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ACS A0565547 User's Manual

1. Idle Time Options Length of time the pump continues to run unloaded 0 999 sec 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 energy savings against the costs associated with waiting for a pump to start up when there is a demand for material Alarm Options General Pump fault The control has one input pump that you can wire to disabled disabled generate alarms for situations of your choosing For enabled 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 turns on Enable this option if and only if your facility has installed a miscellaneous alarm on the input for Pump Fault for this pump Pump Filter Cleaning Options Vacuum pulsed filter When this option is enabled the controller disabled disabled cleaning periodically sends compressed air backward through vacuum pulse Compressed air filter the pump s air filter to dislodge accumulated dust and enabled 5 cleaning debris comp air Enable this option if and only if the pump has the enabled equipment for compressed air filter cleaning Conveys before Number of conveying cycles to stations between filter cleaning cleanings Adjust this setting based on experience T
2. Immediately report any potentially dangerous situation to your supervisor or appropriate person Maintenance Responsibility Proper maintenance is essential to safety If you are a maintenance worker you must make safety a priority to effectively repair and maintain equipment Before removing adjusting or replacing parts on a machine remember to turn off all electric supplies and all accessory equipment at the machine and disconnect and lockout electrical power Attach warning tags to the disconnect switch Be sure that all non current carrying parts are correctly connected to earth ground with an electrical conductor that complies with current codes Install in accordance with national and local codes When you have completed the repair or maintenance procedure check your work remove your tools Rigging and handling equipment Reporting a Safety Defect If you believe that your equipment has a defect that could cause injury you should immediately discontinue its use and inform the manufacturer The principle factors that can result in injury are failure to follow proper operating procedures i e lockout tagout or failure to maintain a clean and safe working environment 4 Pump 38 Station Controllers Chapter 1 Safety viii Chapter 2 Functional Description 2 1 Models Covered in This Manual This manual provides operation installation and maintenance instructions for 4 Pump 38 Station Conveying Controllers Model
3. Default Alarm Options No convey When this option is enabled the controller issues disabled disabled a no convey alarm if it has repeatedly attempted enabled 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 before Number of attempts before alarm the number of alarm 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 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 4 Pump 38 Station Controllers Chapter 6 Configurable Settings 37 of 44 6 2 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 which cover operation procedures Names Description Cd Options __ Default
4. 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 A RA RAR N Read and follow these operation and installation instructions when installing operating and maintaining this equipment If these instructions become damaged or unreadable additional copies are available from the manufacturer Follow all SAFETY CODES Wear SAFETY GLASSES and WORK GLOVES Work only with approved tools and devices Disconnect and or lock out power before servicing or maintaining the equipment Use care when LOADING UNLOADING RIGGING or MOVING this equipment Operate this equipment within design specifications OPEN TAG and LOCK ALL DISCONNECTS before working on equipment You should remove the fuses and carry them with you Make sure the equipment and components are properly GROUNDED before you switch on power When welding or brazing in or around this equipment make sure VENTILATION is ADEQUATE PROTECT adjacent materials from flame or sparks by shielding with sheet metal An approved FIRE EXTINGUISHER should be close at hand and ready for use if needed Do not restore power until you remove all tools test equipment etc and the equipment and related components are fully reassembled Only PROPERLY TRAINED personnel familiar with the information in this
5. lockable e Branch circuit fusing e Fully accessible NEMA 12 style electrical control enclosure Controller Features e Mitsubishi brick PLC icon based 6 color touch screen controller e Monitors Station status and Pump status 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 4 Pump 38 Station Controllers Chapter 2 Functional Description 10 of 44 2 4 Optional Features Options marked with indicate options that can be factory installed or retrofitted in the field 230 1 50 Operation Required to operate with a 230 1 50 supply voltage Audible visual alarm Alarm light and horn assembly that can be remote mounted and wired into the controller to indicate an alarm condition Ethernet Capability Enables controller to be connect to an ethernet network Line Filter Surge Suppressor Recommended for additional protection of electronic control components 2 5 Safety Devices and Interlocks This section includes information on safety devices and procedures that are inherent to the Controller This manual is not intended to supersede or alter safety standards established by the user of this equipment Instead the material contained in this section is recommended to supplement these procedures in order to provide a safer working environment At the completion of this section the operator and maintenan
6. 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 up as described in the previous chapter Basic Tasks Reviewing Station Status The starting point for all operations is the Station Status screen To reach this screen from any other screen touch STATION STATUS on any screen The Station Status screen appears Figure 9 Station Status Screen During Operation The status of each station is color coded You can see an explanation of each status by using the online help To do so from this screen complete the following steps 1 Touch HELP The HELP Menu screen opens 2 Touch Station States The Station Symbols Help screen opens explaining the status represented by each color 3 When you are finished reviewing the information touch HELP MENU The Help Menu screen opens 4 Pump 38 Station Controllers Chapter 4 Operation 23 of 44 The following table explains the status represented by each color at the Station Status screen Gray outline Station is not enabled The controller ignores any demands or alarms Station is enabled and idle full Station requires material Blue Station is being loaded with material Light blue Dry Air Air to convey material is coming from dry air s
