Home

Sterling Plumbing Heat Pump 882.00254.00 User's Manual

1. 7 50D Plus or 7 50D Controller Chapter 6 Configurable Settings 77 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 Operation Names Description Cd 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 EE EE 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 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 i
2. SCC 7 Pump 50D amp D Plus Station Controllers Part Number 882 00254 00 Bulletin Number CV3 645 Effective 11 27 05 Write Down Your Serial Numbers Here For Future Reference We are committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice DCN No Copyright 2005 All rights reserved Please note that our address and phone information has changed Please reference this page for updated contact information These manuals are obsolete and are provided only for their technical information data and capacities AXCAUTION Portions of these manuals detailing procedures or precautions in the operation inspection maintenance and repair of the products may be inadequate inaccurate and or incomplete and shouldn t be relied upon Please contact the ACS Group for more current information about these manuals and their warnings and precautions Parts and Service Department The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications which will maximize your equipment s performance and efficiency To assist in expediting your phone or fax order please have the model and serial number of your unit when you contact us A customer replacement parts list is included in this manual for your convenience ACS welcomes inquiries on all your parts needs and is dedicat
3. When entering a password all four digits must be supplied For example if you enter a password of 2 here you will need to enter 0002 when the controller prompts for the password 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 Note 7 50D Plus or 7 50D Controller 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 Summary 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 Chapter 3 Installation 52 To change the duration of a password 1 Atthe System Setup screen touch Operator Password Duration or Setup Password Duration as appropriate A keypad pops up with an entry of 0 2 Enter the number of minutes range 5 99 Use lt to erase any mistakes Use J to enter the value The keypad disappears and the new setting appears under Operator or Setup Password Duration 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 scre
4. 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 conductors 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 Tei in 9 Sr SS ee keyed edge 2 50 mm white blue 0 10 in data pair 16 AWG 19 3 mm 0 76 in flat edge 7 50D Plus or 7 50D Controller Chapter 3 Installation 15 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 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
5. 48 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 To do so 1 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 number for the pump you are copying from 1 2 Follow the directions below to copy settings to one other pump a range of pumps or all pumps To copy the selected pump s settings to one other pump 1 Touch the gray Copy to Pump button next to the green Copy To Single Pump button The keypad pops up 2 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 3 Touch the green Copy To Single Pump button Complete briefly appears at the top of the screen 4 As appropriate either continue copying to other pumps or touch Return to go back to the Pump n Setup screen 7 50D Plus or 7 50D Controller Chapter 3 Installation 49 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
6. A0555195 One 1 Cord Required amp is Connected as Shown to the Grey Network Flat Cable Main Touch Screen Control Display H Blue Cable 20 ft 6 m One 1 Cord is Needed per Display as Shown Connected to the Marked Terminals of the Main amp Remote Control Boxes Remote Touch Screen a Control Display 7 50D Plus or 7 50D Controller Chapter 3 Installation 25 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 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 KwikLink 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 connec
7. ArmorBlock Mounting Plate Kit Part No A0556696 8 Input 8 Output ArmorBlock Part No A0555192 ArmorBlock Base Part No A0555191 Yellow Patch Cord 20 ft 6m Part No 40555190 D Wel CH ep E D VFC Filter Chamber 2 Attach the other connector to the lower right terminal of the ArmorBlock you used to connect the vacuum pump Tighten the cord grip ring until snug Note Retain the terminal caps from the ArmorBlock They may be used later 3 Dress the excess patch cord cables with cable ties so they do not interfere with operation and to give a pleasing appearance 7 50D Plus or 7 50D 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 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 Figure 16 Proper Central Alarm Connections Yellow Patch Cord 20 ft 6 m Part No A0555190 Vacuum Tube i os 7 Black Power Flat Cable Grey Network Flat Cable ArmorBlock Mounting Plate Kit Pa
8. Attach cable to the tubing with cable ties at about three foot 3 ft 1 m invervals 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 could disrupt system operation Figure 2 Side View of a Typical Power Cable and Data Cable Installation Cable tie buckle Pa Vacuum tube Black power cable E Grey data cable a 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 7 50D Plus or 7 50D Controller Chapter 3 Installation 16 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 require 8 connector ArmorBlocks vacuum pumps and central alarm stations require 4 connector ArmorBlocks Make sure that each mounting plate has properly attach
9. Before removing adjusting or replacing parts on a machine remember to turn off all electric supplies and all accessory equipment at the machine and disconnect and lockout electrical power Attach warning tags to the disconnect switch Be sure that all non current carrying parts are correctly connected to earth ground with an electrical conductor that complies with current codes Install in accordance with national and local codes When you have completed the repair or maintenance procedure check your work remove your tools Rigging and handling equipment Reporting a Safety Defect If you believe that your equipment has a defect that could cause injury you should immediately discontinue its use and inform the manufacturer The principle factors that can result in injury are failure to follow proper operating procedures i e lockout tagout or failure to maintain a clean and safe working environment 7 50D Plus or 7 50D Controller Chapter 1 Safety 9 Chapter 2 Functional Description 2 1 Models Covered in This Manual This manual provides operation installation and maintenance instructions for 7 Pump 50D amp D Plus 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 7 Pump 50D amp D Plus Station Conveying Controller is a programmable logic controller with 24 VDC or 115 VA
10. Chapter 6 Configurable Settings 75 Named Description FC Options Default On time Number of seconds that the each air pulse lasts during filter cleaning If blow back is not working as desired the service department may ask you to change this setting Off time Number of seconds between air pulses during filter cleaning If blow back is not working as desired the service department may ask you to change this setting Slide Gate Options Only available on 7 50D Plus systems Slide gate When this option is enabled the controller opens the slide gate between the station and the receiver during the dump delay and during blow back Enable this option if and only if the station has a slide gate instead of a flapper and demand switch Purge Options Purge When enabled this option allows the system to empty the material line completely after every convey to this station The station s pump continues to 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 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 0 1 99 0 sec 0 5 99 0 sec disa
11. 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 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 Standard KwikLink Dust Caps Connectors 4 Sei 1 2 Inside KwikLink Connector SS Inside KwikLink Connector with Blank Cap Sy ai with Blank Cap ArmorBlock Mounting Plate Kit 8 Part No A0556696 a 7 50D Plus or 7 50D Controller Chapter 3 Installation 19 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 Armo
12. The color of the icon changes to show the new status 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 p 59 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 7 50D Plus or 7 50D Controller Chapter 4 Operation 64 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 running time since the last reset To review and reset the hour meter 1 At any screen touch Pumps The Pump Summary screen appears 2 Touch and hold the icon for the pump The Pump n Setup screen appears Pump HOUR METER IDLE TIME The box labeled x Hours Resettable shows the running time since the last reset The box labeled x Hours Not Resettable shows total running time 3 To reset the resettable
13. When you touch the fourth digit the controller carries out your request For example it enables or disables the requested pump or station or it goes to the Station n Operator screen If you did not enter the correct password the controller erases the entry You can then try again To give up touch Return Note 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 expires the controller goes to the Station Summary 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 Go to a Station Operator screen To reach this screen go to the Station Summary if needed by touching Stations at any screen Then touch and hold the icon for any station until its Station Operator screen appears 2 Touch Log Off Operator near the lower right of the screen The Station Summary screen appears 7 50D Plus or 7 50D Controller Chapter 4 Operation 59 Enabling and Disabling Stations and Pumps When a station or pump is disabled the
14. a aiaiai kiiin 6 Safety Symbols Used in RE 6 1 2 Warnings and Precautions ciccy stacy tetea es aii a snaias aldate est anda itp retary big cbse Lae let pdeatueeabeueden 7 153 Responsibility ssnin eiie a E EE E aeS 8 General Ee EES 8 Operator Responsibility ccccccsccceccscseecnenaeeaaeeaaeaaaenaaeeaaanaaenaaenaaeaaaeaaaenaaeeaaeeses 9 Maintenance ReESpOnsiblility 22 01 0 0ccccccesseensseeesesessnseneneneeeensssnnsseneceetesesbaenesees 9 EROEM ais sabes ee ege 9 CHAPTER 2 FUNCTIONAL DESCRIPTION e0ee 10 2 1 Models Covered in This Manuall ccc cceenceceeeeeeeeseseeeeeeeeeeeeeensneeeseeeesenenneeeeeees 10 2 2 General Description 10 2 3 DUAN FC E 11 Mechanical EEN 11 Electrical EE 11 Controller EE 11 2 4 Optional Features 0 ccc cece cesseeeceenceeeeeeee esse eeeeeeeeseaeesaeesaeeeeeedeseeeeeeeeeeeeeeeeeeeeeeeeesees 12 2 5 Safety Devices and lnterlockS E 12 Safety Circ it Standard GE 12 Fail Sate Opetation EE 12 Safety Ee 13 CHAPTER 3 INSTALLATION ssseeeeeeeesseeeeeeeeeeaaeeeneeees 14 3 b E leie le i he crn Saar enone eae ae es ee tee ees enews de aap ed sda sede a caw pi dente needa 14 3 2 Mounting the Control Panel o isicscesccsecey cies scateecenenca ve saceeteeenecansyanees EEN tee anes dee 14 3 3 System Installation Overview ite EE REESEN Ae 14 3 4 Electrical CONN ONON S Te tafe e a e aaae aa a aap ng cei eee os eas Abe A AARE E CEAS enih em
