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Sterling Plumbing 882.00252.00 Musical Table User Manual

1. 42 of 51 Names Description Cd Options 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 3 Pump 33 Station Controllers Chapter 6 Configurable Settings 43 of 51 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 proc
2. SCC 3 Pump 33 Station Controllers Part Number 882 00252 00 Bulletin Number CV3 635 Effective 12 05 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 dedicated to providi
3. 3 Enter the number of seconds desired for convey time or dump delay Use Backspace Key to erase any mistakes Use n Enter Key to enter the value The new setting appears under Convey Time or Dump Delay 3 Pump 33 Station Controllers Chapter 4 Operation 34 of 51 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 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 and blinks until the station s demand has been satisfied or you stop the priority convey
4. 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 mix 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 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 Menu button on any screen Then touch System Setup The System Setup screen will open 2 On the System Setup screen Figure 4 touch the Operator Password button or the Setup Password button depending on which password you want to set up A keypad pops up 3 Enter up to four digits If you want to remove password protection enter 0 as the password Use Backspace Key to erase any mistakes Use Enter Key to enter the value The ke
5. 4 Operation 31 of 51 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 0 position To enable or disable a station or pump complete the following steps 1 Go to the Station Status or Pump Status screen if needed To reach this screen from any other screen touch Menu and then Stations or Pumps 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 Ifthe Station Operator or Pump 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 Status 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 Starting and Stopping the System WARNING In an emergency you c
6. 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 eae as as 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 c
7. Owners operators and maintenance personnel must realize that every day safety is a vital part of their jobs If your main concern is loss of productivity remember that production is always affected in a negative way following an accident The following are some of the ways that accidents can affect your production e Loss ofa skilled operator temporarily or permanently e Breakdown of shop morale e Costly damage to equipment e Downtime An effective safety program is responsible and economically sound Organize a safety committee or group and hold regular meetings Promote this group from the management level Through this group the safety program can be continually reviewed maintained and improved Keep minutes or a record of the meetings Hold daily equipment inspections in addition to regular maintenance checks You will keep your equipment safe for production and exhibit your commitment to safety Please read and use this manual as a guide to equipment safety This manual contains safety warnings throughout specific to each function and point of operation 3 Pump 33 Station Controllers Chapter 1 Safety viii 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
8. PROTECT adjacent materials from flame or sparks by shielding with sheet metal An approved FIRE EXTINGUISHER should be close at hand and ready for use if needed Do not restore power until you remove all tools test equipment etc and the equipment and related components are fully reassembled Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration We expect you as a user to abide by the foregoing recommendations in order to make operator safety a reality 3 Pump 33 Station Controllers Chapter 1 Safety vii 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
9. aiiin te anes eanna ia Eaa oG aaka nadaan 19 Setting Up PUMPS e a aa a a a EE EEEa 23 Finishing Setup Setting Up Passwords nsnnnnnnnnnnnnnnrnnnrnnrrnnrrrnrrnnrrnnrrnnrenne 25 CSAR INIA STAMUP E E E A TET AATA N 27 CHAPTER 4 OPERATION ccccccecssseeeeeeeeeneeeeeeeeeeaaeeenenees 28 AeT SQVEIVIOW EE E feces E T shu aseetesth tectisuntMastactads TAE 28 A 2 BASIC URASKS x5 Sacsc E A E A aeGdansecuauaciasseriseasalssiie stash iges aestranseeataeesleciteneas 28 IRGVIG WIIG SIAUOIN SANUS a seenaticadhacidoactseseite den hieuttuauiiade dass aN hale lines i aiaiai 28 3 Pump 33 Station Controllers Chapter 1 Safety iii Reviewing Pump Status 0 ccccceeeeeeeeeeneeeeeeeeeeeeeeeseeeeeeeseeeeteeeseeeteeeteeeteeeeeeeeeeees 30 Logging On and Logging Off essnee ts Sena Maal na Neon ce enh eiae 31 Enabling and Disabling Stations and PUIMPS 1 ceecceeeee eee teeeentnneeeeeeeeeneeees 32 Starting and Stopping the SYStOM cc cccscceeceeceeaeeeaeeeaeeeaeeeaaeesaeeaaeeaaeeaaaeae 32 Reviewing and Adjusting Basic Station Settings ccccccceceseessteteeeeeeeeeeeene 33 Navigating among the Station Operator SCre Nn cccccseeeeeeeeeeeentteeeeeeeenenees 33 Adjusting Convey Time and Dump Delay ccccesecceeeeeeteentnneeeeeeeeeeetnnnnnanaes 34 Activating and Stopping Priority Convey for a Station cscecceseeeeeeeeeeeesnnnees 35 4 3 Adjusting Advanced Seung Ss occsicesc
10. defined Warranty Restrictions cccccccccecteeesstteeeeeeeeeeeeenee Error Bookmark not defined Warranty Liabilities ceecccceceeeeeeeeenttteeeeeeeeeeeeenee Error Bookmark not defined Customer Responsibilities 1 c ccssseeseeseeenneeee Error Bookmark not defined 8 2 Optional COMPONENTS aanre a a A EEA Er ENEE KEERA Ea 47 8 3 Drawings and DiagramS eeeeesseseeeieeeeeeeerrrtttttttttttttttttttettkttinntnssasttttnnnnnnasateeeenna 48 8 4 Spate Parts LiSt iv ccseescswssceses seen seteddeesscaivevsavegedvesaseves seuss Car E E Eer eE EAREN E aE EE aR E 49 ACG Volta gonn enm yonni a a aaa i a aa vee a a a daai aia 49 DC Vola gE a a a a ee ee aaae a TA Ae la eg eae Ak datane naa 49 8 5 Returned Material POMC ssssisusisiiverirersencesrsssanessersnetrrik nunui deran dakak t nat bes atde ak indi tads 49 Credit IROTOTITS aisneis asata awa Monat ota edo ae ea OA ETA 49 WV ET AIILY IROL INS ieee couse Rwy weer ou evecare a a A Mate ee ae AE 50 8 6 Safety Tag INfOrmationl ssc ccicececcasiassccnieecngtauaydvuncneelackhdeiiadacdeiont ecngeearesueead eennenenseneees 50 Controller Safety Ta Sass 6s hel Pak Shs davis eae ti yasse sa cds das snes doe ends eee 50 8 7 Controller Identification Serial Number Tag eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeenaaae 50 8 8 Technical Assistance Contact Information ececeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeenaaaeees 51 Parts Depanment fox sin addon ete O