7. E T line Material line is disconnected from material source disconnected Material line is disconnected from material source material source Vacuum line is disconnected Vacuum line is disconnected from station 1 station No convey Take off compartment is not Take off compartment is not adjusted properly properly Convey time is too short eee time is too Convey time is too short d Note As a stopgap measure you can disable the no convey alarm for this station until the problem can be remedied See pp 37 Not assigned Critical Station has not been assigned to a pump Pump Alarms Pump failure Critical Too many stations assigned to pump More than 20 stations are assigned to this pump Critical System Alarms Alarm message Possible cause Low batter Battery for the controller is defective y Battery for the controller is old and drained 4 Pump 38 Station Controllers Chapter 7 Troubleshooting 40 of 44 Chapter 8 Appendix 8 1 Warranty The Manufacturer warrants all equipment manufactured 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 unus
8. ER RUSR E Re ped ack 12 CHAPTER 3 INSTALLATION eere nnne 13 c MENU Cri EIE IDEE 13 3 2 Mounting the Control Panel ierra rete ct he uen ER eth o eie P eee 13 3 3 Electrical Connections asri a a a aa aa Aaaa aa aea eaa 13 Making Control Panel Power Drop Wiring Connections essuessuss 13 Connecting the Control Panel to Vacuum Hoppers ssssssssssseeeseeeeenee 14 Connecting the Control Panel to the Pump Package ssssssssss 14 MENU 14 Setting the Number of Stations and the Number of Pumps sssss 15 Setting Up Alarm Sil nCes ccccccccccsscccsecnseceaeeeaaeeaaeeaaeeeaeeaaaeaaaeeaaeaaaeaaaeenaeeae 16 Setting UP Pump Staging itd dete e dete te a datiuo 17 Setting Up StationS a setti so beste art fertis eta i sca Eo ea eade 17 Setting UD PUMPS usce tta tvi t eee d eed e dedo 19 Finishing Setup Setting Up Passwords ir taa epe esas 20 Setup PassWOotd 2 eu eed ee P Fe e He EET DILE TY Te CX re Ea FYRN Le Ve V KORR an 20 Operator Password MEPPEN 21 3 5 Jnitial Start p 11 dr ttr eo te ea d Rp ex ee Poeta betae tas naa de ds dx e ut dd 22 CHAPTER 4 OPERATION 5 2302 Lis cU co ieu c Sa dete Co vendes oa 23 MEN MIL LEE DEI 23 4 2 AE 5r as ra m E ta be ea lah davai s 23 4 Pump 38 Station Controllers Chapter 1 Safety iii Reviewing Station Status sss 23 Reviewing Pump St
9. Proximity Switch es Check proximity sensors for proper operation and proper wiring to the PLC Repair as needed Reset the conveying times to a reasonable value and adjust as needed 4 Pump 38 Station Controllers Chapter 7 Troubleshooting 39 of 44 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 7 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 Status or the Pump Status screen or touch Help at any other screen When you are finished reviewing the help touch Return Station Alarms Alarm message Possible cause Material line is blocked Vacuum line is blocked Convey time is too long time fill station only High vacuum ec valve has malfunctioned Vacuum switch has Vacuum switch has malfunctioned O 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 Minit
10. Station Status or Pump Status screen if needed To reach this screen from any other screen touch STATION STATUS or PUMP STATUS button Each disabled station or pump has an icon with a status of offline black with a white 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 Operator or Pump Setup screen appears when you touch the icon then you have kept your finger on the screen too long Touch STATION STATUS or PUMP STATUS to return to the Status screen and try again Starting and Stopping the System WARNING In an emergency you can use the power switch on the front of the controller cabinet if a password is required to stop the system and you do not know the password Note 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 green or yellow and icons for enabled pumps are green Enabling stations and pumps is described on p 27 A button to start and stop the system is located in the lower left of the Station Status and Pump Status screens When the system is off the button is red and reads START SYSTEM When the system is on the button is green and reads STOP SYSTEM Depending on the setup at your facility the system may prompt for a
11. keypad disappears and the System Setup screen shows the new setting 3 5 Initial Startup Once you have finished all the setup described above you are ready to start the system To start your system complete the following steps l At any screen touch STATION STATUS or PUMP STATUS on the bottom left side of the station status or pump status screen For each station that you want to use briefly touch its icon The icon turns green indicating that the station is full or the icon turns yellow indicating that the station needs material Touch PUMPS STATUS The Pump Status screen opens Figure 7 For each pump that you want to use briefly touch its icon The icon turns green indicating that the pump is ready Touch START SYSTEM in the lower left hand corner of the screen The system starts If any alarm messages appear on the screen see p 39 4 Pump 38 Station Controllers Chapter 3 Installation 22 of 44 Chapter 4 Operation 4 1 Overview Your 4 pump 38 station 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 three sub sections e
12. screen display doesn t Fuse in display is blown Replace come on when the control panel Loose wiring to display Repair IS pewered Up Display is faulty Replace A pump package doesn t run even though it is on line and its indicator is lit The motor overload has tripped Reset the overload and check the motor for the proper amp draw on tag Main fuse in power drop or optional fused disconnect has blown Replace the fuse Motor contact is faulty Repair or replace as required A vacuum receiver is being by passed in the loading cycle The vacuum receiver is off line Use the controller to put the vacuum receiver on line The convey time for the vacuum receiver is set to zero Use the controller to enter a longer convey time The field installed station bypass switch is simulating a Bin Full condition Normal operation Set the switch so the vacuum receiver is back in the loading sequence The field installed station bypass switch is bad or mis wired Repair replace or re wire The vacuum receiver was assigned to the wrong pump during setup Repeat the setup procedure Vacuum receivers are overfilling Conveying times are too long Time Fill Mode only Time the vacuum receiver s during loading and set the conveying times to a few seconds less Maximum conveying times are too long and the PLC does not recognize the Vacuum Receiver Full