15. connect a vacuum receiver to the network 1 Attach one connector of the yellow patch cord to the terminal on the vacuum receiver terminal box Tighten the cord grip ring until snug 2 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 The installation steps listed above also apply to the 7 50D 4 connector ArmorBlock Note the following illustrations for 4 and 8 connector ArmorBlocks Figure 10 7 50D 4 Connector ArmorBlock Connections Pump Verify A 10 Pump Starter C 00 High Vacuum A I1 Vent Solenoid C 01 Pump Fault 1 B 12 B Blowback Solenoid D 02 Pump Fault 2 B 13 E SC es A Local Alarm Light D 03 4 Input 4 Output X T Connector ArmorBlock AB 1485P P1R4 DR4 Part No A0555169 3 Dress the excess patch cord cable with cable ties so it does not interfere with operation and gives a pleasing appearance Figure 11 7 50D Plus 8 Connector ArmorBlock Connections T Connector AB 1485P P1R4 DR4 Part No A0555169 Sequence Valve E 00 Demand Switch A 10 A G f Local Alarm Light E 01 Volume Fill Prox AJ RPV Material A Solenoid F 02 Receiver Level S Slide Gate G 04 Sensor C 14 S Blowback G 05 Not used D Purge Solenoid H 06 N 8 Input 8 Output ArmorBlock 7 50D Plus or 7 50D Controller Chapter 3 Installation 28 3 Dress
16. controller makes no 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 must be in the 0 position To enable or disable a station or pump 1 Go to the Station Summary or Pump Summary 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 black with a gray outline 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 Note If the Station n Operator or Pump n Setup screen appears when you touch the icon then you have kept your finger on the screen too long Touch Stations or Pumps to return to the Summary screen and try again If you find it difficult to touch the icon briefly enough ask the setup personnel at your facility to lengthen the touch switch delay 7 50D Plus or 7 50D Controller Chapter 4 Operation 60 Reviewing and Adjusting Basic Station Settings Reaching and Reading the Station Operator Screens The 7 50D Plus or 7 50D Controller has a Station Oper
17. 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 1 Go to the Station n Operator screen as described on p 61 or go to the Station n Setup screen 2 Touch Priority Convey Activate 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 1 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 there are any inaccuracies in the proportions the mix will contain
18. following illustration for 4 connector ArmorBlocks Figure 13 4 Connector ArmorBlock Connections Pump Verify A 10 Pump Starter C 00 High Vacuum A 11 Vent Solenoid C 01 Pump Fault 1 B 12 GL l fy Blowback Solenoid D 02 Pump Fault 2 B I3 gt Local Alarm Light D 03 4 Input 4 Output T Connector ArmorBlock ABH1485P P1R4 DR4 Part No A0555169 5 Dress the excess patch cord cables with cable ties so they do not interfere with operation and to give a pleasing appearance 7 50D Plus or 7 50D Controller Chapter 3 Installation 30 Figure 14 Proper Vacuum Pump Connections Black Power Flat Cable Vacuum Tube Grey Network Flat Cable Yellow Patch Cord 20 ft 6 m Part No A0555190 Two 2 Cords Required Vacuum Pump 7 50D Plus or 7 50D Controller ArmorBlock Mounting Plate Kit Part No A0556696 4 Input 4 Output ArmorBlock Part No A0558296 ArmorBlock Base Part No A0555191 Chapter 3 Installation 31 Connecting Filter Chambers Make sure that all previous installation steps have been done first before starting this task You ll use one yellow patch cord to connect To connect a filter chamber to the network 1 Attach one connector of the yellow patch cord to the terminal on the filter chamber terminal box Tighten the cord grip ring until snug Figure 15 Proper Filter Chamber Connections Black Power Flat Cable ei Vacuum Tube 5 sek aa Grey Network Flat Cable
19. injection mold uses to make each part compared with the capacity of the receiver and b how important it is to keep your injection 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 7 50D Plus or 7 50D Controller Chapter 6 Configurable Settings 74 Name Description SC Options Default 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 Alarm Options 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 Local alarm When this opti
20. mistakes Use J 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 the 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 J 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 Complete briefly appears at the top of the screen As appropriate either continue copying to other pumps or touch Return 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 Complete briefly appears at the top of the screen Touch Return to go back to the Pump n Setup screen 7 50D Plus or 7 50D Controller Chapter 3 Installation 50 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 wid
21. safety a reality 7 50D Plus or 7 50D Controller Chapter 1 Safety 7 1 3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the machine All personnel engaged in the use of the machine should become familiar with its operation as described in this manual Proper operation of the machine promotes safety for the operator and all workers in its vicinity Each individual must take responsibility for observing the prescribed safety rules as outlined All warning and danger signs must be observed and obeyed All actual or potential danger areas must be reported to your immediate supervisor General Responsibility No mater who you are safety is important Owners operators and maintenance personnel must realize that every day safety is a vital part of their jobs If your main concern is loss of productivity remember that production is always affected in a negative way following an accident The following are some of the ways that accidents can affect your production 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 th
22. the excess patch cord cable with cable ties so it does not interfere with operation and to give a pleasing appearance Figure 12 Proper Vacuum Receiver Connections Black Power Flat Cable Sr Vacuum Tube a ea Grey Network Flat Cable na ArmorBlock Mounting Plate Kit Yellow Patch Cord 20 ft 6 m J Part No A0556696 Part No A0555190 7 50 D Plus Connections 8 Input 8 Output ArmorBlock Part No A0555192 ArmorBlock Base Part No A0555191 Vacuum Receiver 7 50D Connections 7 50D Plus or 7 50D Controller Chapter 3 Installation 29 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 You ll use two yellow patch cords to connect To connect a vacuum pump to the network 1 Attach one connector of the first yellow patch cord to the lower terminal on the vacuum pump terminal box Tighten the cord grip ring until snug 2 Attach the other connector to the upper left terminal of the ArmorBlock Tighten the cord grip ring until snug 3 Attach one connector of a yellow patch cord to the upper terminal on the vacuum pump terminal box Tighten the cord grip ring until snug 4 Attach the other connector to the upper right 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
23. these stations For each station whose receiver has a low level switch you should calibrate the sensor now and at the same time check this input To calibrate the sensor remove the receiver s cover extract the low level switch and place the switch in a container of the material that you will be using at this station Adjust the sensor according to the procedure given in the manufacturer s documentation for the switch While you are doing this check that 1 The box on this screen is green when the sensor indicates that no material is present and 2 The box is black when the sensor indicates that material is present Note You will not see any alarms for receiver low level during this procedure In order to prevent nuisance alarms when the system starts the controller s software is designed to issue these alarms only after material has been detected in the receiver at least once When you have finished calibration and checking reinstall the switch in the receiver e Pump inputs verify high vacuum fault 1 fault 2 All boxes for pump inputs should be black Because these inputs can turn on only when the pump is running it is not possible to check their operation further at this point If any input does not operate as expected check the wiring on the ArmorBlock If this does not solve the problem phone the Service Department for assistance 7 50D Plus or 7 50D Controller Chapter 3 Installation 40 Setting U
24. 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 cable 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 Discard the standard resistor cap to eliminate confusion Mount the mounting plate assembly on the vacuum line at the end of the cable run See Page 17 for more information Using the straight blade cable cutter carefully trim each flat cable so it sticks out past the final KwikLink connector by 4 to 3 s Place a dust cap over the end of the trimmed cable 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 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 Making sure that the cable is completely straight carefully close the hinged assembly and apply firm even pressure until the
25. 1 99 Use lt to erase any mistakes Use to enter the value The keypad disappears and the new setting appears under Pump Staging Setting Up Touch Switch Delay During operation the controller normally displays the Station Summary screen or the Pump Summary screen showing the current status of all stations or pumps Briefly touching the icon for a station or pump toggles between taking it offline disabling it and putting it online enabling it Touching the icon and holding it takes the user into the controller s menu system The setting for touch switch delay determines how long the user must keep an icon touched before a menu appears The factory default is 1 5 seconds You need to change this setting only if you find that users are having difficulty with the current setting To change the touch switch delay 1 Go to the System Setup screen if needed To reach this screen from the Station Summary or Pump Summary screen touch and hold the icon for any station or pump until the Station n Operator or Pump n Setup screen appears Then touch System The System Setup screen appears The current delay is displayed under Touch Switch Delay 2 Touch Touch Switch Delay A keypad pops up with an entry of 0 3 Enter the number of seconds range 0 0 99 0 As with many ATM machines the first digit you enter initially appears to the right of the decimal point and moves to the left as you enter more digits You do not need to use the dec