11. enter a new value 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 41 44 for details on the options and their default settings 5 As appropriate setup the rest of the stations using either of the following methods e Copy this station s settings to one or more other stations as described below e Use the Back or Next buttons to navigate to other stations Touch Back to go to the previous Station Setup screen or touch Next to go to the next Station Setup screen e Touch Goto and enter a station number to go to that station s setup screen 3 Pump 33 Station Controllers Chapter 3 Installation 20 of 51 Copying Settings from One Station to Others If other stations at your facility will use the same settings as a station you have already set up you can copy the settings from this station to the others To copy settings from one station to others complete the steps below e At the Station Setup screen See Figure 7 for the station you want to copy from touch Copy in the upper right corner The Station Copy screen appears showing the station number for the station you are copying from Figure 8 Station Copy Screen SOURCE STATION 1 RETURN Stations Follow the directions below to copy settings to one other station a range of stations or all stations Copying to One Other Station 1 On t
12. match the actual time needed to fill the station 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 Length of time allowed for material to drain from 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 Number address of the pump to which this station s vacuum line is connected E 0 0 3 0 not assigned Special convey 3 Pump 33 Station Controllers When this option is enabled the station s vacuum valve remains open for the convey 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 Chapter 6 Configurable Settings disabled disabled enabled
13. on page 38 10 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 11 Touch Return and then Pumps to return to the Pump Status screen 12 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 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 3 Pump 33 Station Controllers Chapter 4 Operation 38 of 51 Standby Pump Errors 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 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 l 2 3 4 5
14. the alarm message banner appears with a Suppression Silence Time Expired message If a new alarm occurs both horns and lights turn on See page 45 for a list of alarms and their possible causes 3 Pump 33 Station Controllers Chapter 4 Operation 40 of 51 Chapter 5 Maintenance No Periodic maintenance is required on this unit 3 Pump 33 Station Controllers Chapter 5 Maintenance 41 of 51 Chapter 6 Configurable Settings This section describes the proper setup of the 3 pump 33 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 Last convey time Dump delay Assigned to pump n 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 Adjust this value to
15. to enter the value The 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 Menu on the right side of the screen The Menu screen appears Figure 2 Touch Stations The Station Status screen appears Figure 5 For each station that you want to use briefly touch its icon The icon turns blue indicating that the station is ready or the icon turns yellow indicating that the station needs material Touch Pumps The Pump Status screen opens Figure 8 For each pump that you want to use briefly touch its icon The icon turns blue indicating that the pump is ready Touch Push to Start System in the lower right hand corner of the screen The system starts If any alarm messages appear on the screen see p 45 3 Pump 33 Station Controllers Chapter 3 Installation 27 of 51 Chapter 4 Operation 4 1 Overview Your 3 pump 33 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 a
16. 1 On the Pump Copy screen Figure 10 touch the green Copy to All Pumps button Complete briefly appears on the screen 2 Touch Return to go back to the 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 most settings can be changed only after entering the password The password will be required to display the following screens e System Setup to review and change system wide settings 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 3 Pump 33 Station Controllers Chapter 3 Installation 25 of 51 Operator Password If you define a password for operators then a password will be required to carry out any function other than reviewing station and pump status silencing alarms reviewing the alarm log and looking at help screens Entering the operator s password will give the user access to the functions at the following screens e Station Status to enable or disable a station and start or stop system e Pump Status to enable or disable a pump and start or stop system e Station Operator
17. 2 Touch Help The Help Menu screen appears 3 Touch Pump States The Pump Symbols Help screen appears explaining the status represented by each color 4 When you are finished reviewing the information touch Return The Help Menu appears 5 Touch Menu to return to the Menu screen The following table explains the status represented by each color at the Station Status 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 Pump is conveying material to a station Blue blinking Blow Back Pump s air filter is being cleaned by blowing compressed air backward Samp eine a aeee it Red blinking Pump isin alarm eee Red outline blinking Critical Pump is in critical alarm The controller has disabled the pump until the alarm is cleared 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 44 For details on the hour meter see page 36 3 Pump 33 Station Controllers Chapter 4 Operation 30 of 51 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