13. suitable for resale Warranty Returns Prior to the return of any material authorization must be given by the manufacturer A RMS number will be assigned for the equipment to be returned Reason for requesting the return must be given All returns are to be shipped prepaid The invoice number and date or purchase order number and date must be supplied After inspecting the material a replacement or credit will be given at the manufacturer s discretion if the item is found to be defective in materials or workmanship Purchased components are covered under their specific warranty terms 8 6 Safety Tag Information Controller Safety Tags High Voltage Read Operation and Inside Enclosure a Installation Manual SPLGS 4 Pump 38 Station Controllers Chapter 8 Appendix 43 of 44 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 XXX4 38 Serial No 31K0182 Control Voltage 24VDC 8 8 Technical Assistance Contact Information Parts Department Call toll free 7am 5pm CST 800 423 3183 or call 414 354 0970 Fax 414 354 6421 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
14. time and causes the alarm banner to disappear 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 complete the following steps 1 Go to the System Setup screen Figure 3 by touching the SYSTEM SETUP button on any screen 2 On the System Setup screen touch the STROBE SUPPRESS button A keypad pops up Figure 3 System Setup Screen SYSTEM SETUP STATIONS PUMPS PUMP STROBE 3 Enter the number of minutes between 0 and 99 that you want the strobe lights to stay off If you want the light to stay on as long as the alarm persists change the setting to 0 If you want the light to stay off until a new alarm occurs enter 99 in the keypad Use CLR to erase any mistakes Use ENT to enter the value The keypad disappears and the new setting appears under STROBE SUPPRESS 4 On the System Setup screen touch the HORN SILENCE button A keypad pops up 5 Enter the number of minutes between 0 and 99 that you want the horn to stay off If you want the horn to stay on as long as the alarm persists change the setting to 0 If you want the horn to stay off until a new alarm occurs enter 99 in the keypad Use CLR to erase any mistakes Use ENT to enter the value The keypad disappears and the new setting appears under HORN SILENCE 4 Pump 3
15. 4 Pump 38 Station Controllers Part Number A0565547 Bulletin Number SM2 615 1 Effective 12 15 03 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 2003 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 dedicated to providing excell
16. 8 Station Controllers Chapter 3 Installation 16 of 44 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 complete the following steps 1 Goto the System Setup screen by touching the SYSTEM SETUP button on any screen 2 Touch the PUMP STAGING button A keypad pops up 3 Enter the number of seconds between 0 and 99 for the length of the delay between the start of one pump and the next Use CLR to erase any mistakes Use ENT to enter the value The keypad disappears and the new setting appears under PUMP STAGING Setting Up Stations Before starting the system you must define several settings for each station such as which pump conveys material to it This section first discusses how to use the controller s menu system to configure stations The table on pages 36 37 discusses the individual choices To set up each station perform the following 1 Goto the Station Status screen if needed To reach this screen press station status button on any screen
17. Figure 4 Station Status Screen 2 Onthe Station Status screen Figure 4 touch the icon for the station you want to setup and hold it for several seconds The Station Operator screen opens 4 Pump 38 Station Controllers Chapter 3 Installation 17 of 44 3 On the Station Operator screen Figure 5 touch the STATION SETUP button The Station Setup screen opens Figure 6 Station Setup Screen PREVIOUS STATION 1 SETUP NEXT PURGE ENABLED 4 On the Station Setup screen Figure 6 adjust settings as required Touching any box that appears in red for disabled toggles it to green for enabled and vice versa Touching any white box gives you a keypad to enter a new value Keypad entry works 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 decimal point Use CLR to erase any mistakes Use ENT to enter the value The keypad disappears and the Station Setup screen shows the new value in the selected white box Touching RESET TO DEFAULTS in the lower right of the screen changes all the settings for this station back to their factory defaults See pp 35 38 for details on the options and their default settings 4 Pump 38 Station Controllers Chapter 3 Installation 18 of 44 5 As appropriate setup the rest of the stations using either of the fol
18. Pump Alarms oe test eaa desee Toad vcn tele deste ed ies Po tox ra det 40 System Alatms sso eet enti ec n e n i e xe e E Y ED DA x PR Rx 40 CHAPTER 8 APPENDIX eeeeeeeeee rennen nnn nnn 41 MERI ETE 41 8 2 Optional Component cccccccceceeccceeeeaeeeaeeeaeeeaeeaaeeaaeeaaaeeaaeeaaeaaaeaaaeaaaeeaaanaaanaes 41 8 3 Drawings and Diagraitis oae oet tee rhe ES RR CR ERR RE enti ceeeea tienen 42 9 4 Spare Parts List oues er eaten e ea age da E EER REFER ER EC PR NE EMEN SER NER e E Re S noe RENE 42 8 5 Returned Material Polley ementi it Ee b o Pt mat dauid tetrum tt UNE 43 NCODMICIUI M D a ede cede along Ae eet see ato dee 43 Warranty Return Sonnen oto dd reps cueste Det dub apnd Reso gee abe 43 8 6 Safety Tag Information reete tete te Rink eH e tene be ber in atu iia 43 Controller Safety Fags is oet ont eee a oes 43 8 7 Controller Identification Serial Number Tag sse 44 8 8 Technical Assistance Contact Information seeeneeee 44 Parts Department ei ette etui ed ta et eaae ae ea oov t 44 Service Department siisii a a R Ee 44 Sales Department miee eet ren e e K E ed Va XY TY da CHA FER EREKE KEARE 44 Contract Department ssssssssssssssssssssesse ener nnn n nsns nnns nnns 44 4 Pump 38 Station Controllers Chapter 1 Safety iv Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for