26. C control circuit easy to use touchscreen operator interface terminal and optional audible visual alarm 2 2 General Description Our material conveying systems create vacuum for the automatic conveying of most free flowing dry pelletized or granular materials Material characteristics determine the type of equipment needed to convey the material A typical use for our equipment is an in plant distribution system for plastic processing plants Our central vacuum systems are as varied as the applications they service The tubing and equipment furnished in our system is designed to convey the material s specified at the time of purchase at specific rates and distances We can advise you on your system capabilities based on system makeup distance material and conveying rates you want System capacity is directly affected by the pressure drop in the overall system such as number of material line bends pipe length Y tubes T tubes etc Use the minimum effective amount of vinyl flex hose to maximize material line efficiency Keep material lines as straight as possible Refer to the Mechanical Components Product manual Part No A0536580 for installation recommendations Note Vacuum leaks occurring anywhere in your system reduce capacity 7 50D Plus or 7 50D Controller Chapter 2 Functional Description 10 2 3 Standard Features Mechanical Features Time fill Capability The length of time allowed for material to drain from the
27. End Termination 87 Chapter 8 Appendix 7 50D Plus or 7 50D Controller 8 4 Spare Parts List AC Voltage Quantity Part Number Description 1 A0563932 2 1A Power Supply 1 A0569862 Input Card 1 A0572817 Output Card 2 A0569859 Air Grill with Filter 3 A0541611 Fuse MDL 75 4 A0540997 Fuse MDL 1 1 A0540993 Fuse MDL A 1 A0505812 Fuse MDL 1 25 DC Voltage Quantity Part Number Description 1 A0563993 10A Power Supply 1 A0551976 Input Card 1 A0572817 Output Card 2 A0569859 Air Grill with Filter 3 A0540997 Fuse MDL 1 4 A0542204 Fuse MDL 2 25 1 A0542208 Fuse MDL 3 2 1 A0544790 Fuse MDL 8 8 5 Returned Material Policy Credit Returns Prior to the return of any material authorization must be given by the manufacturer A RMS number will be assigned for the equipment to be returned Reason for requesting the return must be given 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 7 50D Plus or 7 50D Controller Chapter 8 Appendix 88 Warranty Returns Prior to the return of any material
28. Touch Source Pump The keypad pops up 2 Enter the number of the failed pump Use lt to erase any mistakes Use to enter the value The number appears under Source Pump 3 Touch Standby Pump The keypad pops up 4 Enter the number of the standby pump Use lt to erase any mistakes Use J to enter the value The number appears under Standby Pump and a button labeled Transfer to Standby Pump appears on the screen Return Help Note When you enter the second pump number the controller checks to make sure that both pumps 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 ofa Transfer to Standby Pump 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 7 50D Plus or 7 50D Controller Chapter 4 Operation 67 Hold a station
29. alve closes when material covers the enabled station s proximity sensor or the convey time elapses whichever comes first When disabled the station s vacuum valve remains open until the convey time has elapsed Enable this option for volume fill stations and disable it for time fill stations 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 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 alarm The setting for this option depends on a how much material your
30. 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 connectors 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 7 pump 50 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 Run the black power and the grey data KwikLink flat cables from the start of the system to the end attaching them to vacuum tubing with nylon cable ties 2 Set up mounting plates with tubing clamps install KwikLink connectors and ArmorBlocks onto mounting plates as required 3 Install KwikLink connectors and ArmorBlock cable plates to mounting plates and install on vacuum tubing at each node location just before a T fitting or valve 4 Install cable terminations 5 Determine location of network sy
31. ase of an ArmorBlock for centralized purge valves is defective Network flat cable is not properly installed in the base of an Centralized purge valve failure ArmorBlock for centralized purge valves Critical Note Once you have found and corrected the cause of this alarm enable a station p 60 that uses the purge valve for which the alarm occurred To identify such a station go to a Station Operator screen p 61 and navigate among the stations p 62 until you find a station assigned to this purge valve Once the system successfully uses this purge valve it clears the alarm and enables all other stations that use this valve Battery for the controller is defective PLC low batt Battery for the controller is old and drained Power supply for network is not turned on Power flat cable for network is not properly installed in the base of an ArmorBlock for centralized purge valves Patch cord for a centralized purge valve is disconnected Scanner communication failure Critical Scanner duplicate node Two nodes stations pumps central alarms or centralized purge valves are assigned the same address Scanner incorrect node assignment The ArmorBlock for a central alarm has an address for a station Critical The ArmorBlock for a station has an address for a pump 7 50D Plus or 7 50D Controller Chapter 7 Troubleshooting 83 Chapter 8 Appendix 8 1 Warranty The manufacturer warrants all equipment manufacture
32. asswords different from each other If the two passwords are the same as each other then any user who enters the password will have access to all functions To set or remove password protections 1 Go to the System Setup screen if needed To reach this screen from the Station Summary or Pump Summary screen touch and hold the icon for any station or pump until the Station n Operator or Pump n Setup screen appears Then touch System 7 50D Plus or 7 50D Controller Chapter 3 Installation 51 The System Setup screen appears SYSTEM PARAMETERS Stations Pumps Touch Switch Present Present Staging Delay 3 3 Sec 1 5 Sec Alarm Strobe Alarm Horn suppression Silence D Min 15 Min Operator Setup Operator Password Setup Password Password Duration Password Duration oo00 5 Min poon 5S Min The current passwords are displayed under Operator Password and Setup Password A value of 0000 means that no password is required 2 Touch Operator Password or Setup Password as appropriate A keypad pops up with an entry of 0 3 Enter up to four digits If you want to remove the password protection simply leave the entry at 0 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 and or Setup depending which passwords are now active Note
33. ator 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 Summary 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 Operator screen Once you have entered the password if needed the Station n Operator screen appears Station 1 Operator Convey Last Convey Assigned Time Ta T Pump 0 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 7 50D Plus or 7 50D Controller Chapter 4 Operation 6l Navigating 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 l 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
34. 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 workmanship Purchased components are covered under their specific warranty terms 8 6 Safety Tag Information Controller Safety Tags High Voltage Inside Enclosure Read Operation and Installation Manual 8 7 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 XXX7 50 Serial No 31K0182 Control Voltage 24VDC 7 50D Plus or 7 50D Controller Chapter 8 Appendix 89 8 8 Technical Assistance Contact Information Parts Department Call toll free 7am 5pm CST 800 423 3183 or call 630 595 1060 Fax 630 475 7005 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
35. back to the Station n Setup screen 4 Adjust settings as required Touching any box that appears in red for disabled toggles it to green for enabled and vice versa except that RPV has three settings as described below 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 You do not need to use the decimal point 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 73 77 for details on the options and their default settings 7 50D Plus or 7 50D Controller Chapter 3 Installation 44 5 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 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 th
36. ble controller with 10 color touch screen operator interface e Diagnostics operating instructions and parts information are built into the interface e Controls up to fifty 50 stations and up to seven 7 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 7 50D Plus or 7 50D Controller Chapter 2 Functional Description 11 2 4 Optional Features Options marked with indicate options that can be factory installed or retrofitted in the field 230 1 60 Operation Required to operate with a 230 1 60 supply voltage 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 Central Purge Capability Material Line Proofing includes an additional PLC located near the quick change manifold CE Package for 220 1 50 Operation Required in Europe and other areas that need 220 1 50 supply voltage 2 5 Safety Devices and Interlocks This section includes information on safety devices and procedures that are inherent to the Controller This manual is not intended to supersede or alter safety standards established by the user of this equipment Instead the material contained in this section is recommended to supplement thes
37. bled enabled disabled enabled 999 sec disabled disabled Purge valve Number address for the purge valve used with this station 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 Proofing Options Material proofing When this option is enabled the controller issues an alarm for the station if the number for Material set to does not match the number for the actual material These numbers refer to material lines Enable this option if and only if your facility has installed the option of material proofing and you want to check the material line connected to this station 7 50D Plus or 7 50D Controller Chapter 6 Configurable Settings disabled enabled 0 not assigned disabled 76 Name Description Longen Default Material set to n Number for the material line that should be 150 not connected to this station alor Material actual Display only Number address for the material line that is actually SE S this station This information is displayed for your reference in troubleshooting RPV Options RPV Remote This option allows the system to use a remote disabled disabled Proportioning Valve proportioning va