18. 6 Touch Return at the Standby Pump screen and then touch Menu From the Menu screen touch Stations Touch and hold a station icon to get to the Station Operator screen Then touch Setup to go to the Station Setup screen Use lt Back and Next gt to review all pump assignments Where necessary choose Assigned to Pump n to set station assignments to 0 unassigned Then return to the Transfer to Standby Pump screen 4 3 Alarms Reviewing Alarms To review your system s alarms touch Alarms on Menu screen The Alarm Log screen appears with the newest alarm listed first Figure 18 Alarm Log Screen Hi Vacuum Hi Hi Hi Hi Menu To scroll up and down through the list touch A and W at the bottom of the list 3 Pump 33 Station Controllers Chapter 4 Operation 39 of 51 Silencing Alarms Whenever a new alarm occurs your controller sounds the horn and turns on the strobe light at each central alarm Touch Alarm Silence on the alarm message banner that appears when a new alarm occurs or press the physical push button included in the central alarm option 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 lights should remain off If the alarm condition still exists when either of these times elapses the corresponding device horn or lights turn on again and
19. 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 blinking Priority Convey Active button The button changes to Priority Convey Activate and stops blinking The controller finishes the current convey if any and resumes normal operation 3 Pump 33 Station Controllers Chapter 4 Operation 35 of 51 4 3 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 31 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 following steps 1 At any screen touch the Menu and then touch Pumps The Pump Status screen opens 2 Touch and hold the icon for the pump The Pump Setup screen opens Figure 15 Pump Setup Screen HeU to Standby 0 HOURS Copy Pumps ON Time OFF
20. Time Pump 0 2 2 0 Fault Disabled Menu Secs Secs ain The box labeled x Hours Resettable shows the running time since the last reset The box labeled x Hours shows total running time To reset the resettable meter touch Hour Meter Reset The time above Hours Resettable changes to 0 3 Pump 33 Station Controllers Chapter 4 Operation 36 of 51 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 l At any screen touch Menu and then touch Pumps The Pump Status 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 Pu
21. a casual attitude toward machinery formed over a period of months or years Your employer probably has established a set of safety rules in your workplace Those rules this manual or any other safety information will not keep you from being injured while operating your equipment Learn and always use safe operation Cooperate with co workers to promote safe practices Immediately report any potentially dangerous situation to your supervisor or appropriate person Maintenance Responsibility Proper maintenance is essential to safety If you are a maintenance worker you must make safety a priority to effectively repair and maintain equipment Before removing adjusting or replacing parts on a machine remember to turn off all electric supplies and all accessory equipment at the machine and disconnect and lockout electrical power Attach warning tags to the disconnect switch Be sure that all non current carrying parts are correctly connected to earth ground with an electrical conductor that complies with current codes Install in accordance with national and local codes When you have completed the repair or maintenance procedure check your work remove your tools Rigging and handling equipment Reporting a Safety Defect If you believe that your equipment has a defect that could cause injury you should immediately discontinue its use and inform the manufacturer The principle factors that can result in injury are failure to follow pr
22. a en an ie 51 Seice DEPAMMONbi nisiowisie Bi E oni ies E E tv E E 51 Sales Department ee aaa aA a enaA EA AAAA TA iaer eaaa EE a ELAES 51 3 Pump 33 Station Controllers Chapter 1 Safety iv Contract Department 3 Pump 33 Station Controllers Chapter 1 Safety v Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining your equipment The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This manual covers only light corrective maintenance No other maintenance should be undertaken without first contacting a service engineer The Functional Description section outlines models covered standard features and optional features Additional sections within the manual provide instructions for installation pre operational procedures operation preventive maintenance and corrective maintenance The Installation chapter includes required data for receiving unpacking inspecting and setup of the equipment We can also provide the assistance of a 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 de
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24. an use the power switch at 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 blue and icons for enabled pumps are yellow Enabling stations and pumps is described on p 31 A button to start and stop the system is located in the lower right of the Station Status and Pump Status 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 Ifconveying 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 3 Pump 33 Station Controllers Chapter 4 Operation 32 of 51 Reviewing and Adjusting Basic Station Settings The 3 pump 33 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 l Go to the Station Status screen if needed To reach this screen from any other screen touch Menu and then touch Stations 2 Touch and hold th
25. at 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 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 a valve has malfunctioned Vacuum switch has Vacuum switch has malfunctioned 22222 O Note After you have corrected the cause of this alarm the alarm will be cleared when the controller has Shea one Se Orr a full load to this station Material container is Material container is empty ss No convey Convey imeistoshtn time is too short this station until the problem can be remedied See pp 43 Pump Alarms Pump failure Critical System Alarms Alarm message Possible cause Battery for the con
