in the enabled receiver drains below the level of the receiver s low level sensor Enable this option if and only if your facility has installed a low level sensor for this station s receiver At times you may wish to disable it during operation as a stopgap measure for dealing with an alarm When this option is enabled a switch at the station is used to disable bypass the station Grinder empty When this option is enabled a proximity switch is used to verify that material is present in the grinder bin The station will only be conveyed to when the receiver is empty and the grinder bin has material Grinder empty with When this option is enabled alarm monitoring is Alarm added to the grinder empty option described above If the grinder bin has material and the receiver is full a grinder full alarm is generated Option output Local alarm When this option is enabled the controller turns disabled disabled on the local alarm light for any alarm at this enabled specific station Enable this option if and only if your facility has installed a local alarm light for this station Blow back When this option is enabled the controller disabled disabled periodically sends compressed air backward enabled through the station s air filter to dislodge accumulated dust and debris Enable this option i
52. en Symbols Colors touch Station The Station Symbols help screen appears explaining the status represented by each color 4 When you are finished reviewing the information touch Stations or Pumps The Station Status or Pump Status screen appears 10 Pump 80 Station Controller Chapter 4 Operation 51 The following table explains the status represented by each color at the Station Status screen Offline Station is not enabled The controller ignores any demands or alarms White Blow Back Station s air filter is being cleaned by blowing compressed air backward through it station Medium Station is in priority convey mode Its pump will be temporarily Green Convey dedicated to filling it as soon as possible Station is in critical alarm The controller has disabled the station until the alarm is cleared Purple Closed Station is in closed loop convey Loop Light Yellow Waiting Station is waiting for material to become available Station is being loaded Additional basic information about each station convey time dump delay pump assignment and if enabled RPV setting purge settings etc is available at the Station n Operator screen See page 55 for details Detailed configuration settings for each station are available at the Station n Setup screen See page 39 for details Reviewing Pump Status The Pump Status screen is the counterpart of the Station Status screen To reach the Pump Status screen f
53. en a e a De tits a a Rls aaa a Ma eee 9 Mechanical Features sssssssaaannnnnnnerrrsrennorerrrnnnnnnnrrrrrnrnnunnnrennnnnnnaasaonersnaaasnnnnnnne 9 Electrical Feat rO Soniaren R AEE T RE 10 Controller FeatureS enneeennennannnnnneeennneeennnrnerenneeernnnrernnnnorrnnneerrnnnnrnnnnneeenn enerne 10 2 4 Optional POAC Seen e aana E a beth ante aaa teeter eek ienaa 10 2 5 Safety Devices and InterlOcks esssneeeeenneeoorenrereenetstrrrnoetrnntereteneerrnnteernnnrsteereeee 10 Safety Circuit StandardS 0 ens0000ene0eeeneononennereernrenernnnnerennnerernnrnnrennneernnneeeene ene 11 Fail Sale Operation insna a R e 11 Safety Device LOCK OUNS i iisses ft taste ac esealaa see doce Sedene Wevndtdpaadeuc deadegetee teduedadensene 11 CHAPTER 3 INSTALLATION ccccsssessseeesessesseeeeeeeeeseneeees 12 Sad UMC AMINO rc sn a a a loans a a ash a taa a 12 3 2 Mounting the Control Panel visetcicci cas scecvehsinezos saeedhaenie deste nnessatactsastenalesaatbnpeneetd anions 12 3 3 System Installation Overview eee cceeeeecceeeeeeeeceeeeeeceeeeeeeeaeeeeeeseaaeeeeeeaaaeeeeesaaaeeeenae 12 3 4 Electrical Connection S yssen ebecdeca ideas setae uae a ace ae a tetett pasit 13 Making Control Panel Power Drop Wiring Connections cccceeeeteeetenteeeeteee 13 Running KwikLink Cables saoasnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnnennnnennnnnnnne 13 Setting Up and Installing MOUNTING PIAt S
54. ent is Not Correct voces ci25 is exkcheak cot sau scba hata dead nib enc ta adedeeaet enetendedenectbeee 2 REUN Sanieren a ach A teed sean A tea teeah ae E E eter hemes ste 2 Table Ob GOMGI Sees cen AEA E necvbaumleeeel gyntenecdassateuedece tials wae 3 CHAPTER TD SAFETY ana A 1 1 How to Use This Manual Sanat eacic cade tie vecnoeweecunnte dan tasteneeaecones cSedcanccacstamsaseerceteetonmnaee 5 Safety Symbols Used in this MAnu l 0 2 ccccccccceseeeeeeeeneeeeeeeneeeeeeesaaeeeeseaaeeeesenaaes 5 1 2 Warnings and Precautions az cre crcesedey thins steers eis sod ch a da ee Mt saves cca Teuton 6 t3 Responsibility aen epai a odes Rods Adin wens aiety ae T Mons ed ad eas age epee tet 7 General AGSPONSIDINNY cfs esac ecaeaie 3 catacen atthe cane Seep takes eae he Seaetiwetd eendeadicernesas tees 7 Operator Responsibility ai 0 ca sales sexaciss e524 ie weleadeeaiss aa pee gua tanansauaecenexeie cers tacacdaagtdsabazte 7 Maintenance ROSDONMSIDINIY 2cccs 2 dec casves des ou cchpepehy vcvedca ve cevecacaseesivxeoodeetedvrosibeskeneted 8 Reporting a Safety Defect ssh ci rieix sen 3 oe abate de waates eoeede soda tudes oehes Blo eciebeaebetepancuyies 8 CHAPTER 2 FUNCTIONAL DESCRIPTION sseeeeeeeeeeQ 2 1 Models Covered in This Manual c cceeesseceeeeeeeeeeeeeeeeeeeeeeeeaaeeeeeesaaeeeeessaaeeenseaaes 9 2 2 General Descriptio csi pects teeta ecat ce dele ace ce r e tied ra aae daa E Pee cee eee 9 23 Standard Features il
55. er e Remote Display 2 Select 745_00090_00 mer e Remote Display 3 Select 745_00091_00 mer eee 10 Pump 80 Station Controller Chapter 8 Appendix 102 e Remote Display 4 Select 745_00092_00 mer 11 Press the Load F2 button 12 The Replace Communications Confirmation Screen Fig 15 will appear 13 Press the Yes F7 button 14 The RSView ME Station Screen will appear Fig 12 15 The application will load This will take several seconds While it is loading several buttons will be grayed out 16 When the application completes loading press the Terminal Settings F4 button 17 The Terminal Settings Menu will appear Fig 23 Terminal Settings System Information Time Date Regional Settings 2 Start 2ijrsview ME Station LAS Fig 23 18 Press the down arrow Y button to highlight Startup Options 19 Press the enter 4 button to select Startup Options 10 Pump 80 Station Controller Chapter 8 Appendix 103 20 The Startup Options Screen Fig 24 will appear Startup Gptions RSView ME Station Startup Startup Tests Fig 24 21 Press the enter 4 button to select RSView ME Station Startup button 10 Pump 80 Station Controller Chapter 8 Appendix 104 22 The RSView ME Station Startup RSView ME Station Startup Screen Fig 25 will appear Configuration Mode Options Run Options Cancel F8 Boca
56. er 8 Appendix 87 11 12 13 14 Wait for the Restore Complete message This message is only displayed for 10 seconds 16 17 18 Wait for the Save Complete message This message is only displayed for 10 seconds 20 21 about 10 seconds Ifa firmware upgrade is required this will take about 2 3 minutes Do not turn off power until the upgrade completes CENS Fig 8 Turn off power to the control enclosure Wait 5 seconds Turn on power Go to the System Setup Screen by pressing the System Setup button on any screen Go to the Save Restore Screen by pressing the Save Restore button on the right side of the screen Restore Settings by pressing the yellow Restore Settings button Remove compact flash card labeled PLC Configure 744 00130 00 from the PLC CPU by pressing the retaining clip to the right and pulling the compact flash card straight out Insert the operation compact flash card containing the new version of the software labeled PLC Operate 744 00131 00 into the PLC CPU Save Settings by pressing the yellow Save Settings button Go to the System Setup Screen Fig 6 by pressing the System Setup button Verify that the clock has the correct time If not set the correct time by pressing the Set Time amp Date button 10 Pump 80 Station Controller Chapter 8 Appendix 88 VersaView CE 1000H Setup Use this procedure to setup a new VersaView display or to upgrade a VersaView display