38. d 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 ArmorBlock 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 7 50D Plus or 7 50D Controller Chapter 3 Installation 21 Figure 7 Securing the Seal Block to the Cable Base Match arrows When the so the seal lines of the block is in the seal block correct meet the position over base it is the cable fully seated base To secure the seal block 1 Start the th
39. d by it to be free from defects in workmanship and material when used under recommended conditions The company s obligation is limited to repair or replace FOB the factory any parts that are returned prepaid within one year of equipment shipment to the original purchaser and which in the company s opinion are defective Any replacement part assumes the unused portion of this warranty This parts warranty does not cover any labor charges for replacement of parts adjustment repairs or any other work This warranty does not apply to any equipment which in the company s opinion has been subjected to misuse negligence or operation in excess of recommended limits including freezing or which has been repaired or altered without the company s express authorization If the serial number has been defaced or removed from the component the warranty on that component is void Defective parts become the property of the warrantor and are to be returned The company is not liable for any incidental consequential or special damages or expenses The company s obligation for parts not furnished as components of its manufactured equipment is limited to the warranty of the manufacturers of said parts Any sales use excise or other tax incident to the replacement of parts under this warranty is the responsibility of the purchaser The company neither assumes nor authorizes any other persons to assume for it any liability in connection with the
40. e Its pump will be temporarily dedicated to filling it as soon as possible Red blinking Station is in alarm Red outline blinking Critical Station is in critical alarm The controller has disabled the station until the alarm is cleared Additional basic information about each station convey time dump delay pump assignment and if enabled RPV setting purge settings and material proofing is available at the Station n Operator screen See p 61 for details Detailed configuration settings for each station are available at the Station n Setup screen See p 74 for details 7 50D Plus or 7 50D Controller Chapter 4 Operation 56 Reviewing Pump Status The Pump Summary screen is the counterpart of the Station Summary screen To reach the Pump Summary screen from any other screen 1 Touch Pumps The Pump Summary screen appears Pump Summary Pump 1 Pump 2 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 1 Touch anywhere in the rectangle in the upper right of the screen The Help Menu appears 2 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 3 When you are finished reviewing the information touch Return The Help Menu appears 4 Atthe Help Menu t
41. e list e Touch A and VY at the bottom of the list 7 50D Plus or 7 50D Controller Chapter 4 Operation 69 Clearing the Alarm Log The controller saves all alarm messages together with the date and time the alarm occurred When you no longer need the history or when the list becomes too long to manage you can erase the log To do so 1 At the Station Summary or Pump Summary screen touch Alarms The Alarm Log appears 2 Touch System on the right hand side of the screen The System Setup screen appears M PARAMETERS Stations Present Alarm Strobe Suppression D Min Pumps Pump Present Staging 3 3 Seg Alarm Horn Silence 15 Min Touch Switch Delay 1 5 Sec Operator Setup Password Setup Password Duration Password Duration Operator Password ooo0 5 Min agog 5 Min 3 Touch Clear Alarm Log A warning message pops up asking for confirmation 4 Touch Continue The System Setup screen appears To confirm that the log has been erased you can return to the Station Summary or Pump Summary screen and touch Alarms 7 50D Plus or 7 50D Controller Chapter 4 Operation 70 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 the manufacturers logo on the controller s scr
42. e 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 factory trained technician to help train your operator s for a nominal charge This section includes instructions checks and adjustments that should be followed before commencing with operation of the equipment These instructions are intended to supplement standard shop procedures performed at shift daily and weekly intervals The Operation chapter includes a description of electrical and mechanical controls in addition to information for operating the equipment safely and efficiently The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service Preventive maintenance sections are included to ensure that your equipment provides excellent long service The Troubleshooting chapter serves as a guide for identification of most common problems Potential problems are listed along with possible causes and related solutions The Appendix contains technical specifications drawings schematics and parts lists A spare parts list with part numbers specific to your machine is provided with your shipping paperwork package Refer to this section for a listing of spa
43. e others To do so 1 At the Station n Setup screen for the station you want to copy from touch Copy in the screen s upper right The Station Copy screen appears showing the station number for the station you are copying from Source Station 1 2 Follow the directions on the following pages to copy settings to one other station a range of stations or all stations 7 50D Plus or 7 50D Controller Chapter 3 Installation 45 To copy the selected station s settings to one other station l Touch the gray Copy to Station button next to the green button labeled Copy To Single Station The keypad pops up 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 Touch the green Copy to Single Station button Complete briefly appears at the top of the screen As appropriate either continue copying to other stations or touch Return to go back to the Station n Setup screen To copy the selected station s settings to a range of other stations 1 Touch First Station button next to the green button labeled The keypad pops up Enter the station number for the hopper 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 Station Copy screen shows the stati
44. e 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 e Identify and locate specific 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 w
45. e safety program can be continually reviewed maintained and improved Keep minutes or a record of the meetings Hold daily equipment inspections in addition to regular maintenance checks You will keep your equipment safe for production and exhibit your commitment to safety Please read and use this manual as a guide to equipment safety This manual contains safety warnings throughout specific to each function and point of operation 7 50D Plus or 7 50D Controller Chapter 1 Safety 8 Operator Responsibility The operator s responsibility does not end with efficient production The operator usually has the most daily contact with the equipment and intimately knows its capabilities and limitations Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates or through a casual attitude toward machinery formed over a period of months or years Your employer probably has established a set of safety rules in your workplace Those rules this manual or any other safety information will not keep you from being injured while operating your equipment Learn and always use safe operation Cooperate with co workers to promote safe practices Immediately report any potentially dangerous situation to your supervisor or appropriate person Maintenance Responsibility Proper maintenance is essential to safety If you are a maintenance worker you must make safety a priority to effectively repair and maintain equipment
46. e settings clear the alarm log and go to the network status screens e Station Setup to review and change settings for all station options e Pump Setup to review 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 Summary to enable or disable a station and start or stop system e Pump Summary 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 review the last purge time and purge valve and set the intended material line for material proofing Entering the setup password will give the user access to all functions Note If you want to protect the operator s functions with a password you must also define a setup password If you leave the setup password undefined then all users will have access to all functions If you want two different levels of password protection you must make the p
47. e taS 15 Making Control Panel Power Drop Wiring Connections sss11100000esssieeeeeeneee 15 Running KwikLink CableS iscesissscnssisssnsrrsrrrirsrnssrirsiriinirniiiririrseriererisneeisses 15 Setting Up and Installing Mounting Plates 17 Terminating Cable Funs nanenane 18 Addressing and Installing Ammorb iocke TN 20 Installing KwikLink Connectors EE 23 Connecting the Controller to the Nebwork 24 Connecting the Power Supply Enclosure to hehNetwork 26 Connecting Vacuum Receivers to the Network 28 Connecting Vacuum Pumps and Filter Chambers to the Network 0 30 Connecting Central Alarms to the Network sseeseessssseseeeeseeeeernnnesssreerrnnnnnsnseeens 33 D Re EE 35 Setting Up the SVSIOIM EE 36 Setting Up Stations E 43 Setting UP PUMPS reena erare a a nA AEEA a raaraa ar EE ARERR 47 Finishing Setup Setting Up Passwords ceseeesseetseesteeeneeeteeeseeeteeeeeeeeeeees 51 3 6 Initial Stanmtup E E E A E A A ET E AEA 53 7 50D Plus or 7 50D Controller Chapter 1 Safety 3 ERARIERACDRERGTHION egugeggegetegedereegeteggeg eege eege dee 54 Gu E e EE 54 4 2 Starting and Stopping the Systemm cece ee eeeeseeceneeceteeeeeeeeeneneeeeeeeeseeeseenenee 54 4 3 BASIC TASKS ceciccetex preiti iien eei o o ieee iienaa A sad EE aA ERAKETAK EES Tes 55 Reviewing Station Status c cccceceeseeseeesseeseeeseeeeseeeseeeseeeseeeseeeseeeeeeeseeeeeeeeeees 55 FREVIGWING gl 57 L