26. between the start of one pump and the next Use Backspace Key to erase any mistakes Use Enter Key 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 Status screen or the Pump Status 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 button 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 complete the following steps 1 Go to the System Setup screen by touching the Menu button on any screen Then touch System Setup The System Setup screen will pop up 2 On the System Setup screen Figure 4 touch the Button Delay button A keypad pops up 3 Enter the number of seconds between 0 and 99 for the button delay Use Backspace Key to erase any mistakes Use Enter Key to enter the value The keypad disappears and the new setting appears under Button Delay 3 Pump 33 Station Controllers Chapter 3 Installation 18 of 51 S
27. bled 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 See page 44 for details on the options and their default settings 3 Pump 33 Station Controllers Chapter 3 Installation 23 of 51 4 As appropriate setup the rest of the pumps using either of the following methods e Copy this pump s settings to one or more other pumps as described below e Use the Back or Next buttons to navigate to other pumps Touch Back to go to the previous Pump Setup screen or touch Next to go to the next Pump Setup screen e Touch Goto and enter a pump number to go to that pump s setup screen Copying Settings from One Pump to Others If other pumps at your facility will use the same settings as a pump you have already set up you can copy the settings from this pump to the others To do so At the Pump Setup screen Figure 9 for the pump you want to copy from touch Copy in the upper right corner The Pump Copy screen appears showing the pump number for the pump you are copying from Figure 10 Pump Copy Screen RETURN Pumps Follow the directions below to copy settings to one other station a range of stations or all stations e Copying to One Other Pump 1 On the Pump Copy screen Figure 10 touch the gray Copy to Pump button The keypad pops up 2 Enter the pump number for the station you are copying to U
28. d 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 3 Pump 33 Station Controllers Chapter 2 Functional Description 10 of 51 2 3 Standard Features Mechanical Features Time fill Capability The length of time a station s vacuum valve remains open to allow material to be drawn into its receiver Volume fill Capability The length of time a station s vacuum valve remains open to allow material to be drawn in The vacuum valve will close when material covers the station s volume fill proximity sensor or this time elapses whichever comes first Pump Blowback Filter Cleaning Outputs When this feature is enabled the controller periodically sends compressed air backward through the pump s air filter to dislodge accumulated dust and debris Electrical Features e 115 1 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 12 style electrical control enclosure Controller Features e Allen Bradley PLC with 6 color touch screen display e Monitors Station status and Pump status e Allows operator to tran
29. d the new setting appears under Pumps Present 3 Pump 33 Station Controllers Chapter 3 Installation 16 of 51 Setting Up Alarm Silences When an alarm occurs a horn sounds and a strobe light flashes at each installed central alarm An alarm banner screen appears An alarm message and Alarm Silence button are on the banner Touching this button silences the horn and turns off the lights for configurable periods of 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 Menu button on any screen Then touch System Setup The System Setup screen will pop up 2 On the System Setup screen Figure 4 touch the Strobe Suppress button A keypad pops up with an entry of 0 Figure 4 System Setup Screen Stations Pumps Menu 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 leave the setting at 0 If you want the light to stay off until a new alarm occurs enter 99 in the keypad Use Backspace Key to erase any mistakes Use Enter Key to enter the value The keypad disappears and the new s
30. e 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 14 Station Operator Screen STATION 1 OPERATOR Stations Assigned To Pump 1 Priority Convery Menu Activate Settings in the box labeled Convey the red Priority Convey Activate button and the menu controls on the right hand side of the screen appear for all stations 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 needs to be changed this must be done at the Station Setup screen 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 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 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 Backspace Key to erase any mistakes Use Enter Key to enter the value To exit to the Station Status or Pump Status
31. edures Names Description Cd Options __ Default Idle Time Options Auto shutdown delay Alarm Options Blow Back Options Blow back Every n loads Length of time the pump continues to run 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 The control has one input pump that you can wire to generate alarms for 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 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 When this option is enabled the controller periodically sends compressed air backward 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 Number of conveying cycles to stations between filter cleanings Adjust this setting based on experience The more dust and debris in your material line the smaller this number needs to be Number of pulses of compressed a