57. er end of the range you are copying to Use lt to erase any mistakes Use to enter the value The keypad disappears and the Station Copy screen shows the station number you entered under First Station 3 TouchLast Station button next to the light grey button labeled First Station The keypad pops up 4 Enter the station number for the hopper at the upper end of the range you are copying to Use lt to erase any mistakes Use to enter the value The keypad disappears and the Station Copy screen shows the station number you entered under Last Station 5 Touch the green Copy To Range of Stations button Copy Complete briefly appears at the top of the screen 6 As appropriate either continue copying to other stations or touch Station Setup to go back to the Station Setup screen To copy the current station s settings to all other stations 1 Touch the green Copy To All Stations button Copy Complete briefly appears at the top of the screen 2 Touch Station Setup to go back to the Station n Setup screen Setting Up Pumps Before starting the system you must define several settings for each pump such as how quickly to shut it down when it is not in use and whether the pump has a local alarm This section first discusses how to use the controller s menu system to configure pumps The table on page 77 discusses the individual choices Setting Up a Single Pump 1 Go to the Pump Status screen To reach
58. et the date touch Month A keypad will pop up for you to enter the number of the current month i e May 5 You can repeat this process to set the current day and year by pressing Day and Year as appropriate Use lt to erase any mistakes Use to enter the value The keypad disappears and the new setting appears under Set Time amp Date Naming Purge Valves and Materials You can assign purge valves and materials names rather than keep them assigned by numbers You can name stations and pumps as well Refer to the Setting Up Stations and Setting Up Pumps sections later in this chapter 1 Go to the System Setup screen and touch Name Purge Vlv Material and scroll through the list of purge valve materials and find the one you want to rename 2 Use the up and down arrows to select the purge valve material you would like to name 3 Select Press to Change at the bottom of the list A keypad will pop up 3 You can then type in a name of up to eight alpha numeric characters Make sure to choose different names as the system does not recognize duplicate names Use lt to erase any mistakes Use to enter the value Checking Addressing and Wiring for System Components Once you have set the number of stations and pumps as described previously you should verify that the controller is communicating with all stations pumps and central alarms and with the ArmorBlocks for all central purge valves To do so 1 Atthe Sys
59. eying system from damage during high vacuum conditions The valve plunger will unseat itself and allow ambient air to leak into the vacuum lines when the vacuum climbs too high Central Purging This feature allows any remaining material to be cleaned out of the material line after every convey Local Blowback Filter Cleaning When this feature is enabled the controller periodically sends compressed air backward through the pump s air filter to dislodge accumulated dust and debris 10 Pump 80 Station Controller Chapter 2 Functional Description 9 Implosion Filter Cleaning When this feature is enabled the controller periodically pulls a vacuum on the filter chamber and then releases it to dislodge accumulated dust and debris Grinder Empty This feature allows a station to receive material from a grinder bin The level of material in the bin is monitored to assure there is enough material to convey Material Sharing This feature allows multiple pumps 6 max to be connected to a material source The controller will let one pump at a time draw from the material source Electrical Features e 115 1 60 or 220 1 50 supply voltage e 24 VDC control voltage e Lockable ON OFF switch e Branch circuit fusing e Fully accessible NEMA 12 style electrical control enclosure Controller Features e Allen Bradley Compact Logix programmable controller with 10 color touch screen operator interface e Diagnostics operating instructions and
60. f and only if the station has the equipment for compressed air filter cleaning 10 Pump 80 Station Controller Chapter 6 Configurable Settings 65 Name sd Description Options Default Every n loads Number of conveying cycles between filter 1 99 5 cleanings Adjust this setting based on experience The more dust and debris in your material line the smaller this number needs to be pulses Number of pulses of compressed air sent 1 99 5 through the station s filter during cleaning If blowback is not working as desired the service department may ask you to change this setting On time Number of seconds that the each air pulse lasts 0 1 99 9 sec during filter cleaning If blowback is not working as desired the service department may ask you to change this setting Off time Number of seconds between air pulses during 0 1 99 9 sec 1 0 sec filter cleaning If blowback is not working as desired the service department may ask you to change this setting Slide gate When this option is enabled the controller disabled disabled opens the slide gate between the station and enabled the receiver during the dump delay and during blowback Enable this option if and only if the station has a slide gate instead of a flapper and demand switch Purge When enabled this option allows the system to disabled disabled empty the material line completely after every enabled convey to this station The station s pump continues to
61. f this does not solve the problem phone the Service Department for assistance Setting Up Alarm Silences When an alarm occurs a horn sounds and a strobe light flashes at each installed central alarm An alarm window will also appear in the center of the operator interface screen s The window will display a description of the alarm the time and date it occurred and a Push To Silence button Touching this button silences the horn s and turns off the light s for configurable periods of time You can set different lengths of time for keeping the horn silent and keeping the light turned off If a new alarm occurs the horn sounds and the light turns on again To set the lengths of time for suppressing the alarm strobe and horn 1 Go to the System Setup screen To reach this screen from any other screen touch System Setup on the right hand side of the screen 10 Pump 80 Station Controller Chapter 3 Installation 38 System Setup DeviceNet Nodes Alarm Strobe Alarm Horn Set Time ee Suppression Silence 2 Station 0 Mi 10 Mi i 14 09 2 sy 6 23 2005 P RD Pumps Operator Password Password Duration 5 Min 1 station per Block Configuration The current settings are displayed under Alarm Strobe Suppression and Alarm Horn Silence When a station node is configured for the default 2 stations per block see Setting up the System on page 37 one option input and one option output per station is available When a station node is c
62. gures 12 15 and 16 connection is shown on first pump on the block only for clarity 10 Pump 80 Station Controller Chapter 3 Installation 30 Figure 15 Proper Filter Chamber Connections Blowback POWER FLAT CABLE BLACK o m pA Ci Fe 7 woe fas oe o Q EPEE TEE K 4 O E pm NETWORK FLAT CABLE GREY OE S a 4 INPUT 4 OUTPUT ARMORBLOCK i fl PART 40558296 SUPPLIED WITH VACUUM PUMP PATCH CORD 20FT 6M YELLOW PART A0555190 FILTER CHAMBER XFC S INCLUDED IN INSTALLATION KIT 10 Pump 80 Station Controller Chapter 3 Installation 31 Figure 16 Proper Filter Chamber Connections Implosion Type POWER FLAT CABLE BLACK PATCH CORD 20FT 6M YELLOW PART NUMBER A0S55190 VACUUM PIPE NETWORK FLAT CABLE GREY 4 INPUT 4 OUTPUT ARMORBLOCK PART A0558296 SUPPLIED WITH VACUUM PUMP IMPLOSION FILTER CHAMBER Note Retain the terminal caps from the ArmorBlock They may be used later 2 Dress the excess patch cord cables with cable ties so they do not interfere with operation and to give a pleasing appearance 10 Pump 80 Station Controller Chapter 3 Installation 32 Connecting Central Alarms to the Network Make sure that all previous installation steps have been done first before starting this task First determine where the best location for central alarms should be and install the alarm module s there You ll use two yellow patch cords to connect To
63. hapter 7 Troubleshooting 73 Chapter 8 Appendix 8 1 Optional Components The following 1s a list of options that your controller may be equipped with 230 1 60 Operation Required to operate with a 230 1 60 supply voltage Additional audible visual alarm with silence button Alarm light and horn assembly that can be remote mounted and wired into the controller to indicate an alarm condition Remote Interface 10 Pump 80 Station Controller Chapter 8 Appendix 74 8 2 Drawings and Diagrams Figure 20 10 Pump 80 Station Controller with 10 Display A AN p Also review electrical drawings supplied in the packet with this manual Note Allow 12 of clearance on each side of the controller for ventilation and cables 10 Pump 80 Station Controller Chapter 8 Appendix 75 Figure 21 Typical System Installation Layout VA TUBI BLACK DUTPUT POWER FLAT CABLE GREY INPUT POWER NETWORK FLAT CABLE i Ss is Ss a O LEFT_END r T 5 RIGHT END FT_END Pp a GHT_END TERMINATION j TERMINATION CENTRAL ALARM WITH MAI NTROL ay H SCREEN DISPLAY B 7 VACUUM LINE SEQUENCE VALVE POWER SUPPLY WITH VACUUM HOPPER OPTIONAL REMOTE VACUUM PUMI OUCH SCREEN DISPLAY 8 3 Main Control Panel Spare Part