48. ec filter cleaning If blow back is not working as desired the service department may ask you to change this setting 7 50D Plus or 7 50D Controller Chapter 6 Configurable Settings 79 Chapter 7 Troubleshooting 7 1 General Troubleshooting Problem IL Possible cause Solution The controller panel is not Plug in the controller panel plugged in The external disconnect The controller panel doesn t light recommended in the dedicated Close the switch on up at all circuit is open off drop is blown tripped Broken controller power switch Reset the circuit breaker and EES check the motor for the proper A pump package doesn t run overload has tripped prop amp draw on tag though it i li dit Pra OI E eee ee 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 The bin below it is full if its Nonna operato hen Ihe SE f level drops material conveys to amber indicator light is off the hopper Using the controller place the The hopper is off line hopper on line A vacuum hopper is being 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 loading sequence The field installed station bypass PE switch is bad or mis wired pal Tep Leg Time the ho
49. ected Critical Solenoid patch cord has been cut Solenoid valve has malfunctioned Material line is blocked Vacuum line is blocked Convey time is too long time fill station only High vacuum Sequence valve has malfunctioned Vacuum switch has malfunctioned Note After you have corrected the cause of this alarm the alarm will be cleared when the controller has conveyed a full load to this station Local alarm s light bulb is defective Patch cord for local alarm is disconnected Local alarm output failure Patch cord for local alarm has been cut Note As a stopgap measure you can disable the alarm output for this station until the problem can be remedied See pp 43 and 74 Material container is empty Material line is disconnected from material source Vacuum line is disconnected from station No convey Take off compartment is not adjusted properly Convey time is too short Note As a stopgap measure you can disable the no convey alarm for this station until the problem can be remedied See pp 43 and 74 Not assigned to a pump r Critical Station has not been assigned to a pump ArmorBlock is not installed Not present ArmorBlock is not addressed properly Critical ArmorBlock is defective l Base of ArmorBlock is defective Network flat cable is not installed in base properly Power supply is not turned on Power supply is not connected properly Power supply s incoming fuse s have failed Power supply s outp
50. ed to providing excellent customer service For immediate assistance please contact e North Central and South America 8am 5pm CST 1 800 483 3919 for drying conveying heating and cooling and automation For size reduction 1 800 229 2919 North America emergencies after 59m CST 847 439 5855 North America email acsuscanadacustserv corpemail com e Mexico Central amp South America Email acslatinamericacustserv corpemail com e Europe Middle East amp Africa 48 22 390 9720 Email acseuropecustserv corpemail com e India 91 21 35329112 Email acsindiacustserv corpemail com e Asia Australia 86 512 8717 1919 Email acsasiacustserv corpemail com Sales and Contracting Department Our products are sold by a worldwide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Let us install your system The Contract Department offers any or all of these services project planning system packages including drawings equipment labor and construction materials and union or non union installations For assistance with your sales or system contracting needs please Call North Central and South America 1 262 641 8600 or 1 847 273 7700 Monday Friday 8am 5pm CST Europe Middle East Africa 48 22 390 9720 India 91 21 35329112 Asia Australia 86 512 8717 1919 Facilities ACS offers facilities around the world to service you no matter where yo
51. ed tube clamps as required Each mounting plate requires two 2 tube clamps Always use locking washers especially in high vibration environments Figure 3 Side View of a Typical Mounting Plate Assembly with ArmorBlock Base A Rotate 30 to 45 downward Installing Assembled Mounting Plates After you ve set up the mounting plates 1 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 2 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 7 50D Plus or 7 50D Controller Chapter 3 Installation 17 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 19 for an illustration Make sure that each connector is installed
52. een changes to an Alarm Silence button To silence the alarm 1 Touch Alarm Silence in the lower right hand corner of the screen The horns and lights at the central alarms turn off The local alarm light stays on The button changes back to the company logo Your controller has separate configurable 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 7 50D Plus or 7 50D Controller Chapter 4 Operation 71 Chapter 5 Maintenance 5 1 5 2 Preventative Maintenance No preventative maintenance is required on this unit Corrective Maintenance Network Scanner Module Considerations The manufacturer includes a network scanner software diskette with your controller this diskette and instructions are located in your Customer Information Packet Keep this diskette and the instructions in a safe place Should the network scanner module require replacement use the scanner software to restore the program You can e Purchase a programmed replacement scanner module from the manufacturer e In extreme cases you can purchase the module from your local Allen Bradley dealer and program it yourself with the scanner software diskette you can also have your A B dealer do that for you We suggests that yo
53. en touch Stations on the right hand side of the screen The Station Summary 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 Summary 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 system starts If any alarm messages appear on the top of the screen see p 71 7 50D Plus or 7 50D Controller Chapter 3 Installation 53 Chapter 4 Operation 4 1 Overview Your 7 50D Plus or 7 50D 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 and clearing alarms Note Before you carry out any of the procedures in this chapter the system must be set
54. erminal of the controller marked NETWORK NO 1 Tighten the cord grip ring until snug 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 seated 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 2 Determine the length of blue remote cable you need and cut it to length Run the cable from the remote interface to the main controller neatly dressing the cable with cable ties so it does not interfere with system operation and to give it a neat appearance Attach connectors at each end following the connector manufacturer s instructions Attach one connector to the remote interface terminal marked REMOTE DISPLAY Tighten the cord grip ring until snug Attach the other connector to the terminal of the controller marked REMOTE DISPLAY Tighten the cord grip ring until snug 7 50D Plus or 7 50D Controller Chapter 3 Installation 24 Figure 8 Proper Controller and Remote Interface Connections ArmorBlock Mounting Plate Kit Black Power Flat Cable Part No A0556696 Vacuum Tube Grey Network Flat Cable pala Power or Network Tap Cable Drop Part No
55. f 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 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 Blow Back 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 filter 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 through the pump s filter during cleaning If blow back is not working as desired the service department may ask you to change this setting 7 50D Plus or 7 50D Controller Chapter 6 Configurable Settings 78 Name Description SC Options Default On time Number of seconds that the air compressor 0 1 99 0 sec 1 0 sec remains on for each pulse during filter cleaning If blow back 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 5 99 0 s
56. first latch locks into place Note Make sure that the flat cable is completely staight 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 7 50D Plus or 7 50D Controller Chapter 3 Installation 18 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
57. 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 2 Touch Return The Pump n Setup screen appears 3 Touch Pumps The Pump Summary 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 7 50D Plus or 7 50D Controller Chapter 4 Operation 68 3 5 Alarms Reviewing Alarms At the Station Summary or Pump Summary screen 1 Touch Alarms The Alarm Log screen appears with the newest alarm listed first put Power Failure ot ned put Failure ut Failure To scroll up and down through th
58. ill go to the open condition tripping out the safety circuit 7 50D Plus or 7 50D Controller Chapter 2 Functional Description 12 At no time should the safety device fail and allow the operation to continue for example if a safety switch is guarding a motor and the safety switch fails the motor should not be able to run Safety Device Lock Outs Some safety devices disconnect electrical energy from a circuit The safety devices that are used in this Controller are primarily concerned with electrical power disconnection WARNING Always disconnect and lockout all electrical power and pneumatic i e compressed air sources prior to servicing the 7 Pump 50D amp D Plus Station Controller Failure to do so may result in serious injury No one but the person who installed the lockout may remove it 7 50D Plus or 7 50D Controller Chapter 2 Functional Description 13 Chapter 3 Installation 3 1 Uncrating 7 Pump 50D amp D Plus 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
59. imal point Use lt to erase any mistakes Use J to enter the value The keypad disappears and the new setting appears under Touch Switch Delay 7 50D Plus or 7 50D Controller Chapter 3 Installation 42 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 73 77 discusses the individual choices Setting Up a Single Station 1 Go to the Station Summary screen if needed To reach this screen from any other screen touch Stations on the right hand side of the screen The Station Summary screen appears 2 Touch the icon for the station you want to set up and hold it for several seconds The Station n Operator screen for the selected station appears Convey Last Convey Assigned Time Time To 30 Sec D Sec Pump 0 7 50D Plus or 7 50D Controller Chapter 3 Installation 43 3 Touch Setup at the Station n Operator screen The Station n Setup screen appears Convey Dumop Time ii i Delay 30 Sec Attempts Attempts B4 Alarm ER B4 Alarm 5 On Pulse is Time Material set To Cycle Time 10 Sec 7 50D Plus shown Note Touching Help in the lower right of this screen gives you a menu of online help for the choices in this screen Touching Return at the help menu brings you