32. etting 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 42 43 discusses the individual choices Setting Up a Single Station 1 Go to the Station Status screen if needed To reach this screen from any other screen touch Menu on the right hand side of the screen and then touch Stations The Station Status screen appears Figure 5 Station Status Screen Menu 2 On the Station Status screen Figure 5 touch the icon for the station you want to setup and hold it for several seconds The Station Operator screen opens Figure 6 Station Operator Screen Before Setup STATION Stations Assigned Menu 3 On the Station Operator screen Figure 6 touch the Station Setup button The Station Setup screen opens 3 Pump 33 Station Controllers Chapter 3 Installation 19 of 51 Figure 7 Station Setup Screen STATION Convey Time 30 Secs Assigned To Pump No Convey 0 capi B4 Alarm Priority Convery Activate Defaults Menu 4 On the Station Setup screen Figure 7 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
33. etting appears under Strobe Suppress 4 On the System Setup screen Figure 4 touch the Horn Silence button A keypad pops up with an entry of 0 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 leave the setting at 0 If want the horn to stay off until a new alarm occurs enter 99 in the keypad Use Backspace Key to erase any mistakes Use Enter Key to enter the value The keypad disappears and the new setting appears under Horn Silence 3 Pump 33 Station Controllers Chapter 3 Installation 17 of 51 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 Go to the System Setup screen by touching the Menu button on any screen Then touch System Setup The System Setup screen will pop up 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
34. 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 hopper is off line Use the controller to put the vacuum receiver on line The convey time for the hopper 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 hoppers 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 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 3 Pump 33 Station Controllers Chapter 7 Troubleshooting 45 of 51 7 2 Alarms The form
35. he Station Copy screen Figure 8 touch the gray Copy to Station button The keypad pops up 2 Enter the station number for the station you are copying to Use Backspace Key to erase any mistakes Use an Enter Key to enter the value The keypad disappears and the Station Copy screen shows the station number you entered 3 Touch the green Copy to Signal Station button Complete briefly appears on the screen 4 As appropriate either continue copying to other stations or touch Return to go back to the Station Setup screen Copying to a Range of Other Stations 1 On the Station Copy screen Figure 8 touch the gray First Station button The keypad pops up 3 Pump 33 Station Controllers Chapter 3 Installation 21 of 51 2 Enter the station number for the lower end of the rang Backspace Key to erase any mistakes Use Enter Key to enter the value The keypad disappears and the Station Copy screen shows the station number you entered under First Station e you are copying to Use 3 On the Station Copy screen Figure 8 touch the gray Last Station button The keypad pops up 4 Enter the station number for the upper end of the rang Backspace Key to erase any mistakes Use Enter Key to enter the value The keypad disappears and the Station Copy screen shows the station number you entered under Last Station e you are copying to Use 5 Touch the green Co
36. ieeics3sci dee tteestaucysaniaeettonseevsatin ta sncenanndiudisbannesenteneds 36 Reviewing and Resetting a Pump Hour Meter sseeseeeseeenseenteenseenseenes 36 Transferring Stations to a Standby PUMP ccccccccceeeetttteeeeeeeeteneentneeeeeeeeenenes 37 4 3 Alar S seeds mictccta cries Gash a onde e a a ea a teeaeatunn came aeaaee 39 IRGVIGWING Alaris ssaniu nant a E aAA D A ORANA Ra i 39 Silencing AGI INS aroiu ennaa e a a eaea a aaa tar Mie 40 CHAPTER 5 MAINTENANCE cceeeeeeeesseeeeeeeseeaaeeeneeees 41 CHAPTER 6 CONFIGURABLE SETTINGG scceeeeees 42 6 1 Options for Station Setup vases sess tascncsicny chees seedeeeeencewedeaced nec neeelayandey acts ceeee anes ecentelens 42 6 2 Options for PUMP Setup ccccccseceseceeeeeeeeeaaeeaaeeaaeeaaeeaaeeaaeeaaeeaaeeaaaeaaaeaaaeaaeasaeaaea 44 CHAPTER 7 TROUBLESHOOTING csscceeeeeeeesseeeeeeees 45 7 1 General Troubleshooting sales casescdensateneg stave ccapeccenetenass veces cide eeedaenans vanity eereneneneee eres 45 Pee PARTING EAA EAT AAE E AENA TT 46 Station Alarmi S a aseos aded pnd m rao a a ad a N aan 46 Pump ALANIS gase e a e a aa a A RR 46 System Alar MS 5 ses Sieh scat el ose gus OR I AE a be ah 46 CHAPTER 8 APPENDIX ccccceeeeesseseeeeeeeeaeseeeeeeseeaaeeneeees 47 dat Warranty anoen ei a e AE E a EREE EEIT A AT a aa E ENEA 47 Warranty Spe cifiCationS 0 cccccccceeisseeeeeeeeeeeenee Error Bookmark not
37. ir 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 Number of seconds that the air compressor remains on for each pulse during filter cleaning If filter cleaning is not working as desired the service department may ask you to change this setting 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 3 Pump 33 Station Controllers Chapter 6 Configurable Settings 0 999 sec disabled enabled disabled enabled comp air enabled disabled j disabled vacuum pulse 44 of 51 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 The external disconnect recommended in the dedicated circuit is open off Close the switch on Fuse circuit breaker in the power Replace reset drop is blown tripped Control power switch is broken Replace The touch screen display doesn t Fuse in display is blown Replace come on when the control panel is Loose wiring to display Repair powered 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
38. l with Filter 3 A0541611 Fuse MDL 75 4 A0540997 Fuse MDL 1 1 A0540993 Fuse MDL 5 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 3 Pump 33 Station Controllers Chapter 8 Appendix 49 of 51 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
39. mp Status screen touch and hold the icon for any pump until the Pump Setup screen appears At the Pump Setup screen touch Transfer Stations To Standby Pump The Transfer to Standby Pump screen opens Figure 16 Transfer To Standby Pump Screen Transfer to Standby Pump Source Standby Pump Pump 1 2 RETURN Touch Source Pump The keypad pops up Enter the number of the failed pump Use Backspace Key to erase any mistakes Use Enter Key to enter the value The number appears under Source Pump Touch Standby Pump The keypad pops up 3 Pump 33 Station Controllers Chapter 4 Operation 37 of 51 9 Enter the number of the standby pump Use Backspace Key to erase any mistakes Use Enter Key to enter the value The number appears under Standby Pump and a button labeled Transfer to Standby Pump appears on the screen Figure 17 Transfer To Standby Pump Button Transfer to Standby Pump Source Standby Pump Pump 1 2 RETURN 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 a 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 another error occurs see the Standby Pump Errors section
40. n operator s password The section is divided into three sub sections 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 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 Menu on the right hand side of the screen and then touch Stations The Station Status screen appears Figure 11 Station Status Screen During Operation Menu 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 Menu The Menu screen opens 2 Touch Help The Help Menu screen opens 3 Touch Station States The Station Symbols Help screen opens explaining the status represented by each color 3 Pump 33 Station Controllers Chapter 4 Operation 28 of 51 4 When you are finished reviewing the information touch Return The Help Menu screen opens 5 Touch Menu to return to the Menu screen The following table explains the status represented by each color at the Station Status screen Gray outline Station is not enabled The cont
41. nergy They also provide a means of locking out or isolating the energy for servicing equipment Various agencies have contributed to the establishment of safety standards that apply to the design and manufacture of automated equipment The Occupational Safety and Health Administration OSHA and the Joint Industrial council JIC are just a few of the organizations that have joined with the plastics industry to develop safety standards Every effort has been made to incorporate these standards into the design of the conveying system however it is the responsibility of the personnel operating and maintaining the equipment to familiarize themselves with the safety procedures and the proper use of any safety devices Fail Safe Operation If a safety device or circuit should fail the design must be such that the failure causes a Safe condition As an example a safety switch must be a normally open switch The switch must be held closed with the device it is to protect If the switch fails it will go to the open condition tripping out the safety circuit At no time should the safety device fail and allow the operation to continue for example if a safety switch is guarding a motor and the safety switch fails the motor should not be able to run Safety Device Lock Outs Some safety devices disconnect electrical energy from a circuit The safety devices that are used in this Controller are primarily concerned with electrical power disco
42. ng 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 you are located
43. nnection WARNING Always disconnect and lockout all electrical power and pneumatic i e compressed air sources prior to servicing the 3 Pump 33 Station Controller Failure to do so may result in serious injury No one but the person who installed the lockout may remove it 3 Pump 33 Station Controllers Chapter 2 Functional Description 12 of 51 Chapter 3 Installation 3 1 Uncrating 3 Pump 33 Station Controllers are shipped mounted on a skid enclosed in a plastic wrapper and contained in a cardboard box 1 Pry the crating away from the skid Note Remove the nails holding the box to the skid and lift the box off carefully avoiding staples in the 1 x 4 wood supports Cut the steel banding 2 Use a pry bar to remove the blocks securing the unit to the skid 3 Lift unit from sides inserting forklift under the base The forks must be equidistant from the centerline of the unit and the unit must be balanced on the forks Lift slowly and only high enough to clear the skid Use a pry bar if necessary to carefully remove the skid from the unit 4 Lower slowly 3 2 Mounting the Control Panel Note Before you mount the panel consider how you run wiring to the 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
44. 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 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 CE Package for 220 1 50 Operation Required in Europe and other areas that need 220 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 3 Pump 33 Station Controllers Chapter 8 Appendix 47 of 51 8 3 Drawings and Diagrams Figure 19 3 pump 33 station Controller with 6 Display 30 Depth dimension is 12 Also review electrical drawings supplied in the packet with this manual 3 Pump 33 Station Controllers Chapter 8 Appendix 48 of 51 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 Gril
45. ompany 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 M 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 3 Pump 33 Station Controllers Chapter 1 Safety ii Table of Contents CHAPTER 1 SAFETY aiaia a a aaa Aaaa aa VI 1 1 How to Use This Manu
46. open the Password Entry keypad screen Figure 13 Password Entry Screen RETURN 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 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 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 Status screen and you must reenter the password to continue working When you have finished any tasks that require the password you should log off If you forget to do this the controller will log you off when the password expires To log off complete the following steps 1 Go to the Menu screen by touching Menu from any other screen 2 Touch Log Off Password The Station Status screen opens 3 Pump 33 Station Controllers Chapter
47. oper operating procedures i e lockout tagout or failure to maintain a clean and safe working environment 3 Pump 33 Station Controllers Chapter 1 Safety ix Chapter 2 Functional Description 2 1 Models Covered in This Manual This manual provides operation installation and maintenance instructions for 3 Pump 33 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 3 Pump 33 Station Conveying Controller is a programmable logic controller with 24 VDC or 115 VAC 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 affecte
48. 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 3 Pump 33 Station Controllers Chapter 3 Installation 13 of 51 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 On115 VAC control voltage systems run a common hot 115 VAC wire and a common neutral wire from the controller to each vacuum hopper in the system On 24 VDC control voltage systems run a common 24 VDC wire and a common 0 zero VDC wire from the controller to each vacuum hopper in the system 2 Onall systems run two wires to each vacuum hopper one each from the controller to the Bin Full switch LS and to the Atmospheric Sequence T solenoid SOL valve 3 Make sure
49. py to Range of Stations button Complete briefly appears on the screen 6 As appropriate either continue copying to other stations or touch Return to go back to the Station Setup screen Copying to All Other Stations 1 On the Station Copy screen Figure 8 touch the green Copy to All Stations button Complete briefly appears on the screen 2 Touch Return to go back to th Station Setup screen 3 Pump 33 Station Controllers Chapter 3 Installation 22 of 51 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 44 discusses the individual choices Setting Up a Single Pump l Go to the Pump Status screen if needed To reach this screen from any other screen touch Menu on the right hand side of the screen and then touch Pumps The Pump Status screen appears Figure 8 Pump Status Screen Stations Menu 2 Touch the icon for the pump you want to set up and hold it for several seconds The 3 Pump Setup screen opens Figure 9 Pump Setup Screen Before Setup Slepirsi g to Standby 0 HOURS Copy Pumps ON Time OFF Time Pump 0 2 2 0 Fault i Menu is deca Disabled Adjust settings as required Touching any box that appears in red for disa
50. 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 XXX3 33 Serial No 31K0182 Control Voltage 24VDC 3 Pump 33 Station Controllers Chapter 8 Appendix 50 of 51 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 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 ha
51. roller ignores any demands or alarms Station is enabled and idle full Station requires material Station is being loaded with material Light blue Station is dumping material into its receiver Green blinking Priority Station is in priority convey mode Its pump will be temporarily dedicated to filling it as soon as possible Red blinking Alarm 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 and pump assignment is available at the Station Operator screen See page 33 for details Detailed configuration settings for each station are available at the Station Setup screen See page 42 for details about each of these settings 3 Pump 33 Station Controllers Chapter 4 Operation 29 of 51 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 Menu on the right hand side of the screen and then touch Pumps The Pump Status screen appears Figure 12 Pump Status Screen During Operation Stations 1 18 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 Menu The Menu screen appears
52. screen touch Stations or Pumps 3 Pump 33 Station Controllers Chapter 4 Operation 33 of 51 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 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 Time To adjust a station s convey time or the dump delay 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 or Dump Delay A keypad pops up
53. scription of electrical and mechanical controls in addition to information for operating the equipment safely and efficiently The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service Preventive maintenance sections are included to ensure that your equipment provides excellent long service The Troubleshooting chapter serves as a guide for identification of most common problems Potential problems are listed along with possible causes and related solutions The Appendix contains technical specifications drawings schematics and parts lists A spare parts list with part numbers specific to your machine is provided with your shipping paperwork package Refer to this section for a listing of spare parts for purchase Have your serial number and model number ready when ordering Safety Symbols Used in this Manual The following safety alert symbols are used to alert you to potential personal injury hazards Obey all safety messages that follow these symbols to avoid possible injury or death Danger DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury Warning WARNING indicates a potentially hazardous situation or practice which if not avoided could result in death or serious injury Caution CAUTION indicates a potentially hazardous situation or practice which if not avoided ma
54. se Backspace Key to erase any mistakes Use an Enter Key to enter the value The keypad disappears and the Pump Copy screen shows the pump number you entered 3 Touch the green Copy to Single Pump button Complete briefly appears on the screen 3 Pump 33 Station Controllers Chapter 3 Installation 24 of 51 4 As appropriate either continue copying to other pumps or touch Return to go back to the Pump Setup screen e Copying to a Range of Other Pumps 1 On the Pump Copy screen Figure 10 touch the gray First Pump button The keypad pops up 2 Enter the pump number for the lower end of the range you are copying to Use Backspace Key to erase any mistakes Use Enter Key to enter the value The keypad disappears and the Pump Copy screen shows the pump number you entered under First Pump 3 On the Pump Copy screen Figure 10 touch the gray Last Pump button The keypad pops up 4 Enter the pump number for the upper end of the range you are copying to Use Backspace Key to erase any mistakes Use Enter Key to enter the value The keypad disappears and the Pump Copy screen shows the pump number you entered under Pump Station 5 Touch the green Copy to Range of Pumps button Complete briefly appears on the screen 6 As appropriate either continue copying to other pumps or touch Return to go back to the Pump Setup screen e Copying to All Other Pumps
55. sees 11 2 5 Safety Devices and lnterlockS ses sates peracdeessses bo ceenctdghatdstdoer tended davuert vas sr an Kauae tetorts 12 Safety Circ it SlANGAandS ino ade e hee es 12 Fail Sate Operation meri Sresi oe ated ead n e o E RE 12 Safety Device Lock OuUtS s iseserrosirsisrininiisnssrnidvadanidiiidianis oiie eines 12 CHAPTER 3 INSTALLATION ssseeeeeeeesseeeeeeeeeeeaeeeeeeees 13 Berl Uncrate a ovens a es bate tees A AE eed aap E A eed a caw eh den a 13 3 2 Mounting the Control Panel isi cece cccey cies scatsace nes caves saceeteeenecansyebees cheth ces tee ana eee 13 3 3 Electrical CONNMECTIONS 2 ce ceeeceeeeeeeeeeeeeeeecaeeaaeeaaeeeaeeeaaeaaaeaaaeeaaeeaaaaaaaeaes 13 Making Control Panel Power Drop Wiring Connections ccceetetteeeeeeteeeeee 13 Connecting the Control Panel to Vacuum HOPPel6 0ccccccceccceeeeeceeeeeseeees 14 Connecting the Control Panel to the Pump Package cccccececeteeeneeeeeeeeees 14 BF SOUP A E E A duetwesaeds nedesmbebsamtbnavensecedees 15 Setting the Number of Stations and the Number Of PUMP6G ccccccccccceee 15 Setting Up Alarm Sil nCes ccccccccccsscceeeccneceeeeeaaeeeaeeaaeeaaeeaaaeaaaeaaaeaaaeaaaeeaaaeaes 17 Setting Up PUMP Staging cccccccccccssecsnecsnscanecsneaaeeeaaeeaaeeaseeaaneaaeaaaeeaaaaanaaeneas 18 Setting Up Touch Switch Delay i siascece cise toate laeded cde ee ee a vetoes 18 Setting OP StQUONS iristen icini e
56. setting the number of stations and pumps setting variables such as convey time and blow back interval and setting up passwords We recommend that you carry out these procedures in the order given here Note Before carrying out these procedures install all equipment as described in this section and in the Mechanical Components manual Setting the Number of Stations and the Number of Pumps Figure 1 Default Station Status Screen Before Setup Pumps Menu 1 Atthe Station Status screen Figure 1 or at the Pump Status screen touch the Menu button The Menu screen opens Figure 2 Menu Screen Stations 2 At the Menu screen Figure 2 touch the System Setup button The System Setup screen opens 3 Pump 33 Station Controllers Chapter 3 Installation 15 of 51 Figure 3 System Setup Screen Before Setup Setup Duration 5 Min 3 Atthe System Setup screen Figure 3 touch Stations Present A keypad jl up 4 Enter the total number of stations 1 33 to be controlled by the system Use Backspace Key to erase any mistakes Use Enter Key to enter the value The keypad disappears and the new setting appears under Stations Present 5 Touch Pumps Present A keypad pops up 6 Enter the total number of pumps 1 3 to be controlled by the system Use Backspace Key to erase any mistakes Use Enter Key to enter the value The keypad disappears an
57. sfer stations to a standby pump when a pump fails e Electronic time delay between pump startups to prevent an excessive power demand at your facility 2 4 Optional Features Options marked with indicate options that can be factory installed or retrofitted in the field 230 1 60 Operation Required to operate with a 230 1 60 supply voltage Audible visual alarm Alarm light and horn assembly that can be remote mounted and wired into the controller to indicate an alarm condition CE Package for 220 1 50 Operation Required in Europe and other areas that need 220 1 50 supply voltage 3 Pump 33 Station Controllers Chapter 2 Functional Description 11 of 51 2 5 Safety Devices and Interlocks This section includes information on safety devices and procedures that are inherent to the Controller This manual is not intended to supersede or alter safety standards established by the user of this equipment Instead the material contained in this section is recommended to supplement these procedures in order to provide a safer working environment At the completion of this section the operator and maintenance personnel will be able to do the following 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 e
58. that the solenoid and the proximity switch if supplied on vacuum hoppers are the same voltage 24 VDC as the control panel voltage Consult the control panel serial tag and the solenoid valve nameplates 4 Wire size depends on control voltage distance number of vacuum hoppers and the number of wires in each raceway Consult a qualified electrician 5 Properly ground each hopper to reduce static build up generated by material conveying Connecting the Control Panel to the Pump Package 1 Wire the pump package motor starter coil M to the terminal provided in the control panel enclosure 2 Wire the pump package vacuum relief valve solenoid SOL A to the terminal provided in the control panel enclosure 3 Wire the pump package vacuum switch VS to the terminal located in the control panel enclosure 4 On vacuum pumps wire the pump package blowback solenoid SOL B to the terminal located in the control panel enclosure 5 On115 VAC control voltage systems run a common hot 115 VAC wire and a common neutral wire from the controller to each pump package in the system On 24 VDC control voltage systems run a common 24 VDC wire and a common 0 zero VDC wire from the controller to each pump package in the system 3 Pump 33 Station Controllers Chapter 3 Installation 14 of 51 3 4 Setup This section provides the procedures for configuring your 3 pump 33 station controller Configuration of your controller includes
59. troller is defective Eoubat Battery for the controller is defective ener Battery for the controller is old and drained 3 Pump 33 Station Controllers Chapter 7 Troubleshooting 46 of 51 Chapter 8 Appendix 1 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 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
60. ve 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 3 Pump 33 Station Controllers Chapter 8 Appendix 51 of 51
61. y result in minor or moderate injury or in property damage 3 Pump 33 Station Controllers Chapter 1 Safety vi 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 RRAK 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
62. ypad 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 3 Pump 33 Station Controllers Chapter 3 Installation 26 of 51 To change the duration of the password complete the following steps 1 On the System Setup screen Figure 4 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 Backspace Key to erase any mistakes Use Enter Key

Sterling Plumbing 882.00252.00 Musical Table User Manual

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