64. he light grey button labeled First Pump The keypad pops up Enter the number for the pump at the upper end of the range you are copying to Use lt to erase any mistakes Use to enter the value The keypad disappears and the Pump Copy screen shows the pump number you entered under Last Pump Touch the green Copy button labeled Copy To Range of Pumps Copy Complete briefly appears at the top of the screen As appropriate either continue copying to other pumps or touch Pump Setup to go back to the Pump n Setup screen To copy the current pump s settings to all other pumps l 2 Touch the green Copy To All Pumps button Copy Complete briefly appears at the top of the screen Touch Pump Setup to go back to the Pump n Setup screen 10 Pump 80 Station Controller Chapter 3 Installation 46 Finishing Setup Setting Up Passwords You can set up passwords for two levels of security for operators and for setup personnel The controller comes from the factory with neither password set This allows every user access to all functions Setup Password If you define a password for setup personnel then most settings can be changed only after entering the password The password will be required to display the following screens e System Setup to review and change system wide settings and go to the network status screens e Station Setup to review and change settings for all station options e Pump Setup to review
65. ic safety devices e Understand the proper use of the safety devices provided e 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 controller 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 th
66. ight side of the screen Naming Stations To name a station go to the Station Status screen Touch the icon for the station you want to name and hold it for several seconds The Station n Operator Settings screen for the selected station appears Touch Station Setup at the Station n Operator Settings screen The Station n Setup screen appears 1 Press Name Line 1 at the bottom of the Station n Setup screen A keypad will pop up 10 Pump 80 Station Controller Chapter 3 Installation 41 2 Youcan enter a name of up to four 4 alpha numeric characters If you would like to enter a longer name you can go back to the Station n Setup screen and press Name Line 2 torepeatthe process Using Name Line 2 will allow you to enter up to four 4 more alpha numeric characters for a total of eight 8 characters The characters will appear as two four digit names on two separate lines Use lt to erase any mistakes Use to enter the value Note Make sure to choose different names as the system does not recognize duplicate names 3 You can scroll through the stations by scrolling through Back and Next at the top of the screen Copying Settings from One Station to Others If other stations at your facility will use the same settings as a station you have already set up you can copy the settings from this station to the others To do so 1 At the Station n Setup screen for the station you want to copy from touch Copy in the scree
67. incorrect 1 Material is backing up and causing high vacuum alarms for time fill stations only Convey time is too long 2 System is not keeping up with the demand for material Convey time is too short or dump delay is too long For your reference the Station n Operator screen shows the length of time the controller actually spent conveying material during the most recent delivery under Last Convey Time To adjust a station s convey time or the dump delay 1 Go to the Station n Operator screen as described on p 55 or go to the Station n Setup screen 2 Touch Convey Time or Dump Delay A keypad pops up 3 Enter the number of seconds desired Use lt to erase any mistakes Use to enter the value The new setting appears under Convey Time or Dump Delay Activating and Stopping Priority Convey for a Station Before activating priority convey make sure that all other stations using the same pump have adequate material in reserve to continue operation No material will be conveyed to these stations during priority convey If you want the controller to fill a specific station with material immediately you can activate priority convey for that station When you do so the controller temporarily dedicates the station s pump to it ignoring demands from other stations assigned to that pump Once the chosen station is full normal operation resumes You can also use this feature to give one station
68. ining the new version of the software labeled PLC Configure 744 00130 00 into the PLC CPU Fig Fig 1 3 Turn on power 10 Pump 80 Station Controller Chapter 8 Appendix 82 4 Wait for the Run LED on the top front of the CPU to turn solid green and for the I O LED to stop blinking Fig 2 for 30 seconds Since a new CPU requires a firmware upgrade this will take about 2 3 minutes Do not turn off power until the upgrade completes Log L35E Fig 2 Turn off power to the control enclosure Wait 5 seconds Turn on power 6 Wait for the I O LED to stop blinking Fig 2 7 Remove the card labeled PLC Configure 744 00130 00 from the PLC CPU by pressing the retaining clip to the right and pulling the compact flash card straight out 8 Ifyou have a compact flash card with your system settings save on it insert it into the PLC CPU If not skip to step 14 oO 10 Pump 80 Station Controller Chapter 8 Appendix 83 9 Go to the System Setup Screen Fig 3 by pressing the System Setup button on any screen System Setup SYSTEM PARAMETERS Stations Pumps Present Present Save 1 1 Restore DeviceNet Nodes Alarm Strobe Alarm Horn Name Se g amp Date Stations uppression Silence Purge Vlv A Material n 6 23 2005 Pumps Operator Password Operator Password Setup Not Active Password Duration Password 5 Min Help Fig 3 10 Go to the Save Restore Screen Fig 4 by pressing the Save Restore button on the right
69. ires the controller goes to the Station Status screen and you must reenter the password to continue working When you have finished any tasks that require the password you should log off If you forget to do this the controller will log you off when the password expires To log off 1 Goto System Setup 2 Touch Log Off on the right of the screen The Station Status screen appears Enabling and Disabling Stations and Pumps When a station or pump is disabled the controller does not attempt to use it and ignores any alarms that occur for it Disabling a station or pump at the controller s screen is similar to bypassing a station with its bypass switch Enabling a station or pump makes it available for use For a station to be available for the system it must be enabled at the controller s screen and its bypass switch if present must be in the 0 position To enable or disable a station or pump 1 Go to the Station Status or Pump Status screen if needed To reach this screen from any other screen touch Stations or Pumps on the right hand side of the screen Each disabled station or pump has an icon with a status of offline silver All other statuses are enabled statuses 2 Touch the icon for the station or pump briefly The station or pump switches to the new state as indicated by the color of its icon 3 Ifthe Station n Operator or Pump n Setup screen appears when you touch the icon then
70. ither PUMP Clon Apune onnie implosion with sealing valve or Local Alarm enabled Purge Valve X Failure Patch cord is cut or disconnected Solenoid has failed ArmorBlock is not installed properly Purge Valve X Not Present ArmorBlock is not addressed correctly ArmorBlock is defective ArmorBlock base is defective Patch cord is cut or disconnected Purge Valve X Power Failure Solenoid has failed Pick up wand is not positioned properly Receiver Level Take off compartment is not adjusted properly Patch cord is cut or disconnected FPA PAUE Solenoid has failed Sequence Valve Failure Patch cord is cut or disconnected Solenoid has failed Slide Gate Failure Patch cord is cut or disconnected Solenoid has failed 10 Pump 80 Station Controller Chapter 7 Troubleshooting 72 Pump Alarms Blowback Solenoid Failure Patch cord is cut or disconnected Critical Solenoid has failed Patch cord is cut or disconnected Clearing Valve Failure i l Solenoid has failed Pump disconnect is off Failure Patch cord is cut or disconnected Pump contactor has malfunctioned The alarm is user configured The alarm is user configured High vacuum switch is maladjusted High Vacuum Switch Failure High vacuum switch is wired incorrectly High vacuum switch is defected ArmorBlock is not installed properly Not Present ArmorBlock is not addressed correctly Critical ArmorBlock is defective Base of ArmorBlock is defective Patch cord is
71. larm The setting for this option depends on a how much material your mold uses to make each part compared with the capacity of the receiver and b how important it is to keep your mold from running out of material and shutting down A higher setting will give you fewer alarms at the risk of emptying the receiver without warning A lower setting will give more frequent alarms at the risk of disrupting operations unnecessarily 10 Pump 80 Station Controller Chapter 6 Configurable Settings 64 Name sid Description S Partial convey When this option is enabled the controller disabled disabled issues a partial convey alarm if it has enabled repeatedly attempted to convey material to the station and material has moved from the station into the receiver but the volume fill proximity sensor has never signaled that the station is full The number of attempts is controlled by the next setting For a volume fill station this option should usually be enabled At times you may wish to disable it during operation as a stopgap measure for dealing with an alarm For a time fill station disable this option attempts B4 alarm Number of attempts before alarm the number of times the controller will attempt to convey material to a station before it issues a partial convey alarm The setting for this option depends on the same considerations as those given above for number of attempts before a no convey alarm Rec
72. ly 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 10 Pump 80 Station Controller Chapter 1 Safety 8 Chapter 2 Functional Description 2 1 Models Covered in This Manual This manual provides operation installation and maintenance instructions for 10 Pump 80 Station 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 10 Pump 80 Station Conveying Controller is a programmable logic controller with 24 VDC control circuit easy to use touch screen operator interface terminal and optional audible visual alarm 2 2 General Description Our material conveying systems create vacuum for the automatic conveying of most free flowing dry pelletized or granular materials Material characteristics determine the type of equipment n
73. m Critical Pump is in critical alarm The controller has disabled the pump until the alarm is cleared Light Yellow Pump is waiting for material to become available Additional information about each pump including configuration settings and the number of hours the pump has been running is available at the Pump n Setup screen For details on configuration settings see page 42 For details on the hour meter see page 58 Logging On and Logging Off Your controller may be set up to require a password for any operation other than reviewing station and pump status silencing alarms reviewing the alarm log and looking at help screens If so a password entry screen will appear Password Entry A Password is required for the selected action Please press the button below to enter a password Enter Password Press the Enter Password button A keypad will appear 10 Pump 80 Station Controller Chapter 4 Operation 53 e Enter the alphanumeric password Each digit appears as an as you touch it Press when complete If you have lost the password s contact the manufacturer for assistance Once you have logged on the password remains active until you log off or the password expires Setup personnel at your facility control the number of minutes before the password expires While the password is active you can continue to carry out password protected tasks without reentering the password If the timer exp
74. n s upper right The Station Copy screen appears showing the station number for the station you are copying from Source Station 1 1 Copy to Copy To 7 AR Station Stations Sing 5 Station 6 Pane Copy to First Last Station Ranei Station Station Setup ange o 5 10 Stations 5 10 System Setup Password Not Active Copy to All Stations Help 2 Follow the directions on the following pages to copy settings to one other station a range of stations or all stations To copy the selected station s settings to one other station 1 Touch the gray Copy to Station button next to the green button labeled Copy To Single Station The keypad pops up 2 Enter the station number for the station you are copying to Use lt to erase any mistakes Use to enter the value The keypad disappears and the Station Copy screen shows the station number you entered under Copy to Station 3 Touch the green Copy to Single Station button Copy Complete briefly appears at the top of the screen 10 Pump 80 Station Controller Chapter 3 Installation 42 4 As appropriate either continue copying to other stations or touch Station Setup to go back to the Station n Setup screen To copy the selected station s settings to a range of other stations 1 TouchFirst Station button next to the green button labeled Copy to Range of Stations The keypad pops up 2 Enter the station number for the hopper at the low
75. nfigurable settings for how long the horns should remain silent and how long the lights should remain off If the alarm condition still exists when either of these times elapses the corresponding devices horns or lights turn on again If a new alarm occurs both the horns and the lights turn on 10 Pump 80 Station Controller Chapter 4 Operation 61 Chapter 5 Maintenance 5 1 Preventative Maintenance To maintain cooling fan check and clean and or replace filter 10 Pump 80 Station Controller Chapter 5 Maintenance 62 Chapter 6 Configurable Settings 6 2 This section describes the proper setup of the 24 pump 128 station control system parameters These parameters are operator changeable however these items should require setup only during the initial installation Only authorized personnel should change them Many of the variables and setup parameters have been preset at the factory and do not need to be changed However this section of the manual will address all of the setup parameters that were available at the time of printing The purpose of this is to familiarize the reader with all the setup parameters and their usage Memory Module Considerations The operator interface and the PLC central processing unit use memory modules to store the operating program and user settings The module is installed in the front of the PLC CPU card The memory module returns the controller to the factory default settings if an el
76. nk connector It should make two audible snaps when properly seated 3 Align the square connector of the black drop cable so the cable leads down from the connector Evenly press the square connector onto the top of the upper KwikLink connector It should make two separate audible snaps when properly seated 4 Attach the keyed round connectors to the receptacles on the side of the power supply enclosure marked 24 VDC POWER SUPPLY Tighten the cord grip ring until snug 5 Dress the excess cables with cable ties so they do not interfere with operation and to give a pleasing appearance If more than one power supply is required to properly energize the grey network flat cable 1 Remove the terminal block jumpers on all but the most centrally located network power supply enclosures For locations of jumpers refer to the drawing shipped inside the power supply enclosure Note Only one power supply should be connected to each section of the black auxiliary power flat cable Do not remove any jumpers on power supplies that transmit energy to the black flat power cable 10 Pump 80 Station Controller Chapter 3 Installation 24 Figure 9 Proper Power Supply Enclosure Connections OUTPUT POWER FLAT CABLE BLACK VACUUM PIPE ARMORBLOCK MOUNTING PLATE KIT ACS PART No 40556696 NOTE EACH MOUNTING BLOCK REQUIRES lt 2 CLAMPS SPECIFIC TO THE PARTICULAR SIZE OF CONVEY PIPE USED NETWORK FLAT CABLE GREY POWER T
77. nnectors ArmorBlocks vacuum hoppers the filter cham ber atmospheric valve if so equipped and the pump motor starter s vacuum switch es and vent valve s Mount the control 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 System Installation Overview Installing the 10 pump 80 station controller is easy and straightforward Because the system uses networked distributed I O modules you ll only need to run two cables for the entire system The following is a typical installation sequence 1 Set up mounting plates with tubing clamps install KwikLink connectors and ArmorBlocks bases onto mounting plates as required 2 Install KwikLink connectors and ArmorBlock base plates to vacuum tubing at each node location just before a T fitting or valve 3 Run the black power and the grey network flat cables from the start of the system to the end attaching them to vacuum tubing with nylon cable ties 4 Install cable terminations 5 Determine location of network system nodes and set addresses for ArmorBlocks as required 6 Set up and connect to the controller and if purchased remote display Connect grey patch cords from controller terminals to KwikLink connectors installed in Step 3 7 After determining quantity and location s of where to install system power supply ies consult fac
78. o 60 Central purge valves 10 Pump 80 Station Controller Chapter 3 Installation 17 e 61 to 63 Alarm stations Setting ArmorBlock Addresses Locate the rotary switches underneath the ArmorBlock The two switches are e MSD most significant digit for tens e LSD least significant digit for units ones For example if you wanted to set an address at 36 you set the MSD rotary switch at 3 and the LSD rotary switch at 6 To set an address of 8 set the MSD rotary switch at 0 leading zero then set the LSD rotary switch at 8 e Using a permanent black marker write the number of the address on the white label located on the bottom front of the ArmorBlock We suggest that you place numbered tags at node locations to ease installation and reduce any confusion of locations To set the node address e Use a small straight bladed screwdriver to rotate the switches Line up the small arrowhead on the switch with the number you want to select The following figure shows that the address is set at 01 the MSD rotary switch is set at O and the LSD rotary switch is set at 1 10 Pump 80 Station Controller Chapter 3 Installation 18 Figure 5 ArmorBlock Address Node Rotary Switches Installing ArmorBlocks The ArmorBlock cable base should already be attached to the mounting plate aligned so it is perpendicular to the flat cables If not reinstall it with its proper alignment To install the flat cables in the ArmorBl
79. ock cable base 1 Lay the flat cable into the ArmorBlock cable base grey data cable on the bottom and the black power cable on the top making sure that the keyed edge is properly seated toward the top Caution EXERCISE CARE when handling the seal block Cable contacts are SHARP Only ONE attempt to pierce the cable is allowed for proper contact Figure 6 Using seal block to pierce cable 2 Align the seal block so the L shaped tabs are towards the top and the arrows are matched on the bottom of the cable base and seal block Make sure that the arrows and the four captive screws on the seal block are properly aligned Gently press it into place Make sure that you align the seal block properly when you attach it to the base Doing so maintains the integrity of the sealed base Note You can only pierce the cable once Once pierced the seal block must not be removed This insures that the inner conductors are not exposed to the elements Figure 7 Securing the Seal Block to the Cable Base 10 Pump 80 Station Controller Chapter 3 Installation 19 Match arrows so the seal block is in the correct position over the cable base To secure the seal block 1 Start the threads of each of the four captive screws into the cable base receptacle holes 2 Drive each of the screws about halfway down using the proper torque sequence Bottom screw top screw left screw right screw Doing so insures that the cables are pierc
80. onfigured for 1 station per block three option inputs and three option outputs are available for the station 2 Touch Alarm Strobe Suppression or Alarm Horn Silence as appropriate A keypad pops up with the current setting 3 Enter the number of minutes you want the horn or light to be turned off once the alarm silence button is pushed range 0 99 If the alarm condition is not corrected or the defective device is not disabled through the touch screen the audible and visual alarms will reoccur after the times expire If you want the light or the horn to stay on as long as the alarm persists simply press 0 If you want the horn or the light to stay off until a new alarm occurs use 99 for its entry Use lt to erase any mistakes Use to enter the value The keypad disappears and the new setting appears under Alarm Strobe Suppression orAlarmHorn Silence 4 Repeat for the other device strobe or horn as appropriate Setting Up Pump Staging To avoid an excessive power demand at your facility when the conveying system starts up you can stagger the times at which pumps start Whenever a demand would cause two pumps to start simultaneously your choice for pump staging sets the delay between the start of one pump and the start of the next The factory default is a delay of five seconds You need to change this setting only if this delay is too long or too short for your facility To set the delay between the start of one pump and th
81. ors Use a long jawed straight bladed cable cutter at least 1 2 long to cut KwikLink flat cable You ll install two 2 colors of flat cable black and grey The black cable transmits output power and the grey cable transmits input power and data transmission Figure 1 KwikLink Cable Cross Section Edge Identification Cross Section Edge Identification dc power pair 16 AWG red black 5 3 mm Jem keyed edge al mm e lt white blue 0 10 in data pair 16 AWG 19 3 mm 0 76 in flat edge Installing KwikLink Cable Before you install flat cable determine how much length you need to install black power cable and grey data cable Typical installations have equal lengths of each This is a good time to plan for the future and run these cables to each possible location in the plant Use a straight blade cable cutter to make the cut at each end 10 Pump 80 Station Controller Chapter 3 Installation 13 To install KwikLink cables 1 Cut both black and grey cables to the proper length 2 Use cable ties to attach KwikLink cables black cable above grey cable on the vacuum tubing Attach cable to the tubing with cable ties at about three foot 3 ft 1 m intervals Make sure that cable ties are snug but not tightened enough to bend the flat cable Caution Install KwikLink cable on vacuum tubing only DO NOT install KwikLink cable on material conveying tubing as static electricity formed at material lines
82. p Purchased components are covered under their specific warranty terms 10 Pump 80 Station Controller Chapter 8 Appendix 77 8 5 Safety Tag Information Controller Safety Tags High Voltage Inside Enclosure Read Operation and Installation Manual 8 6 Controller Identification Serial Number Tag Located on the side of the controller box Street Address Town State Zip Code Telephone Number Fax Number XXX CONTROL PANEL Model No XXX10 80 Serial No 31K0182 Control Voltage 24VDC 10 Pump 80 Station Controller Chapter 8 Appendix 78 8 7 Technical Assistance Contact Information Parts Department Call toll free 7am 5pm CST 800 423 3183 or call 262 641 8610 Fax 262 641 8653 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications which will maximize your equipment s performance and efficiency To assist in expediting your phone or fax order please have the model and serial number of your unit when you contact us A customer replacement parts list is included in this manual for your convenience ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service Service Department Call toll free 8am 5pm CST 800 423 3183 or call 262 641 8600 Emergencies after 50m CST call 847 439 5655 We have a qualified service department ready to help Service contracts are available for most
83. parts information are built into the interface e Controls up to eighty 80 stations and up to ten 10 Vacuum Power Units e Controls up to three central alarms e Allows operator to transfer stations to a standby pump when a pump fails e Electronic time delay between pump startups to prevent an excessive power demand at your facility 2 4 Optional Features Noise Filter Surge Suppressor Provides protection to electronic devices in the control panel from power surges and electrical noise Closed Loop Conveying This feature allows material to be conveyed and processed without being contaminated by outside influences such as dust other materials etc Additional audible visual alarm with silence button Alarm light and horn assembly that can be remote mounted and wired into the controller to indicate an alarm condition Remote Interface 4 max 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 10 Pump 80 Station Controller Chapter 2 Functional Description 10 e Identify and locate specif
84. peration Names Description Options Default Idle Time Options Auto Shutdown Delay Length of time the pump continues to run 0 999 sec 45 sec unloaded without demand from any station After this time has elapsed the pump shuts down to save power and to prevent wear on the pump Adjust this setting to fit the needs of your facility in trading off the savings against the costs associated with waiting for a pump to start up when there is a demand for material Alarm Options Local alarm When this option is enabled the controller turns disabled disabled on the local alarm light for any alarm at this enabled specific pump Enable this option if and only if your facility has installed a local alarm light for this pump Pump fault 1 The ArmorBlock for each pump has two inputs disabled disabled that you can wire to generate alarms for enabled situations of your choosing These alarms can be configured as standard or critical Standard means that the pump continues to operate Critical means that the pump is disabled For example you may have a sensor that turns on when material reaches the top of a filter chamber waste bin When this option is enabled the controller issues an alarm if the sensor wired to the input for Pump Fault 1 turns on Enable this option if and only if your facility has installed a miscellaneous alarm on the input for Pump Fault 1 for this pump Pump fault 2 See the explanation for Pump fault
85. re necne teia e E cht ulate ines ilo n asus tts 78 8 6 Controller Identification Serial Number Tag ssssesssssnnssssrrnreseeneessnrrsserrnnrrrennnesene 78 8 7 Technical Assistance Contact Information c ccceeeeeeeeeeeeeeneeeeeeeneeeeeenenaeeeeeeeaas 79 PAHS Depantment isrann n a e ER AE dap EAE ET E aE e 79 Service TIED AMINCM eos scant 22 oicurdaene san uicesbasin des buennedovteuddennusdvaudecaueseecemiecarcenanniaade 79 Sales Department e uid ean scan socal r ae ses Rabel dadiuth od ated eee ieseana Ent 79 Contract DCD ANION ds asseio EE n odd oa aiiis 79 10 Pump 80 Station Controller Chapter 1 Safety 4 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 pre operational 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 fac
86. ree ee te Fonts He Launch Back up system WARNING BRutil a Start Storage Card2 ll System Backup Rec Fig 22 46 Press the OK button in the upper right corner of the Warning Window Fig 22 47 After a short delay the VersaView will reboot 48 If the calibration screen Fig 18 appears follow the on screen instructions use a pencil eraser pen cap or other dull pointing device 49 The Windows CE desktop will appear for a short time The VersaView will then launch the Primary Display program 50 If you are upgrading setting up the Primary screen the VersaView setup is complete If you are setting up a Remote screen continue to the next section Remote Display Remote Display 1 Remove the VersaView Program Compact Flash Card labeled 744 00134 00 10P80S Disp Program 2 Cycle power on the VersaView 3 An Error Screen Fig 10 will appear stating that the Runtime file was not found 4 Press the OK F7 button 5 The RSView ME Station Screen Fig 12 will appear 6 Insert the new VersaView Program Compact Flash Card labeled 744 00134 00 10P80S Disp Program Press the Load Application F1 button The Load Application Screen Fig 13 will appear Press the Source F1 button so the circle next to External Storage 1 is filled 0 Use the up and down arrows to select the appropriate program for the display you are setting up e Remote Display 1 Select 745_00089_00 m
87. rom any other screen 1 Touch Pumps The Pump Status screen appears Pump Status System Setup Stations Alarms Push to Stop System Help The status of each pump is color coded as summarized in the upper right of the screen You can see a more detailed explanation of each status by using the online help To do so from this screen 10 Pump 80 Station Controller Chapter 4 Operation 52 2 Touch anywhere in the rectangle in the upper right of the screen or the Help button on the lower right side of the screen The Help Menu appears 3 Inthe section of the Help Menu labeled Screen Symbols Colors touch Pump The Pump Symbols help screen appears explaining the status represented by each color 4 When you are finished reviewing the information touch Pumps or Stations The Pump Status or Station Status screen appears The following table explains the status represented by each color at the Pump Status screen Color Label___ Description _ S o Offline Pump is not enabled The controller ignores any alarms Pump is off waiting for demand from a station Light Green Pump is on waiting for demand from a station If there is no demand before the end of the auto shutdown delay the pump will turn off Green Loading Pump is conveying material to a station White Cleaning Pump s air filter is being cleaned by blowing compressed air backward ee it Orang Alarm Pump is in alarm eee is in alar
88. s 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 10 Pump 80 Station Controller Chapter 1 Safety 6 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
89. s List Quantity Part Number Description 1 Filter only Clean as needed 1 A0569859 Fan grill with filter 1 739 00017 00 4A Power supply 1 A0542203 2A MDL fuse 1 A0568903 10A FNQ fuse 1 A0542205 2 5A MDL fuse 1 A0542209 4A MDL fuse 10 Pump 80 Station Controller Chapter 8 Appendix 76 8 4 Returned Material Policy Credit Returns Prior to the return of any material authorization must be given by the manufacturer A RMS number will be assigned for the equipment to be returned Reason for requesting the return must be given All returned material purchased from the manufacturer is subject to 15 75 00 minimum restocking charge All returns are to be shipped prepaid 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 Prior to the return of any material authorization must be given by the manufacturer A RMS number will be assigned for the equipment to be returned Reason for requesting the return must be given All returns are to be shipped prepaid 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 workmanshi
90. s is Station n alarm text for example Station 12 receiver low level The format for all pump alarms is Pump n alarm text Any alarm that does not start with Station or Pump is a system alarm The following tables list all alarms alphabetically together with possible causes A critical alarm is one that causes the affected device to stop 2 You can also see a list of alarms and their causes in the controller s online help To display this information touch the color key of statuses in the upper right hand corner of either the Station Status or the Pump Status screen or touch Help at any other screen When you are finished reviewing the help touch Return Station Alarms Blowback solenoid failure Critical High vacuum cleared when the controller has conveyed a full load to this station Invalid pump assignment Invalid pump assignment setting No convey Material line is disconnected from source Vacuum line is disconnected from station Note As a stopgap measure you can disable the no convey alarm for this station until the problem can be remedied See pp 64 Not present Critical EE A Partial convey Note As a stopgap measure you can disable the partial convey alarm for this station until the problem can be remedied See pp 66 10 Pump 80 Station Controller Chapter 7 Troubleshooting 71 An assigned station has closed loop enabled and the pump has e
91. se properly 10 Drive the two screws at the center points about halfway down first on the latch side then the hinge side 11 Continue to tighten the screws a little at a time until fully tightened no more than 15 inch pounds 5 6 Nem of torque Note You can only pierce the cable once Once pierced the KwikLock connector must not be removed This insures that the inner conductors are not exposed to the elements Installing Inside KwikLink Connectors with Blank Caps Once installed on the grey data cables these connectors permit you to measure voltage in the system so you can analyze how it is working The system cannot work properly unless these inside mounted connectors have the blank non conductor caps installed 1 Lay the cable in the hinged base noting the correct keyed profile flat edge toward the hinge keyed edge toward the latch Make sure that the cable is properly seated inside 2 Making sure that the cable is completely straight carefully close the hinged assembly and apply firm even pressure until the first latch locks into place Note Make sure that the flat cable is completely straight before continuing 10 Pump 80 Station Controller Chapter 3 Installation 16 The latch has two catches the first loosely holds the connector on the cable the second requires more pressure to close the connector tightly The cable must be in the correct position for the connector to close properly 3 Drive the two scre
92. sh 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 M Bill of lading M Packing list M Operating and Installation packet MI Electrical schematic and panel layout drawings M 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 parts and service department immediately at 1 262 641 8610 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 10 Pump 80 Station Controller Chapter 1 Safety 2 Table of Contents Shipping IMNTONMAU ON 22a cite hates elecaten dsituceaccteccdta ac ddaates tebadstadad i Rtanate cp ateea deeds ttanaleadcetagatanies 2 Unpacking and Inspection f3s 0t sscbedox cede hates sousedautodaneuree sebecestuloebetaceseeasauastoreacsceaats 2 In the Event OF Shipping DAMA iushctesisesdabsvactavantduetshtacdiieba ness bio diteans ovendavoegt ae 2 If the Shipment is Not COMpPIete i2ic225 s2cstk os cadese dodnns ig adeageendeS a Aegon becieacedeanediacnetee 2 If the Shipm
93. side of the screen Save Restore Settings SAVE SETTINGS System Setup DeviceNet Nodes Stations Saved at Pumps 8 57 Jun 24 2005 Password Not Active Fig 4 11 Restore Settings by pressing the yellow Restore Settings button 12 Wait for the Restore Complete message This message is only displayed for 10 seconds 13 Remove compact flash card with the saved settings from the PLC CPU by pressing the retaining clip to the right and pulling the compact flash card straight out 14 Insert the operation compact flash card containing the new version of the software labeled PLC Operate 744 00131 00 into the PLC CPU 10 Pump 80 Station Controller Chapter 8 Appendix 84 15 Save Settings by pressing the yellow Save Settings button 16 Wait for the Save Complete message This message is only displayed for 10 seconds 17 Go to the System Setup screen by pressing the System Setup button 18 Verify that the clock has the correct time If not set the correct time by pressing the Set Time amp Date button 10 Pump 80 Station Controller Chapter 8 Appendix 85 CompactLogix L35E Upgrade Use this procedure to upgrade the software on a CompactLogix PLC for use on a 10 Pump 80 Station Convey Control 1 Ifthe control is off turn it on and wait for the control to power up 2 Verify that the key switch on the front of the PLC CPU is in the RUN position 3 Remove existing compact flash card from the PLC
94. tag ae aonan son Meagaas Main fuse in power drop circuit Replace the fuse reset circuit indicator is lit breaker has blown breaker Motor contact is faulty Repair or replace as required eo sels Normal operation When the e P i ie level drops material conveys to g the hopper P the controller place the A vacuum hopper is being The The hopper is off ine S The hopper is off ine ig P on line bypassed in the loading cycle The field installed station bypass Normal operation Set the switch switch is simulating a Bin Full so the hopper is back in the condition a sequence The maior acute installed station bypass maior acute is bad or mis wired 5 Repair replace or rewire replace Or rewile Time the hopper s during loading and set conveying times to a few seconds less Check proximity sensors for proper operation Repair as needed Reset the conveying times to a reasonable value and adjust as needed Power supply shorting out Repair shorting circuit Controller blows fuses improper Improper fuse installed Improper fuse installed Replace fuse with one that has a prop proper rating Conveying times are too long Time Fill mode only Vacuum hoppers are over filling Maximum conveying times are too long and or the controller does not recognize the Hopper Full proximity switch es 10 Pump 80 Station Controller Chapter 7 Troubleshooting 70 7 2 Alarms The format for all station alarm
95. tem Setup screen touch DeviceNet Nodes on the right side of the screen The DeviceNet Status screen appears 10 Pump 80 Station Controller Chapter 3 Installation 37 DeviceNet Status Station Nodes Nde 1213 7415 6 7 8 9 10 i 12 13 14 15 Em m Next Stations Pumps Input 4 eee se Setup Node 3i EM EM EH EEN EEA EH ED ED aoe Iput 1 D R E D S E E e Input 2 D a E E E E E A E pieces Input 3 see Input 4 D N E E E E E E E Help 2 Check that the expected components are shown as present green and not present grey Disregard any error messages For example if you have 18 stations boxes 01 through 18 in the Stations section should be green and boxes 19 through 80 should be grey For central purge valves you should see a green box for each ArmorBlock installed If the screen display is not as expected either a component s ArmorBlock has an incorrect address or the ArmorBlock is not correctly wired to the network When you have verified that the controller is communicating with the other system components you should verify that the inputs on all ArmorBlocks for stations and pumps are wired correctly and are working correctly To do so Node numbers are stacked vertically as column headings in this screen 3 Check that all inputs are on green or off grey as expected and that they switch on and off as required If any input does not operate as expected check the wiring on the ArmorBlock I
96. tem starts If any alarm messages appear on the top of the screen see Section 3 5 on page 61 10 Pump 80 Station Controller Chapter 3 Installation 49 Chapter 4 Operation 4 1 Overview Your 10 80 controller electrically controls valves and solenoids to convey material from a central location to individual stations as needed The controller senses demands for material at the stations and responds to the demands in a timely fashion This section gives the procedures for using your controller and it covers tasks that can be carried out with no password or with an operator s password The section is divided into four sub sections e Starting and stopping the system e Basic tasks tasks normally carried out by a station operator e Advanced tasks tasks normally carried out by setup personnel e Alarms silencing Before you carry out any of the procedures in this chapter the system must be set up as described in the previous chapter Starting and Stopping the System In an emergency you can use the power switch on the upper right hand side of the controller cabinet if a password is required to stop the system and you do not know the password Normally all the stations and pumps you want to use should be enabled before you start the system When the system is stopped icons for enabled stations are blue when full and dark yellow when they need material Icons for enabled pumps are blue Enabling stations and pumps is described on
97. this screen from any other screen touch Pumps on the right side of the screen The Pump Status screen appears 10 Pump 80 Station Controller Chapter 3 Installation 43 Pump Status System Setup Stations Alarms 2 Touch the icon for the pump you want to set up and hold it for several seconds The Pump n Setup screen appears Pump Setup 1 Back Next lt gt Goto Copy Hour Meter Stations Pumps Filter a Pump Cleaning Service Disabled System Setup Password Not Active Fault 1 Fault 2 Disabled Disabled Pump Help 3 Touching Help in the lower right of this screen gives you a menu of online help for the choices in this screen 4 Adjust settings as required Touching any box that appears in red for disabled toggles it to green for enabled and vice versa Touching any box that appears in light gray gives you a keypad to enter a new value Keypad entry works as with many ATM machines the first digit you enter initially appears in the rightmost column and moves to the left as you enter more digits Use lt to erase any mistakes Use to enter the value The keypad disappears and the Pump n Setup screen shows the new value in the selected gray box See page 64 for details on the options and their default settings 5 As appropriate a Copy this pump s settings to one or more other pumps as described below or b Touch Back lt to go to the Pump n 1 Setup screen
98. tore Help The current passwords are displayed under Operator Password and Setup Password No value means that no password is required 10 Pump 80 Station Controller Chapter 3 Installation 47 2 Touch Operator Password or Setup Password as appropriate A keypad pops up 3 Enter up to eight 8 alpha numeric characters If you want to remove the password protection simply leave the entry blank Use lt to erase any mistakes Use to enter the value The keypad disappears and the new setting appears under Operator or Setup Password In addition if you have added a password a new button appears on the screen labeled Log Off Operator If desired you can also change the duration for which a password remains effective During operation the password protected screens are available either until the user logs off or until this time elapses whichever comes first This feature prevents the password from remaining active if a user forgets to log off 4 The password timer starts when the user logs on It expires even if the user is actively using the screens when the chosen time is up If the timer expires the system goes to the Station Status screen Your password duration should be long enough to allow authorized users to complete their tasks but short enough to provide adequate protection against tampering To change the duration of a password 1 Atthe System Setup screen touch Operator Password Duration or Setup Passwor