60. ins 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 1 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 7 50D Plus or 7 50D Controller Chapter 6 Configurable Settings 73 Name L eseegeon FSC Options __ Default Conveying Options Assigned to pump n Number address of the pump to which this 0 7 0 not station s vacuum line is connected assigned No more than 20 stations can be assigned to one pump Volume fill When this option is enabled the station s disabled disabled vacuum v
61. k 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 18 below gives an overview of the basic flow between the menus used in setting up the system Figure 18 Basic Menu Flow for Setup Station hold icon hold icon Station n eeng Pump n Operator 7 Setup Setup System Station n System Setup Greg Setup DeviceNet Node Status DeviceNet Input Status 7 50D Plus or 7 50D Controller Chapter 3 Installation 35 Setting Up the System Setting the Number of Stations and the Number of Pumps At the Station Summary screen shown above or at the Pump Summary screen 1 Touch the icon for any station or pump and hold it for several seconds When the controller arrives from the factory only one icon appears A Station Operator screen similar to the following appears If you started at the Pump Summary screen the Pump n Setup screen appears instead Convey Last Convey Assigned Time Time To 30 Sec O Sec Pump 0 7 50D Plus or 7 50D Controller Chapter 3 Installation 36 2 Touch System at the Station n Operator or Pump n Setup screen The System Setup screen appears Convey Dumop Time Delay 30 Sec 10 Sec Pulse is Losdtai Purge Purge D
62. ket 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 keyed edge is toward the 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 7 50D Plus or 7 50D Controller Chapter 3 Installation 23 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 l Attach the keyed round connector to the t
63. l copies are available from the manufacturer Follow all SAFETY CODES Wear SAFETY GLASSES and WORK GLOVES Work only with approved tools and devices Disconnect and or lock out power before servicing or maintaining the equipment Use care when LOADING UNLOADING RIGGING or MOVING this equipment Operate this equipment within design specifications OPEN TAG and LOCK ALL DISCONNECTS before working on equipment You should remove the fuses and carry them with you Make sure the equipment and components are properly GROUNDED before you switch on power Use 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
64. lt Back 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 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 J to enter the value To exit to the Station Summary or Pump Summary screen touch Stations or Pumps 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 incorrect l Material is backing up and causing high vacuum alarms for time fill stations only Convey time is too long 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 ma
65. lve 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 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 99 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 Cycle time Number of seconds for each cycle in depositing 5 999 sec 10 sec Material A and Material B during the convey time This setting applies only when RPV is enabled with PLC control Example If you set convey time to 30 seconds cycle time to 10 seconds 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 The cycle time should divide evenly into the convey time
66. me fill station the box labeled Volume Fill Prox should be black no further check is needed for these stations For each volume fill station you should calibrate the sensor now and at the same time check this input To calibrate the sensor remove the station s cover extract the volume fill proximity switch and place the switch in a container of the material that you will be using at this station Adjust the sensor according to the procedure given in the manufacturer s documentation for the switch While you are doing this check that 1 The box on this screen is green when the sensor indicates that no material is present and 2 The box is black when the sensor indicates that material is present Then reinstall the switch in the station 7 50D Plus or 7 50D Controller Chapter 3 Installation 39 c Station bypass switch For every station the box labeled Bypass Switch should match the state of the switch at the station Flip the switches at the stations in order to check that 1 Each station s box is black when its bypass switch is in the 0 position station ready to convey and 2 Each station s box is green when its bypass switch is in the 1 position station bypassed Leave each station with its bypass switch off in the 0 position d Station receiver level For each station whose receiver has no low level switch the box labeled Receiver Level should be black no further check is needed for
67. meter touch Hour Meter Reset The time above Hours Resettable changes to 0 7 50D Plus or 7 50D Controller Chapter 4 Operation 65 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 shutdown delay alarms or blow back 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 Summary screen appears Both the source 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 black with a gray outline 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 Summary 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 7 50D Plus or 7 50D Controller Chapter 4 Operation 66 1
68. 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 p 61 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 4 to enter the value The new setting appears under RPV Material B 7 50D Plus or 7 50D Controller Chapter 4 Operation 63 Changing the Line with Material Proofing When this option is enabled the controller issues an alarm for the station if the number for Material set to does not match that of the actual material These numbers refer to material lines To change the line when using material proofing 1 Go to the Station Summary screen if needed by touching Stations on the right hand side of any other screen 2 Disable the station take it offline by touching its icon briefly The icon becomes black with a gray outline 3 Switch lines physically 4 Atthe controller go to the Station n Operator screen as described on p 61 or go to the Station n Setup screen 5 TouchMaterial Set To A keypad pops up 6 Enter the number for the new material line Use lt to erase any mistakes Use J to enter the value The new setting appears underMaterial Set To 7 Touch Stations The Station Summary screen appears 8 Enable the station put it online by touching its icon briefly
69. nt black 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 50 should be black 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 1 Atthe DeviceNet Node Status screen touch DeviceNet Input Status near the lower right of the screen 7 50D Plus or 7 50D Controller Chapter 3 Installation 38 The DeviceNet Input Status screen appears Return Station numbers are stacked vertically as column headings in this screen 2 Check that all inputs are on green or off black as expected and that they switch on and off as required a Station demand switch In a new installation the box labeled Demand Switch should be green for every station vacuum hopper in the system All other boxes for demand switches will be black In a retrofit at an existing installation each station s Demand Switch box should be green unless the receiver bin under the station is in fact full b Station volume fill proximity switch For each ti
70. ogging On and Logging EE 59 Enabling and Disabling Stations and Pumps eee teteentnneeeeeeeeenenee 60 Reviewing and Adjusting Basic Station Settings ccccccccceseeesstiteeeeeeeeeeeene 61 4 4 Advanced WR 64 Reviewing and Resetting a Pump Hour Meier 65 Transferring Stations to a Standby Pump ns c0 scccceces eleven bento eeseec teenies 66 E En EE 69 Reviewing AlarMS ee tere serie Ne des EEN deet 69 Clearing the Alarm LOG EE 70 Sil ncng EE 71 CHAPTER 5 MAINTENANCE cscceeeeeeeessseeeeeeeeeaaeeeeeeees 72 5 1 Preventative Maintenances vierge ENK ae ENekkeiekNed eher EeEERSSSE ENEE eeE 72 5 2 Corrective Maintenance EE 72 Network Scanner Module Considerations ccccccccccceeeeetteeeeeeeteeeennieeeeeeeeenenee 72 CHAPTER 6 CONFIGURABLE SETTINGG cceeeeee 73 6 1 Memory Module Considerations cccccceeeeseseeeeeeeeeeeeeneeeeesenseeeeeseseeseseneseenene 73 6 2 Options for Station Setup cccccccccceececcccaeeeaeeeaeeeaeeeaeeeaeeaaeseaaeeaaeeaaeaaaeeaaeeaaeeaaaaaes 73 6 3 Options for PUMP SEU sste irer ea e a a a ae ee 78 CHAPTER 7 TROUBLESHOOTING c c sscseeeeeeeesseeeeeeees 80 to General Glen ENEE ee 80 LEET 81 SlQUOMAIANNS EE 81 PUMP Alanis iis cs nets is A ai deeg a a a a as 82 EE 83 CHAPTER 8 APPENDIX ainainen a aaae EE EAE aA 84 e 84 Warranty Zpectificattons Error Bookmark not defined Warranty Restrictions 2 0cccececenskeetceeeeeeeeeese
71. on Summary screen appears EM 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 1 Touch anywhere in the rectangle in the upper right of the screen The Help Menu appears 2 Inthe section of the Help Menu labeled Screen Symbols Colors touch Station The Station Symbols help screen appears explaining the status represented by each color 3 When you are finished reviewing the information touch Return The Help Menu appears 4 Atthe Help Menu touch Stations or Pumps The Station Summary or Pump Summary screen appears 7 50D Plus or 7 50D Controller Chapter 4 Operation 55 The following table explains the status represented by each color at the Station Summary screen Gray outline Station is not enabled The controller ignores any demands or alarms Station is enabled and idle full Station requires material Green Loading Station is being loaded with material or is dumping material into its receiver The material line is being purged of material Light Blue The station is dumping material into its receiver Blue blinking Blow Back Station s air filter is being cleaned by blowing compressed air backward through it Black blinking Bypass switch at the station has been turned on disabling the station Green blinking Priority Station is in priority convey mod
72. on company Substantiate the claim by referring to the agent s report A certified copy of our invoice is available upon request The original Bill of Lading is attached to our original invoice If the shipment was prepaid write us for a receipted transportation bill Advise customer service regarding your wish for assistance and to obtain an RMA return material authorization number If the Shipment is Not Complete Check the packing list as back ordered items are noted on the packing list In addition to the equipment itself you should have M Bill of lading M Packing list M Operating and Installation packet KM 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 shipping department immediately For shipments in the United States and Canada call 1 630 595 1060 for all other countries call our international desk at 630 595 1060 Have the order number and item number available Hold the items until you receive shipping instructions Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department 7 50D Plus or 7 50D Controller Chapter 1 Safety 2 Table of Contents CHAPTER 1 SAFETY EEN 6 t f Howto Use Klaue euer EE iae