19. Pump Errors If the error message tells you to disable the source pump and or the standby pump touch RETURN at this screen then PUMP STATUS at the Pump 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 complete the following steps 1 2 3 4 3 Touch RETURN at the Standby Pump screen and then touch STATION STATUS Touch and hold a station icon to get to the Station Operator screen Then touch STATION SETUP to go to the Station Setup screen Use PREVIOUS and NEXT to review all pump assignments Where necessary choose ASSIGNED TO PUMP to set station assignments to 0 unassigned Then return to the Transfer to Standby Pump screen Touch left side pump value and enter the number of the pump whose hoppers are to be transferred Touch right side pump value and enter destination pump number 4 Pump 38 Station Controllers Chapter 4 Operation 33 of 44 Filter cleaning Our pumps have two options available for filter cleaning these are vacuum pulse or compressed air filter cleaning Touching the ENABLE DISABLE button located in the lower left hand corner of the pump setup screen will allow the operator to turn on off these
20. as you touch it 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 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 us for assistance Once you have logged on the password remains active until 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 Status screen and you must reenter the password to continue working 4 Pump 38 Station Controllers Chapter 4 Operation 26 of 44 Enabling and Disabling Stations and Pumps When a station or pump is disabled the 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 Note 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 Convey position To enable or disable a station or pump complete the following steps 1 Go to the
21. assword will give the user access to the functions at the following screens e Station Status to enable or disable a station and start or stop system e Pump Status to enable or disable a pump and start or stop system e Station 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 purge time Entering the setup password will give the user access to all functions Note Ifyou 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 passwords different from each other If the two passwords are the same Then any user who enters the password will have access to all functions To set or remove password protections complete the following steps 1 Go to the System Setup screen by touching the SYSTEM button on any screen 2 Onthe System Setup screen touch the Operator Password button or the Setup Password button depending on which password you want to set up A keypad pops up with an entry of 0 3 Enter up to four digits If you want to remove password protection enter 0 as the password Use CLR to erase any mistakes Use ENT to enter
22. atue todos duane cae de teak et a Maan te Nabe fub Antal 25 Logging Onan LOGO Off sae soot ei barroco oe dta 26 Enabling and Disabling Stations and Pumps sse 27 Starting and Stopping the System tee dob pta p ae 27 Reviewing and Adjusting Basic Station Settings esses 28 Adjusting Convey Time and Dump Delay essen 29 Activating and Stopping Priority Convey for a Station ssseeussssss 30 Navigating among the Station Operator Screens sss 30 4 3 Adjusting Advanced Settings eene enn nnn 31 Reviewing and Resetting a Pump Hour Meter sssssseeeenee 31 Transferring Stations to a Standby Pump seen 32 Bcd a EE a sone 88 we A TT TA ie aig E A A AT 34 Reviewing Alarms iris e e i ea ea Noone aaea aa iaaea 34 Sil ncing Alarm E EE 34 CHAPTER 5 MAINTENANCE sccceceeesesseeeeeeeseeeaeeeneeees 35 CHAPTER 6 CONFIGURABLE SETTINGS 36 6 1 Options for Station Setup sssssssssseseeeneeeneeneeenneeneennee nnnm nrnnnr nnne 36 6 2 Options for Pump Setup cccccccccceeceneceeeeeaeceaeeeaeeaaaeeaaeeaaeeaaeeaaeeaaeeaaeeaaaeaaaesaaeaes 38 CHAPTER 7 TROUBLESHOOTING 39 ONES 0 i e Peleo iet 39 CLE II dM PE 40 Station Alalms uis iid ete etr ber cd Ree eddy acte dec be opted dudas 40
23. awn 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 Unload time 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 unload time should match the times actually required to fill and empty the station The following problems may occur if these settings are incorrect e Material is backing up and causing high vacuum alarms for time fill stations only Convey time is too long e 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 Operator screen shows the length of time the controller actually spent conveying material during the most recent delivery under Last Convey To adjust a station s convey time or the unload time complete the following steps 1 Go to the Station Operator screen by touching and holding a station icon or go to the Station Setup screen 2 Touch CONVEY TIME A keypad pops up 3 Enter the number of seconds desired for convey time or unload time Use CLR to erase any mistakes Use ENT to enter the value The new setting appears under CONVEY TIME or UNLOAD TIME 4 Pump 38 Station Controllers Chapter 4 Operation 29 of 44 Acti
24. ce 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 conveying system however it is the responsibility of the personnel operating and maintaining the equipment to familiarize themselves with the safety procedures and the proper use of any safety devices Fail Safe Operation If a safety device or circuit should fail the design must be such that the failure causes a Safe condition As an example a safety switch must be a normally open switch The switch must be held closed with the device it is to protect If the switch fails it will go to the open condition tripping out the safety circuit At no time should the safety device fail and allow t
25. decimal point Use CLR to erase any mistakes Use ENT to enter the value The keypad disappears and the Pump Setup screen shows the new value in the selected white box See page 38 for details on the options and their default settings 4 Asappropriate setup the rest of the pumps using the following method e Use the PREVIOUS or NEXT buttons to navigate to other pumps Touch PREVIOUS to go to the previous Pump Setup screen or touch NEXT to go to the next Pump Setup screen 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 all settings can be changed only after entering the password The password will be required to display the following screens e System Setup to review and change system wide settings e Station Setup to review and change settings for all station options e Pump Setup to review and change settings for all pump options 4 Pump 38 Station Controllers Chapter 3 Installation 20 of 44 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 p
26. e 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 Ul Dzialkowa 115 Phone 1 262 641 8600 eee kuxts 0060 CALDBES 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 transportation compan
27. ed by each color 3 When you are finished reviewing the information touch HELP MENU The following table explains the status represented by each color at the Station Status screen Description Gray outline Pump is not enabled The controller ignores any alarms Pump is off waiting for demand from a station Light 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 Blue Conve Pump is conveying material to a station Alarm Pump is in alarm Red i until the alarm is cleared Ramping Pump is in process of starting or stopping Up Down Additional basic information about each pump including configuration settings and the number of hours the pump has been running is available at the Pump Setup screen For details on configuration settings see page 38 For details on the hour meter see page 31 4 Pump 38 Station Controllers Chapter 4 Operation 25 of 44 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 touching a button will open the Password Entry keypad screen Figure 11 Password Entry Screen Enter the four digit password including any leading zeros For example if the password is 1 enter 0001 Each digit appears as an
28. ed 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 expense 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 sale of its equipment not expressed in this warranty Optional Components The following 1s a list of options that your controller may be equipped with 230 1 50 Operation Required to operate with a 230 1 50 supply voltage Audible visual alarm Alarm light and horn assembly that can be remote mounted and wired into the controller to indicate an alarm conditi
29. ent customer service For immediate assistance please contact North Central and South America 8am 5pm CST 1 800 483 3919 for drying conveying heating and cooling and automation For size reduction 1 800 229 2919 North America emergencies after 5pm CST 847 439 5855 North America email acsuscanadacustserv corpemail com e Mexico Central amp South America Email acslatinamericacustserv corpemail com e Europe Middle East amp Africa 48 22 390 9720 Email acseuropecustserv corpemail com 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 you are located For mor
30. excellent long service The Troubleshooting chapter serves as a guide for identification of most common problems Potential problems are listed along with possible causes and related solutions The Appendix contains technical specifications drawings schematics and parts lists A spare parts list with part numbers specific to your machine is provided with your shipping paperwork package Refer to this section for a listing of spare parts for purchase Have your serial number and model number ready when ordering Safety Symbols Used in this Manual The following safety alert symbols are used to alert you to potential personal injury hazards Obey all safety messages that follow these symbols to avoid possible injury or death Danger DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury Warning WARNING indicates a potentially hazardous situation or practice which if not avoided could result in death or serious injury Caution CAUTION indicates a potentially hazardous situation or practice which if not avoided may result in minor or moderate injury or in property damage 4 Pump 38 Station Controllers Chapter 1 Safety V 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
31. he failed pump to the standby pump and carry out any other mechanical procedures needed to use the standby pump 4 At the Pump Status screen touch and hold the icon for any pump until the Pump Setup screen appears 5 At the Pump Setup screen touch Transfer Stations To Standby Pump The Transfer to Standby Pump screen opens Figure 14 Transfer To Standby Pump Screen MOVE STATIC 6 Use CLR to erase any mistakes Use ENT to enter the value 4 Pump 38 Station Controllers Chapter 4 Operation 32 of 44 Figure 15 Transfer To Standby Pump Button MOVE 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 of MOVE button If you get an error message first check to make sure that you have entered the correct numbers and reenter if necessary If another error occurs see the Standby Pump Errors section on page 33 Touch the MOVE button When transfer is complete stations moved will appear on the screen 8 Touch RETURN to return to the Pump Setup screen 9 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 Operator and Station Setup screens show the new pump assignment Standby
32. he more dust and debris in your material line the smaller this number needs to be Cleaning pulses Number of pulses of compressed air sent through the pump s filter during cleaning If filter cleaning is not working as desired the service department may ask you to change this setting Pulse On time Number of seconds that the air compressor remains 0 9 9 sec Compressed air on for each pulse during filter cleaning cleaning only If filter cleaning is not working as desired the service department may ask you to change this setting Pulse Off time Number of seconds between air pulses during filter 0 9 9 sec 1 5 sec Vacuum Pulse cleaning cleaning only If filter cleaning is not working as desired the service department may ask you to change this setting Vacuum time Amount of time clearing valve is closed and vacuum 0 9 9 sec 3 0 sec increases inside filter chamber Vacuum vent time Amount of time clearing valve is open to allow air to 0 9 9 sec 1 5 sec reverse flow through filter 4 Pump 38 Station Controllers Chapter 6 Configurable Settings 38 of 44 Chapter 7 Troubleshooting 7 1 General Troubleshooting Problem Possible Cause Solution The control panel doesn t light up at all The control panel is not turned on Turn on the control panel Fuse circuit breaker in the power Replace reset drop is blown tripped Control power switch is broken Replace The touch
33. he 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 4 Pump 38 Station Controllers Chapter 2 Functional Description 11 of 44 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 4 Pump 38 Station Controller Failure to do so may result in serious injury No one but the person who installed the lockout may remove it 4 Pump 38 Station Controllers Chapter 2 Functional Description 12 of 44 Chapter 3 Installation 3 1 Uncrating 4 Pump 38 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 I x 4 wood supports Cut the steel banding 2 Use a pry bar to remove the blocks securing the unit to the skid 3 Lift unit from sides inserting forklift under the base The forks must be equidistant from the centerline of the unit and the unit must be balanced on the forks Lift slowly and only high enough to clear the skid Use a pry bar if necessary to carefully re
34. ing steps 1 At any screen touch the PUMP STATUS button 2 Touch and hold the icon for the pump The Pump Setup screen opens Pump Setup Screen PUMP 1 SETUP NEAT TOTAL ii HOURS FILTER CAN The box labeled x Hours shows the running time since the last reset The box labeled total x Hours shows total running time To reset the resettable meter touch Hour Meter Reset The time above x Hours changes to 0 4 Pump 38 Station Controllers Chapter 4 Operation 31 of 44 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 pump 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 complete the following steps 1 Atany screen touch PUMP STATUS button The Pump Status screen appears 2 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 white outline 3 Move the vacuum hose from t
35. installing operating and maintaining your equipment The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This manual covers only light corrective maintenance No other maintenance should be undertaken without first contacting a service engineer The Functional Description section outlines models covered standard features and optional features Additional sections within the manual provide instructions for installation pre operational procedures operation preventive maintenance and corrective maintenance The Installation chapter includes required data for receiving unpacking inspecting and setup of the equipment We can also provide the assistance of a 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
36. l esses tenere nnne nnne V Safety Symbols Used in this Manual eene V 1 2 Warnings and Precautions anrea e eet M aces kt aso p dn cet leds Suede det tdes vi 123 Responsibility o acciri edt ehe eerte tote ose Brei cadat Datis pats esa Malas bett oed headed vii General Responsibility eerte i ree ie bp ce OE ee vii Operator Responsibility esee ssssses sessi sesenta Viii Maintenance Responsibility eeeesis i siisiene nne nna nani nhat nnn Viii Reporting a Safely DeleOl nsore seven trial dea ate e Geb UP aa Viii CHAPTER 2 FUNCTIONAL DESCRIPTION 9 2 1 Models Covered in This Manual sseeessssssssssssssssssese nennen nnne 9 2 2 General Description essssesssssssssssseseeee re reitera rrr n irren ren 9 2 3 Standard Eeat res ccrte ee e acea PA SERA Y MAS QR Sa PR a P tiu dv 10 Mechanical Features ctt ed i d ode te erar gt te 10 Electrical Features e o o br a a Reds 10 Controller Fea U E S a ar aa aaa aa e aaia a nennen nennen nnne sensns nnns nsns nnns 10 2 4 Optional Features ra aiaa a aee ai aeaee iaeaea ea aeai eioi teima ard 11 2 5 Safety Devices and lnterlockS udo Fours on Deae tt oiii tine neatenleed i en sitet be T eset 11 Safety Circuit Standards siue e ee ovt inisinia iniia 11 Fail Sate Operation eo ue duode eco dbase ede eased eed dt 11 Safety Device Lock Ouls uide ebbe eise Ta
37. lowing methods e Use the PREVIOUS or NEXT buttons to navigate to other stations Touch PREVIOUS to go to the previous Station Setup screen or touch NEXT to go to the next Station Setup screen Setting Up Pumps Before starting the system you must define several settings for each pump such as how quickly to shut it down when it is not in use This section first discusses how to use the controller s menu system to configure pumps The table on page 38 discusses the individual choices In order to setup up the pumps properly perform the following 1 Go to the Pump Status screen if needed To reach this screen from any other screen touch PUMP STATUS button The Pump Status screen appears Figure 7 Pump Status Screen PUMP 1 P LUM P 4 2 Touch the icon for the pump you want to set up and hold it for several seconds The Pump Setup screen opens 4 Pump 38 Station Controllers Chapter 3 Installation 19 of 44 Figure 8 Pump Setup Screen Before Setup GENERAL PUMP VACUUM PULSE 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 white 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
38. manently e Breakdown of shop morale Costly damage to equipment e Downtime An effective safety program is responsible and economically sound Organize a safety committee or group and hold regular meetings Promote this group from the management level Through this group the safety program can be continually reviewed maintained and improved Keep minutes or a record of the meetings Hold daily equipment inspections in addition to regular maintenance checks You will keep your equipment safe for production and exhibit your commitment to safety Please read and use this manual as a guide to equipment safety This manual contains safety warnings throughout specific to each function and point of operation 4 Pump 38 Station Controllers Chapter 1 Safety vii 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
39. manual should work on this equipment We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration We expect you as a user to abide by the foregoing recommendations in order to make operator safety a reality 4 Pump 38 Station Controllers Chapter 1 Safety vi 1 3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the machine All personnel engaged in the use of the machine should become familiar with its operation as described in this manual Proper operation of the machine promotes safety for the operator and all workers in its vicinity Each individual must take responsibility for observing the prescribed safety rules as outlined All warning and danger signs must be observed and obeyed All actual or potential danger areas must be reported to your immediate supervisor General Responsibility No mater who you are safety is important Owners operators and maintenance personnel must realize that every day safety is a vital part of their jobs If your main concern is loss of productivity remember that production is always affected in a negative way following an accident The following are some of the ways that accidents can affect your production Loss of a skilled operator temporarily or per
40. move the skid from the unit 4 Lower slowly 3 2 Mounting the Control Panel Note Before you mount the panel consider how you run wiring to the vacuum hoppers the filter chamber atmospheric valve if so equipped and the pump motor starter s vacuum switch es and vent valve s Mount the panel on a flat vertical area It should be a visible area that gives your operator access to the control The panel requires a low voltage power drop as listed on the serial tag 3 3 Electrical Connections Refer to local electrical codes the schematic and connection diagrams supplied with this unit and the serial tag for wiring considerations Run all wiring in conduit if codes require it Making Control Panel Power Drop Wiring Connections Hardwire the input power at 110 1 50 60 VAC or 230V 1 50 60 VAC depending on the specifications which are located on the Control Panel Serial Tag The main power switch is located on the front of the enclosure Caution We recommend that you protect PLC memory by providing the control panel with a dedicated circuit a true earth ground and a spike surge protector 4 Pump 38 Station Controllers Chapter 3 Installation 13 of 44 Connecting the Control Panel to Vacuum Hoppers Note Wire size depends on control voltage distance number of vacuum hoppers and the number of wires in each raceway Consult a qualified electrician 1 On24 VDC control voltage systems run a common 24 VDC wire and a comm
41. 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 4 Pump 38 Station Conveying Controller is a programmable logic controller with 24 VDC 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 Vacuum Pump Product manual Part No A0571050 for installation recommendations 4 Pump 38 Station Controlle
42. on Ethernet Capability Enables controller to be connected to ethernet network Line Filter Surge Suppressor Recommended for additional protection of electronic control components 4 Pump 38 Station Controllers Chapter 8 Appendix 4 of 44 8 3 Drawings and Diagrams Figure 17 4 pump 38 station Controller with 6 Display 30 Depth dimension is 10 Also review electrical drawings supplied in the packet with this manual 8 4 Spare Parts List Quantity Part Number Description 1 A0569874 AB 20A Power Supply 24VDC 1606 XL480EP 1 A0569870 Relay Magnecraft 781XAXML 1 A0569859 Filter Grill 1 A0540997 Fuse MDL 1 1 A0542210 Fuse MDL 5 1 A0544793 Fuse MDL 15 5 A0542205 Fuse MDL 2 5 1 A0542209 Fuse MDL 4 4 Pump 38 Station Controllers Chapter 8 Appendix 42 of 44 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
43. on 0 zero VDC wire from the controller to each vacuum hopper in the system 2 Run two wires to each vacuum hopper one each from the controller to the Bin Full switch LS and to the Atmospheric Sequence T solenoid SOL valve 3 Make sure that the solenoid and the proximity switch if supplied on vacuum hoppers are the same voltage 24 VDC as the control panel voltage Consult the control panel serial tag and the solenoid valve nameplates 4 Properly ground each hopper to reduce static build up generated by material conveying Connecting the Control Panel to the Pump Package 1 Wire the pump package motor starter coil M to the terminal provided in the control panel enclosure 2 Wire the pump package vacuum relief valve solenoid SOL A to the terminal provided in the control panel enclosure 3 Wire the pump package vacuum switch VS to the terminal located in the control panel enclosure 4 On24 VDC control voltage systems run a common 24 VDC wire and a common 0 zero VDC wire from the controller to each pump package in the system 3 4 Setup This section provides the procedures for configuring your 4 pump 38 station controller Configuration of your controller includes setting the number of stations and pumps setting variables such as convey time and blow back interval and setting up passwords We recommend that you carry out these procedures in the order given here Note Before carrying out these procedures ins
44. ource rather than Convey ambient air Purple Station is dumping material into its receiver Blue blinking Priority Station is in priority convey mode Its pump will be temporarily dedicated to filling it as soon as possible Alarm Station is in alarm Red outline Critical Station is in critical alarm The controller has disabled the station until the alarm is cleared Air is being drawn through material lines Additional basic information about each station convey time dump delay and pump assignment is available at the Station Operator screen See page 28 for details Detailed configuration settings for each station are available at the Station Setup screen See page 36 for details about each of these settings 4 Pump 38 Station Controllers Chapter 4 Operation 24 of 44 Reviewing Pump Status The Pump Status screen is the counterpart of the Station Status screen To reach the Pump Status screen from any other screen touch PUMP STATUS on any screen The Pump Status screen appears Figure 10 Pump Status Screen During Operation PUMP 1 PUMP 2 ah The status of each pump is color coded You can see an explanation of each status by using the online help To do so from this screen complete the following steps 1 Touch HELP button The HELP Menu screen appears 2 Touch PUMP STATES The Pump Symbols Help screen appears explaining the status represent
45. 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 4 Pump 38 Station Controllers Chapter 4 Operation 27 of 44 Reviewing and Adjusting Basic Station Settings The 4 pump 38 station controller has a Station Operator 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 Operator screen complete the following steps 1 Go to the Station Status screen if needed To reach this screen from any other screen touch STATION STATUS button 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 Operator screen appears Figure 12 Station Operator Screen PREVIOUS CONVEY LAST ASS GNED TIME TO PUMP Buttons in white are settings that you can adjust at this screen Boxes in black are for display only If a pump assignment or purge time can be changed from operator screen this must be done at the Station Setup screen 4 Pump 38 Station Controllers Chapter 4 Operation 28 of 44 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 dr
46. please have the model and serial number of your unit when you contact us A customer replacement parts list is included in this manual for your convenience ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service Service Department Call toll free 8am 5pm CST 800 657 4679 or call 414 354 0970 Emergencies after 5pm CST call 847 439 5655 We have a qualified service department ready to help Service contracts are available for most of our products Sales Department Call 414 354 0970 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 414 354 0970 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 4 Pump 38 Station Controllers Chapter 8 Appendix 44 of 44
47. proper setup of the 4 pump 38 station control system parameters These parameters are operator changeable however these items should require setup only during the initial installation Only authorized personnel should change them Many of the variables and setup parameters have been preset at the factory and do not need to be changed However this section of the manual will address all of the setup parameters that were available at the time of printing The purpose of this is to familiarize the reader with all the setup parameters and their usage 6 1 Options for Station Setup Names Description Cd Options Default Conveying Options Convey time Length of time the station s vacuum valve remains 1 999 sec 30 sec 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 Unload 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
48. rent convey if any and resumes normal operation Navigating among the Station Operator Screens The controls at the top of the screen enable you to move among the Station Operator screens e 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 PREVIOUS e 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 e To exit to the Station Status or Pump Status screen touch STATION STATUS or PUMP STATUS 4 Pump 38 Station Controllers Chapter 4 Operation 30 of 44 Figure 13 PREVIOUS Adjusting Advanced Settings 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 and off with the setup password is the same as for logging on with the operator password see p 26 for step by step instructions for logging on and off 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 complete the follow
49. rs Chapter 2 Functional Description 9 of 44 2 3 Standard Features Mechanical Features Time fill Capability The length of time allowed for material to drain from the 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 supply voltage e 24 VDC control voltage e Single point power and ground connection e Non fused disconnect switch
50. tall all equipment as described in this section and in the manual SPD SPC Series Conveying Systems 4 Pump 38 Station Controllers Chapter 3 Installation 14 of 44 Setting the Number of Stations and the Number of Pumps Figure 1 Default Station Status Screen Before Setup 1 At the Station Status screen Figure 1 or at the Pump Status screen touch the SYSTEM SETUP button The Menu screen opens Figure 2 System Setup Screen Before Setup OPERATOR SETUP PASSWORD PASSWORD DURAT I ON 2 At the System Setup screen Figure 2 touch STATIONS ACTIVE A keypad pops up 3 Enter the total number of stations 1 38 to be controlled by the system Use CLR to erase any mistakes Use ENT to enter the value The keypad disappears and the new setting appears under STATIONS ACTIVE 4 Touch PUMPS ACTIVE A keypad pops up 5 Enter the total number of pumps 1 4 to be controlled by the system Use CLR to erase any mistakes Use ENT to enter the value The keypad disappears and the new setting appears under PUMPS ACTIVE 4 Pump 38 Station Controllers Chapter 3 Installation 15 of 44 Setting Up Alarm Silences When an alarm occurs a horn sounds and a strobe light flashes at each installed central alarm An alarm banner appears in the center of the screen An alarm message and Silence button are on the banner Touching this button silences the horn and turns off the lights for configurable periods of
51. the value The keypad disappears and the System Setup screen shows the password you entered Note 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 The password timer starts when the user logs on It expires even if the user is actively using the screens when the chosen time is up If the timer expires the system goes to the Station Status screen Your password duration should be long enough to allow authorized users to complete their tasks but short enough to provide adequate protection against tampering 4 Pump 38 Station Controllers Chapter 3 Installation 2 of 44 To change the duration of the password complete the following steps 1 On the System Setup screen touch the Operator Password Duration button or the Setup Password Duration button depending on which password duration you want to change A keypad pops up Enter the number of minutes between and 99 that you want to set as the password duration Use CLR to erase any mistakes Use ENT to enter the value The
52. 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 When this option is enabled dry air will be used to disabled disabled convey material to station Requires additional enabled optional equipment When this option is enabled source air is used to disabled disabled cleanout the stations material line after every enabled convey Requires additional optional equipment Purge time Amount of time allowed to clear material line 0 999 Assigned to pump n Number address of the pump to which this 0 4 0 not station s vacuum line is connected assigned 4 Pump 38 Station Controllers Chapter 6 Configurable Settings 36 of 44 Name Description SC Options X Default Special convey When this option is enabled the station s vacuum disabled disabled valve remains open for the convey time even if enabled 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 Names Description Cd Options
53. two options or disable the filter cleaning option altogether Note Each type of filter cleaning requires optional equipment that must be purchased and installed prior to enabling this option 4 3 Alarms Reviewing Alarms To review your system s alarms touch Alarms on any screen The Alarm Log screen appears with the newest alarm listed first Figure 16 Alarm Log Screen DOWN To scroll up and down through the list touch DOWN or UP at the top of the screen Silencing Alarms Whenever a new alarm occurs your controller sounds the horn and turns on the strobe light at each central alarm Touch SILENCE on the alarm message banner that appears when a new alarm occurs The horns and lights at the central alarms turn off Your controller has separate configurable settings for how long the horns should remain silent and how long the light should remain off If the alarm condition still exists when either of these times elapses the corresponding device horn or light turn on again and the alarm message banner appears If a new alarm occurs both horns and lights turn on See page 39 for a list of alarms and their possible causes 4 Pump 38 Station Controllers Chapter 4 Operation 34 of 44 Chapter 5 Maintenance No Periodic maintenance is required on this unit 4 Pump 38 Station Controllers Chapter 5 Maintenance 35 of 44 Chapter 6 Configurable Settings This section describes the
54. vating 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 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 complete the following steps 1 Go to the Station Operator by touching and holding a station icon or go to the Station Setup screen 2 Touch PRIORITY CONVEY ACTIVATE The button changes to PRIORITY CONVEY ACTIVE 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 conveying already in progress 3 To stop a priority convey before the station is completely full Touch the PRIORITY CONVEY ACTIVE button The button changes to PRIORITY CONVEY ACTIVATE The controller finishes the cur
55. y Substantiate the claim by referring to the agent s report A certified copy of our invoice 1s 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 V 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 1 414 354 0970 for all other countries call our international desk at 414 354 0970 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 4 Pump 38 Station Controllers Chapter 1 Safety ii Table of Contents CHAPTER 1 SAFETY onte a Eaa EAA AASE Aah V 1 1 How to Use This Manua

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