99. tory set up and connect to KwikLink connectors installed in Step 3 10 Pump 80 Station Controller Chapter 3 Installation 12 8 Set up and connect vacuum receiver stations to ArmorBlocks installed in Step 3 using yellow patch cords 9 Set up and connect vacuum pump stations and filter chambers to ArmorBlocks installed in Step 3 using yellow patch cords 10 Determine location s of central alarm s set up and connect alarms using yellow patch cords The following sections provide detailed information on these installation steps 3 4 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 115 1 50 60 VAC or 220 1 50 VAC depending on the specifications which are located on the Control Panel Serial Tag The control enclosure draws less than five 5 amps during normal operation at 115 1 50 60 VAC The main power switch is located on the right side 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 Running KwikLink Cables About KwikLink Flat Cables KwikLink flat cable is physically keyed to prevent wiring mishaps This type of cable is unshielded and contains four conduct
100. tory 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 de
101. umps are offline and that the standby pump has no stations assigned to it If these conditions are not all met error messages appear on the screen instead of a Press To Move Stations button If you get an error message first check to make sure that you have entered the correct numbers and reenter if necessary If the error message tells you to disable the source pump and or the standby pump touch Return at this screen then Pumps at the Pump n Setup screen Take the pumps offline and then return to the Transfer to Standby Pump screen If the error message tells you that the standby pump has stations assigned you must either use a different standby pump or you must remove the pump assignment for all stations assigned to the standby pump To remove the assignments touch Return at this screen then Stations at the Pump n Setup screen Hold a station icon to go to its Station Operator screen then touch Setup to go to the Station n Setup screen Use lt Back and Next P to review all pump assignments and where necessary choose Assigned to Pump x to set station assignments to 0 unassigned Then return to the Transfer to Standby Pump screen 1 Touch Transfer To Standby Pump Transfer in Progress appears briefly on the screen followed by Transfer Complete in place of the Transfer To Standby Pump button The controller switches the setting for Source Pump to the new pump and switches the setting for Standby Pump to 0 unassigned
102. unning time since the last reset To review and reset the hour meter 1 At any screen touch Pumps The Pump Status screen appears 2 Touch and hold the icon for the pump The Pump n Setup screen appears Pump Setup 1 Back Next lt gt Goto Copy Stations Pumps Pump Cleaning 5 Service Disabled aie System Setup Password Pump Pump Stations to Not Active Fault 1 Fault 2 Disabled Disabled Pump Help The box labeled x Hours Resetable shows the running time since the last reset The box labeled x Hours shows total running time 3 To reset the resettable meter touch Hour Meter Reset The time above Hours Resetable changes to 0 Transferring Stations to a Standby Pump If a pump fails you can transfer all of the controller s station assignments for that pump to a standby pump To do this you must disable take offline both the source pump and the standby pump and the standby pump must have no stations already assigned to it The transfer operation at the controller s touch screen merely changes the pump assignment for every station on the failed pump It does not transfer any pumps settings for auto 10 Pump 80 Station Controller Chapter 4 Operation 58 shutdown delay alarms or blowback to the standby pump Mechanical connections must be changed manually To transfer stations from a pump to a standby pump l At any screen touch Pumps The Pump Status screen appears Both the so
103. unting plates l Install them at each node location by clipping the tubing clamps onto the vacuum tube just before the node area such as a T valve Orient the mounting plate parallel with the flat cables and at a 30 to 45 angle so the KwikLink connector or ArmorBlock faces the operator on the floor torque the tubing clamp fasteners until tight The flat cable will be installed inside KwikLink connectors and ArmorBlocks as described in the following sections of this chapter Terminating Cable Runs After you ve run the black and grey network cables you need to properly terminate the ends of the cables By doing so you ll insure that the network runs properly You will also have the benefit of being able to measure voltage in the system without disrupting operation This section lists procedures for terminating these cables To properly terminate a cable run l Mount three standard KwikLink connectors to a mounting plate in a triangle configuration See Figure 4 on Page 17 for an illustration Make sure that each connector is installed with the hinge side down Mount the tubing clamps to the mounting plates Each mounting plate requires two 2 tubing clamps Mount the standard resistor cap from the KwikLink connector kit on the top center KwikLink connector for the black power flat cable The standard resistor cap has metal prongs in the center Repeat for the outside end KwikLink connector on the grey data flat c
104. urce pump and the standby pump must be offline If either pump is any other state disable it by touching its icon briefly The icon becomes grey Move the vacuum hose from the failed pump to the standby pump and carry out any other mechanical procedures needed to use the standby pump At the Pump Status screen touch and hold the icon for any pump until the Pump n Setup screen appears At the Pump n Setup screen touch Transfer Stations To Standby Pump The Transfer to Standby Pump screen appears Standby Pump Source Destination Pump Pump None None Return Stations Pumps Password Not Active Touch Source Pump A list of available pumps pops up Scroll through the list to choose a source pump Press Return once you have selected and highlighted your desired source pump The number appears under Source Pump Touch Destination Pump A list of available pumps pops up Scroll through the list of pumps to choose a destination pump Press Return once you have selected and highlighted your desired destination pump The number appears under Standby Pump and a button labeled Press to Move Stations appears on the screen 10 Pump 80 Station Controller Chapter 4 Operation 59 Standby Pump Source Destination Pump Pump Ln 1 Pmp Ln10 Pmp Return Stations Pumps Press to Move Stations Not Active Password 10 When you enter the second pump number the controller checks to make sure that both p
105. ws at the center points about halfway down first on the latch side then the hinge side 4 Continue to tighten the screws a little at a time until fully tightened no more than 15 inch pounds 5 6 Nem of torque Note You can only pierce the cable once Once pierced the KwikLock connector must not be removed This insures that the inner conductors are not exposed to the elements The system should now be properly terminated You can now continue to install components on the system Figure 4 Proper Termination Connections MOUNTING PLATE KIT AEC ae ee CABLE TERMINATOR TYI PART NO A055517 JUTPUT POWER s z IETWORK FLAT TYPICAL 6X FLAT CABLE CABLE A0562514 es ae O poh e T 4 EH Oa Q 2 re xN 4 BLANK CA Se 3LANK CA EACH MOUNTING PLATE KIT REQUIRES 2 TUBING CLAMPS Ay IZED FOR THE CONVEYING SYSTEM VACUUM LINE USED Addressing and Installing ArmorBlocks Addressing ArmorBlocks An ArmorBlock permits you to give it a number address so that the controller network system can recognize its location and function ArmorBlocks are used at vacuum hopper receiver pump and alarm node locations ArmorBlock Address Ranges The number range of ArmorBlock addresses are as follows e 01 to 40 Vacuum hopper receiver stations use a leading zero for numbers 01 to 09 e 41 to 50 Pump stations e 51 t

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