73. on 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 Miscellaneous Options Receiver 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 Blow Back Options Only available on 7 50D Plus systems 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 if and only if the station has the equipment for compressed air filter cleaning Every n loads Number of conveying cycles 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 pulses Number of pulses of compressed air sent through the station s filter during cleaning If blow back is not working as desired the service department may ask you to change this setting 7 50D Plus or 7 50D Controller
74. on number you entered under First Station Touch Last Station button next to the light grey button labeled First Station The keypad pops up 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 J to enter the value The keypad disappears and the Station Copy screen shows the station number you entered under Last Station Touch the green Copy To Range of Stations button Complete briefly appears at the top of the screen As appropriate either continue copying to other stations or touch Return to go back to the Station n Setup screen To copy the current station s settings to all other stations l 2 Touch the green Copy To All Stations button Complete briefly appears at the top of the screen Touch Return to go back to the Station n Setup screen 7 50D Plus or 7 50D Controller Chapter 3 Installation 46 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 pp 78 79 discusses the individual choices Setting Up a Single Pump 1 Go to the Pump Summary screen To reach this screen from any other screen touch Pumps on the right side of the screen The Pump Summary screen appears Pump Summa P
75. ouch Pumps or Stations The Pump Summary or Station Summary screen appears 7 50D Plus or 7 50D Controller Chapter 4 Operation 57 The following table explains the status represented by each color at the Pump Summary screen Blue 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 Loading Pump is conveying material to a station Blue blinking Blow Back Pump s air filter is being cleaned by blowing compressed air backward through it Red blinking Red outline blinking Critical Pump is in critical alarm The controller has disabled the pump until the alarm is cleared 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 p 78 For details on the hour meter see p 65 7 50D Plus or 7 50D Controller Chapter 4 Operation 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 keypad appears when you touch a button for a screen that requires a password e Enter the four digit password including any leading zeros For example if the password is 1 enter 0001 Each digit appears as an X as you touch it
76. p Alarm Silences When an alarm occurs a horn sounds and a strobe light flashes at each installed central alarm The lower right corner of the controller s screen turns into a button labeled Alarm Silence 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 the DeviceNet Input Status or DeviceNet Node Status screen touch Return until the System Setup screen appears To reach this screen from the Station Summary or Pump Summary screen touch and hold the icon for any station or pump until the Station n Operator or Pump n Setup screen appears Then touch System The System Setup screen appears TEM PARAMETERS Stations Pumps Pump Touch Switch Present Present Staging Delay 15 3 3 Sec lee See Alarm Strobe Alarm Horn Suppression Silence 0 Min 15 Min Operator Setup Operator Password Setup Password Passvord Duration Password Duration ooo0 5 Min agog 5 Min The current setting are displayed under Alarm Strobe Suppression and Alarm Horn Silence 2 Touch Alarm Strobe Suppression or Alarm Horn Silence as appropriate A keypad pops up with an entry of 0 3 Enter the number of minutes
77. 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 800 233 4819 or call 630 595 1060 Emergencies after 5pm CST call 847 439 5655 We have a qualified service department ready to help Service contracts are available for most products Sales Department Call 630 595 1060 Monday Friday 8am 5pm CST Our products are sold by a world wide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Contract Department Call 630 595 1060 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 7 50D Plus or 7 50D Controller Chapter 8 Appendix 90
78. pper s during Conveying limes are too long loading and set conveying times EE 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 Replace fuse with one that has a Improper fuse installed j proper rating Vacuum hoppers are over filling Maximum conveying times are too long and or the controller does not recognize the Hopper Full proximity switch es 7 50D Plus or 7 50D Controller Chapter 7 Troubleshooting 80 7 2 Alarms The format for all station alarms 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 Note 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 Summary or the Pump Summary screen or touch Help at any other screen When you are finished reviewing the help touch Return Station Alarms Possible cause Blow back output failure Solenoid patch cord is disconn
79. rBlock addresses are as follows e 01 to 50 Vacuum hopper receiver stations use a leading zero for numbers 01 to 09 e 51 to 57 Pump stations e 58 to 60 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 0 and the LSD rotary switch is set at 1 Figure 5 ArmorBlock Address Node Rotary Switches o i i o Set MSD 0 e H Q Se Sel 7 50D Plus or 7 50D Controller Chapter 3 Installation 20 Installing ArmorBlocks The ArmorBlock cable base shoul
80. range 0 99 If you want the light or the horn to stay on as long as the alarm persists simply leave its entry at 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 7 50D Plus or 7 50D Controller Chapter 3 Installation 4 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 three 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 the next 1 Go to the System Setup screen if needed To reach this screen from the Station Summary or Pump Summary screen touch and hold the icon for any station or pump until the Station n Operator or Pump n Setup screen appears Then touch System The System Setup screen appears The current delay is displayed under Pump Staging 2 Touch Pump Staging A keypad pops up with an entry of 0 3 Enter the number of seconds range
81. re parts for purchase Have your serial number and model number ready when ordering Safety Symbols Used in this Manual The following safety alert symbols are used to alert you to potential personal injury hazards Obey all safety messages that follow these symbols to avoid possible injury or death Danger DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury Warning WARNING indicates a potentially hazardous situation or practice which if not avoided could result in death or serious injury Caution CAUTION indicates a potentially hazardous situation or practice which if not avoided may result in minor or moderate injury or in property damage 7 50D Plus or 7 50D Controller Chapter 1 Safety 6 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 i A RA RR RH E v Read and follow these operation and installation instructions when installing operating and maintaining this equipment If these instructions become damaged or unreadable additiona
82. reads 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 pierced 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 7 50D Plus or 7 50D Controller Chapter 3 Installation 22 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 Pac
83. rt No A0556696 4 Input 4 Output ArmorBlock Es Part No A0558296 ArmorBlock Base Part No A0555191 E Yellow Patch Cord 20 ft 6 m lt gt Part No A0555190 Push to Silence Button Remote Alarm 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 7 50D Plus or 7 50D Controller Chapter 3 Installation 33 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 ArmorBlocks Figure 17 4 Connector ArmorBlock Connections for Central Alarms Alarm Silence Pushbutton A 10 Alarm Strobe Light C 00 Alarm Silence Pushbutton A 11 Alarm Horn C 01 Alarm Silence Pushbutton B 12 Ss Alarm Strobe Light D 02 Alarm Silence Pushbutton B 13 JON Alarm Horn D 03 4 Input 4 Output lt 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 7 50D Plus or 7 50D Controller Chapter 3 Installation 34 3 5 Setup This section provides the procedures for configuring your 7 50D Plus or 7 50D controller Configuration of your controller includes setting the number of stations and pumps setting variables such as convey time and blow bac
84. sale of its equipment not expressed in this warranty Many types of the manufacturer s equipment carry an additional one year service policy Consult your sales representative for specific details 8 2 Optional Components The following is 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 Central Purge Capability Material Line Proofing includes an additional PLC located near the quick change manifold CE Package for 220 1 50 Operation Required in Europe and other areas that need 220 1 50 supply voltage 7 50D Plus or 7 50D Controller Chapter 8 Appendix 84 8 3 Drawings and Diagrams Figure 19 7 pump 50 station Controller with Display 79 Depth dimension is Also review electrical drawings supplied in the packet with this manual 7 50D Plus or 7 50D Controller Chapter 8 Appendix 85 Figure 20 Typical System Installation Layout 7 50D Plus or 7 50D Controller Chapter 8 Appendix 86 Left End Termination Vacuum Pump Main Control Touch Screen Display Optional Remote Touch Screen Display oa oa Power Supply d Central Alarm with Shutoff Switch Vacuum Receiver Det a ZC Right
85. station to its receiver During this time the controller does not attempt to deliver any more material to the station Volume fill Capability The length of time a station s vacuum valve remains open to allow material to be drawn in The vacuum valve will close when material covers the station s volume fill proximity sensor or this time elapses whichever comes first Vent Valve Output The vent valve protects the pump motor from damage during high vacuum conditions if an undetected failure of the vacuum switch should occur The vent valve limits system vacuum by allowing a plunger in the valve to shift and vent the pump Closed Loop Conveying This feature allows material to be conveyed and processed without being contaminated by outside influences such as dust other materials etc Common Purge Valve Output Control for Each Pump This feature allows any remaining material to be cleaned out of the vacuum pump or station Local Blowback Filter Cleaning Outputs When this feature is enabled the controller periodically sends compressed air backward through the pump s air filter to dislodge accumulated dust and debris Electrical Features e 115 1 60 or 230 1 50 60 supply voltage e 24 VDC control voltage e Single point power and ground connection e Non fused disconnect switch lockable e Branch circuit fusing e Fully accessible NEMA 4 style electrical control enclosure Controller Features e Allen Bradley SLC 5 04 programma
86. stem 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 50D Plus or 7 50D Controller Chapter 3 Installation 14 7 After determining quantity and location s of where to install system power supply ies consult factory set up and connect to KwikLink connectors installed in Step 3 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 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 230 1 50 60 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
87. t Solenoid B for remote proportioning valve has malfunctioned Patch cord for sequence valve is disconnected Sequence valve output failure Critical Patch cord for sequence valve has been cut Solenoid for sequence valve has malfunctioned Patch cord for slide gate is disconnected Slide gate output failure Patch cord for slid te has b t Critical atch cord for slide gate has been cut Solenoid for slide gate has failed Pump Alarms i Blow back output failure S SEH Local alarm output failure Note As a stopgap measure you can disable the local alarm output WE Ce Output power failure Critical 7 50D Plus or 7 50D Controller Chapter 7 Troubleshooting 82 Alarm message Possible cause Output power failure Power flat cable for network is not installed in ArmorBlock base Critical properly Pump failure Circuit breaker or overload protector has tripped Critical Contactor has malfunctioned Pump fault 1 Function determined by your facility Pump fault 2 Function determined by your facility Patch cord for contactor is disconnected Pump starter output failure a Patch cord for contactor has been cut Critical es Contactor coil is defective f Patch cord for vent is disconnected Vent solenoid output failure Critical Patch cord for vent has been cut Vent solenoid valve has malfunctioned System Alarms E failure An ArmorBlock for centralized purge valves is defective Critical B
88. tee Error Bookmark not defined Warranty EIER iesse Error Bookmark not defined Customer Responsibilities ccssesseesteeneeeees Error Bookmark not defined 8 2 Optional Components cece e a cesses eee E E EE E EE 84 8 3 Drawings and DiagramS o eutee0eekeEdEEeE dE EES EAeEERAEN EEN ec 85 O 46s Spare Pams E EE 88 AGC ee GE 88 DOV ET EE 88 8 5 Returned Material Policy sei ovouagereegesedek eko ege nt ey dae eu Eed 88 UE 88 Warranty EIERE EE Eet 89 7 50D Plus or 7 50D Controller Chapter 1 Safety 4 8 6 Safety Tag Information EEN 89 Controller Safety EE 89 8 7 Controller Identification Serial Number Tag 89 8 8 Technical Assistance Contact Intormaton 90 Parts earen eege ger Asti E iene dag ER ee asda 90 Service Department 90 Sales Department 90 Contract Department Tassignon sah etreeda Eden Sead EEN gs Saat vada toca tae Saas 90 7 50D Plus or 7 50D Controller Chapter 1 Safety 5 Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining your equipment The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This manual covers only light corrective maintenance No other maintenance should be undertaken without first contacting a service engineer The Functional Description section outlines models covered standard features and optional features Additional sections within th
89. terial 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 61 or go to the Station n Setup screen Touch Convey Time or Dump Delay A keypad pops up 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 Note If you change convey time by more than a few seconds for a station with a remote proportioning valve RPV notify the setup personnel at your facility The setting for the RPV s cycle time should be adjusted to divide evenly into the new convey time see pp 43 and 77 7 50D Plus or 7 50D Controller Chapter 4 Operation 62 Activating and Stopping Priority Convey for a Station Note 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 a head start by
90. tor 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 7 50D Plus or 7 50D Controller Chapter 3 Installation 26 Figure 9 Proper Power Supply Enclosure Connections Black Power Flat Cable Vacuum Tube CR NM Grey Network Flat Cable Se ArmorBlock Mounting Plate Kit Part No A0556696 Power Cable Part No A0555195 Two 2 Cords Required _ Power Supply Enclosure 7 50D Plus or 7 50D Controller Chapter 3 Installation 27 Connecting Vacuum Receivers to the Network Make sure that all previous installation steps have been done first before starting this task To
91. u are located For more information please visit us at www acscorporate com United States Asia Australia India ACS India ACS Schaumburg Corporate Offices ACS Suzhou Gat No 191 1 Sandbhor Complex 1100 E Woodfield Road 109 Xingpu Road SIP Mhalunge Chakan Tal Khed Suite 588 Suzhou China 215126 Dist Pune 410501 India Schaumburg IL 60173 Phone 86 8717 1919 Phone 91 21 35329112 Phone 1 847 273 7700 Fax 86 512 8717 1916 Fax 91 20 40147576 Fax 1 847 273 7804 i Europe Middle East Africa ACS New Berlin Manufacturing Facility 2900 S 160 Street ACS Warsaw New Berlin WI 53151 UI Dzia kowa 115 Phone 1 262 641 8600 eee a Phone 48 22 390 9720 Fax 48 22 390 9724 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 transportati
92. u have a preprogrammed spare network scanner module on hand for such conditions 7 50D Plus or 7 50D Controller Chapter 5 Maintenance 72 Chapter 6 Configurable Settings 6 1 This section describes the proper setup of the 7 50D Plus or 7 50D 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 The modules are installed in the back of the controller interface chassis and on the PLC CPU card The memory module returns the controller to the factory default settings if an electrical fault occurs or if the hardware is replaced Keep in mind that this condition is extremely rare You will then need to set up the controller once again with the settings you programmed in this chapter Options for Station Setup Name Description Options Debut Conveying Options Convey time Length of time the station s vacuum valve 1 999 sec 30 sec rema
93. ump 1 Pump 2 2 Touch the icon for the pump you want to set up and hold it for several seconds The Pump n Setup screen appears IDLE TIME Moura Reszetable 7 50D Plus or 7 50D Controller Chapter 3 Installation 47 Note Touching Help in the lower right of this screen gives you a menu of online help for the choices in this screen Touching Return at the help menu brings you back to the Pump n Setup screen 3 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 You do not need to use the decimal point Use lt to erase any mistakes Use J to enter the value The keypad disappears and the Pump n Setup screen shows the new value in the selected gray box See pp 73 77 for details on the options and their default settings 4 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 or c Touch Next P to go to the Pump 1 Setup screen or d Touch Goto and enter a pump number to go to that pump s setup screen 7 50D Plus or 7 50D Controller Chapter 3 Installation
94. up as described in the previous chapter 4 2 Starting and Stopping the System Note 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 yellow when they need material Icons for enabled pumps are yellow Enabling stations and pumps is described on p 60 A button to start and stop the system is located in the lower right of the Station Summary Pump Summary 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 Note 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 7 50D Plus or 7 50D Controller Chapter 4 Operation 54 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 Summary screen To reach this screen from any other screen 1 Touch Stations The Stati
95. uration Valve 20 Sec 0 Cycle Time 10 Sec Note Touching Help in the lower right of this screen gives you a menu of online help for the choices in this screen 7 50D Plus Screen shown Touching Return at the help menu brings you back to the System Setup screen 3 Touch Stations Present in the upper left of the System Setup screen A keypad pops up 4 Enter the total number of stations 1 50 to be controlled by this controller Use lt to erase any mistakes Use to enter the value The keypad disappears and the new setting appears under Stations Present 5 Touch Pumps Present in the upper part of the System Setup screen A keypad pops up 6 Enter the total number of pumps 1 7 to be controlled by this controller Use lt to erase any mistakes Use to enter the value 7 The keypad disappears and the new setting appears under Pumps Present 7 50D Plus or 7 50D Controller Chapter 3 Installation 37 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 System Setup screen touch DeviceNet Node Status near the lower right of the screen The DeviceNet Node Status screen appears 2 Check that the expected components are shown as present green and not prese
96. ut circuit breaker has tripped ArmorBlock is defective Base of ArmorBlock is defective Power flat cable for network is not installed in ArmorBlock base properly Output power failure Critical 7 50D Plus or 7 50D Controller Chapter 7 Troubleshooting 81 Possible cause Pick up wand is not positioned properly Convey time is too short Take off compartment is not adjusted properly Vacuum line has a leak Note As a stopgap measure you can disable the partial convey alarm for this station until the problem can be remedied See pp 43 and 74 Solenoid patch cord is disconnected Partial convey Purge output failure Critical Solenoid patch cord has been cut Solenoid valve has failed Purge valve not assigned Critical Station has not been assigned to a purge valve Conveying system has malfunctioned Station has been disabled at controller s touch screen Receiver low level Station s bypass switch is active Note As a stopgap measure you can disable the receiver low level alarm for this station until the problem can be remedied See pp 43 and 75 RPV material A failure Patch cord for remote proportioning valve is disconnected Critical Patch cord for remote proportioning valve has been cut Solenoid A for remote proportioning valve has malfunctioned RPV material B failure Patch cord for remote proportioning valve is disconnected Critical Patch cord for remote proportioning valve has been cu

Sterling Plumbing Heat Pump 882.00254.00 User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents