Home

Sterling 882.00255.00 CV3-655 Musical Table User Manual

1. Installing ArmorBlocks The ArmorBlock cable base should already be attached to the mounting plate aligned so it is perpendicular to the flat cables If not reinstall it with its proper alignment To install the flat cables in the ArmorBlock cable base 1 Lay the flat cable into the ArmorBlock cable base grey data cable on the bottom and the black power cable on the top making sure that the keyed edge is properly seated toward the top Caution EXERCISE CARE when handling the seal block Cable contacts are SHARP Only ONE attempt to pierce the cable is allowed for proper contact Figure 6 Using seal block to pierce cable 2 Align the seal block so the L shaped tabs are towards the top and the arrows are matched on the bottom of the cable base and seal block Make sure that the arrows and the four captive screws on the seal block are properly aligned Gently press it into place Make sure that you align the seal block properly when you attach it to the base Doing so maintains the integrity of the sealed base Note You can only pierce the cable once Once pierced the seal block must not be removed This insures that the inner conductors are not exposed to the elements Figure 7 Securing the Seal Block to the Cable Base 24 Pump 128 Station Controller Chapter 3 Installation 19 Match arrows When the so the seal lines of the block is in the seal block correct meet the position over b
2. 1 i 5 Sec Restore ALARN DeviceNet Nodes Name Set Time Suppression Purge Vlv ene Stations 13 47 6 23 2005 Material Pumps Operator Setup Operator Password Setup Password Password Duration Password Duration 5 Min 5 Min Help Not Active Note Touching Help in the lower right of this screen gives you a menu of online help for the choices in this screen 2 Touch Stations Present in the upper left of the System Setup screen 3 This will take you to the Stations Installed screen Stations Installed Node 2 Node 3 Next System Setup Node 4 Node 5 Stations Node 6 Pumps Node 7 Password Node 8 Not Active Node 9 A screen showing a list of stations appears The stations that are not installed are red The stations that are installed are green Briefly touching the icon for a station toggles between not installed and installed 4 Press System Setup to return to the System Setup screen 5 Touch Pumps Present in the upper part of the System Setup screen 6 This will take you to the Pumps Installed screen The screen shows a list of pumps The pumps that are not installed are red The pumps that are installed are green Briefly touching the icon for a pump toggles between not installed and installed 7 Press System Setup to return to the System Setup screen 24 Pump 128 Station Controller Chapter 3 Installation 37 8 The new setting appears under System Parameter
3. Enable this option if and only if your facility has installed a low level sensor for this station s receiver At times you may wish to disable it during operation as a stopgap measure for dealing with an alarm Grinder empty When this option is enabled a proximity switch is used to verify that material is present in the grinder bin The station will only be conveyed to when the receiver is empty and the grinder bin has material Grinder empty with When this option is enabled alarm monitoring is Alarm added to the grinder empty option described above If the grinder bin has material and the receiver is full a grinder full alarm is generated Option output Local alarm When this option is enabled the controller turns disabled disabled on the local alarm light for any alarm at this enabled specific station Enable this option if and only if your facility has installed a local alarm light for this station Blow back When this option is enabled the controller disabled disabled periodically sends compressed air backward enabled through the station s air filter to dislodge accumulated dust and debris Enable this option if and only if the station has the equipment for compressed air filter cleaning 24 Pump 128 Station Controller Chapter 6 Configurable Settings 66 Name Description 0000000 Default Options Every n loads Number of conveying cycles between filter cleanings Adjust this setting based on experience
4. Network Power Failure Control panel network cable is not installed correctly Power supply not connected properly 24 Pump 128 Station Controller Chapter 7 Troubleshooting 74 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 unused portion of this warranty This parts warranty does not cover any labor charges for replacement of parts adjustment repairs or any other work This warranty does not apply to any equipment which in the company s opinion has been subjected to misuse negligence or operation in excess of recommended limits including freezing or which has been repaired or altered without the company s express authorization If the serial number has been defaced or removed from the component the warranty on that component is void Defective parts become the property of the warrantor and are to be returned The company is not liable for any incidental consequential or special damages or expenses The company s obligation for parts not furnished as components of its manufactured equipment is limited to the warranty of the manuf
5. SCC 24 Pump 128 Station Controller Part Number 882 00255 00 Bulletin Number CV3 655 Effective 12 1 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 ACAUTION 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 providin
6. cssseeeeeeeeeneeeeeeeees 71 7 1 gt General Trouble nre eds te et A este 71 2 AIAN EE E EA 72 Station Alarms EE E EAE E N EE EEEE A EE E EEEE 72 PUMP ALAS Hacscuc si iit diene att tiara ited talaia 74 SV SLOT AIS ois besser ates A gente eclesial a ens 74 CHAPTER 6 APPENDIX coincidan 75 8 1 Warranty is cicero asi ciga aa An 75 3 2 Optional Components vacacional te 75 8 37 Drawings and Diagrams isaac 76 8 4 Spare Parts List a aci deel asta ed ewes 77 8 5 Returned Material Policy ic comic idad ces 78 Credit ROTURA A IA AAA 78 Warranty Returns iaa lc cats oak 78 8 6 Safety Tag INOrMalO Mia alas tato nin basic 79 CONTFONEE Safety TAGS i 8 a ee RS 79 8 7 Controller Identification Serial Number Tag ececeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeneaaaes 79 8 8 Technical Assistance Contact Information ceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeenaaaae 80 Parts Department tai 80 Service Department sna a Ida Oda ada ERAS 80 Sales BT cinco ei niamintmmitdaiastami ta eA A EA 80 Contract D Partiment e a a a aaea aa a a aae a e Eg A i 80 24 Pump 128 Station Controller Chapter 1 Safety 4 Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining your equipment The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This manual covers only light corrective maintenance No other
7. 5 Min 5 Min Help The current passvvords are displayed under Operator Passvord and Setup Passvord No value means that no passvvord is required 24 Pump 128 Station Controller Chapter 3 Installation 48 2 Touch Operator Password or Setup Password as appropriate A keypad pops up 3 Enter up to eight 8 alpha numeric characters If you want to remove the password protection simply leave the entry blank Use to erase any mistakes Use to enter the value The keypad disappears and the new setting appears under Operator or Setup Password In addition if you have added a password a new button appears on the screen labeled Log Off Operator If desired you can also change the duration for which a password remains effective During operation the password protected screens are available either until the user logs off or until this time elapses whichever comes first This feature prevents the password from remaining active if a user forgets to log off 4 The password timer starts when the user logs on It expires even if the user is actively using the screens when the chosen time is up If the timer expires the system goes to the Station Status screen Your password duration should be long enough to allow authorized users to complete their tasks but short enough to provide adequate protection against tampering To change the duration of a password 1 Atthe System Setup screen touch Operator Password Duration or Setup
8. 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 24 Pump 128 Station Controller Chapter 6 Configurable Settings 65 Name Description Options Default Partial convey When this option is enabled the controller disabled disabled issues a partial convey alarm if it has enabled repeatedly attempted to convey material to the station and material has moved from the station into the receiver but the volume fill proximity sensor has never signaled that the station is full The number of attempts is controlled by the next setting For a volume fill station this option should usually be enabled At times you may wish to disable it during operation as a stopgap measure for dealing with an alarm For a time fill station disable this option attempts B4 alarm Number of attempts before alarm the number of times the controller will attempt to convey material to a station before it issues a partial convey alarm The setting for this option depends on the same considerations as those given above for number of attempts before a no convey alarm Option Input Receiver low level When this option is enabled the controller disabled disabled issues a receiver level alarm if material in the enabled receiver drains below the level of the receiver s low level sensor
9. Adjust settings as required Touching any box that appears in red for disabled toggles it to green for enabled Many boxes have more than one embedded state Touching any box that appears in light gray gives you a keypad to enter a new value Keypad entry works as with many ATM machines the first digit you enter initially appears in the rightmost column and moves to the left as you enter more digits Use lt to erase any mistakes Use J to enter the value The keypad disappears and the Station n Setup screen shows the new value in the selected gray box Touching Reset To Defaults in the lower right of the screen changes all settings for this station back to their factory defaults See pp 64 68 for details on the options and their default settings 4 As appropriate a Copy this station s settings to one or more other stations as described below or b Touch Back lt to go to the Station n 1 Setup screen or c Touch Next P to go to the Station n 1 Setup screen Lor d Touch Goto and enter a station number to go to that station s setup screen 5 To save or restore settings go to the System Setup screen and touch Save Restore on the right side of the screen Naming Stations To name a station go to the Station Status screen Touch the icon for the station you want to name and hold it for several seconds The Station n Operator Settings screen for the selected station appears Touch Station Setup at the
10. M A RA RAK K M 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 Use extreme caution when working with your conveying system HIGH VACUUM can be dangerous Keep body parts tools clothing and debris away from vacuum inlets When welding or brazing in or around this equipment make sure VENTILATION is ADEQUATE PROTECT adjacent materials from flame or sparks by shielding with sheet metal An approved FIRE EXTINGUISHER should be close at hand and ready for use if needed Do not restore power until you remove all tools test equipment etc and the equipment and related components are fully reassembled Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment We have long recognized th
11. The more dust and debris in your material line the smaller this number needs to be pulses Number of pulses of compressed air sent through the station s filter during cleaning If blowback is not working as desired the service department may ask you to change this setting On time Number of seconds that the each air pulse lasts 0 1 99 9 sec 1 0 sec during filter cleaning If blowback is not working as desired the service department may ask you to change this setting Off time Number of seconds between air pulses during 0 1 99 9 sec 1 0 sec filter cleaning If blowback is not working as desired the service department may ask you to change this setting Slide gate When this option is enabled the controller disabled disabled opens the slide gate between the station and enabled the receiver during the dump delay and during blowback Enable this option if and only if the station has a slide gate instead of a flapper and demand switch Purge When enabled this option allows the system to disabled disabled empty the material line completely after every enabled convey to this station The station s pump continues to draw without picking up material for an extra period of time after conveying is finished Enable this option if and only if you are using a purge valve for this station This option cannot be used with a volume fill station Purge duration Number of seconds allowed for purging The 0 999 sec
12. station s vacuum valve remains open for the convey time plus this time Adjust this setting to the amount of time required for material to travel from the pickup point purge valve to the station Purge valve Number address for the purge valve used with 0 not this station assigned Set this to match the number address for the purge valve that services this station If another station has the purge valve that services this station enter the number of that station range 1 50 If a central purge valve services this station enter the number address of that valve range 51 154 Material set to n Number for the material line that should be 0 150 not connected to this station Ae Hee 24 Pump 128 Station Controller Chapter 6 Configurable Settings 67 Name Description Options Default RPV Remote This option allows the system to use a remote disabled disabled Proportioning Valve proportioning valve to mix two different enabled PLC materials typically virgin and regrind materials enabled local during a convey cycle Touching RPV repeatedly at the Station n Setup screen steps through the three choices Enable this option with PLC control if you will be adjusting the mix from the controller s touch screen Enable this option with local control if the station operator will be adjusting the mix using a timer box at the station RPV material B Percentage of the additive material to be 0 100 30 i
13. 11 Alarm Horn C 01 Alarm Silence Pushbutton B 12 Alarm Strobe Light D O2 Alarm Silence Pushbutton B 13 PA Le Alarm Horn D 03 4 Input 4 Output ArmorBlock for Central Alarms 5 Dress the excess patch cord cables with cable ties so they do not interfere with operation and to give a pleasing appearance 3 5 Setup This section provides the procedures for configuring your 24 pump 128 station controller Configuration of your controller includes setting the number of stations and pumps setting variables such as convey time and blow back interval and setting up passwords We recommend that you carry out these procedures in the order given here Note Before carrying out these procedures install all equipment as described in this section and in the Mechanical Components manual Figure below gives an overview of the basic flow between the menus used in setting up the system Figure 19 Basic Menu Flow for Setup Station Pump Summary Summary hold icon hold icon Pump n Setup System Setup Station n Operator Setup Station n Setup DeviceNet Node Status 24 Pump 128 Station Controller Chapter 3 Installation 36 Setting Up the System Setting the Number of Stations and the Number of Pumps 1 Touch System Setup at the Station Status or Pump Status screen The System Setup screen appears System Setup SYSTEM PARAMETERS Stations Pumps Pump Present Present Staging Save
14. Attach the other connector to the upper right terminal of the ArmorBlock Tighten the cord grip ring until snug 24 Pump 128 Station Controller Chapter 3 Installation 34 Figure 17 Proper Central Alarm Connections PATCH CORD 20FT 6M YELLOW ACS PART ND 40555190 ON ia VACUUM PIPE POWER FLAT CABLE BLACK A NETWORK FLAT CABLE GREY oe E ARMORBLOCK MOUNTING PLATE KIT 4 ACS PART No A0556696 NOTE EACH MOUNTING BLOCK REQUIRES 2 CLAMPS SPECIFIC TO THE PARTICULAR SIZE OF CONVEY PIPE Y i A 4 INPUT 4 OUTPUT ARMORBLOCK ACS PART No A0558296 ARMORBLOCK BASE ACS PART No A0555191 x PATCH CORD 20FT lt 6M gt YELLOW SN ACS PART NO 40555190 7 PUSH TO SILENCE BUTTON ACS PART 440563822 x ALARM ACS PART 840558082 3 Attach one connector of a yellow patch cord to the terminal on the alarm silence switch module Tighten the cord grip ring until snug 4 Attach the other connector to the upper left terminal of the ArmorBlock Tighten the cord grip ring until snug Note Retain the terminal caps from the ArmorBlock They may be used later Note the following illustration for 4 connector central alarm ArmorBlocks 24 Pump 128 Station Controller Chapter 3 Installation 35 Figure 18 4 Connector ArmorBlock Connections for Central Alarms Alarm Silence Pushbutton A 10 Alarm Strobe Light C O0 Alarm Silence Pushbutton A
15. Blowback PATCH CORD 20rr om YELLOW PART PAD5531590 POWER FLAT CABLE BLACK VAQUUN PIPE NCTWORK FLAT CABLE CRE 8 IMPUT 6 OUTPUT PERENA ACS PART 880555132 SUPPLIED WITH VACUUM PUMP FILTER CHAMBER W BLOWBACK 24 Pump 128 Station Controller Chapter 3 Installation 32 Figure 16 Proper Filter Chamber Connections Implosion Type PATCH CORD 20FT 6M YELLOW PART NUMBER A0555190 POWER FLAT CABLE BLACK _ VACUUM PIPE NETWORK FLAT CABLE GREYS ARMURBLUCR MOUNTING PLATE KIT ACS PART 440556696 J 8 INPUT 8 DUTPUT ARMORBLOCK ACS PART A0555192 IMPLOSION FILTER CHAMBER intel Note Retain the terminal caps from the ArmorBlock They may be used later 2 Dress the excess patch cord cables with cable ties so they do not interfere with operation and to give a pleasing appearance 24 Pump 128 Station Controller Chapter 3 Installation 33 Connecting Central Alarms to the Network Make sure that all previous installation steps have been done first before starting this task First determine where the best location for central alarms should be and install the alarm module s there You ll use two yellow patch cords to connect To connect an alarm module to the network 1 Attach one connector of the first yellow patch cord to the terminal on the alarm module Tighten the cord grip ring until snug 2
16. 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 Operator Responsibility The operator s responsibility does not end with efficient production The operator usually has the most daily contact with the equipment and intimately knows its capabilities and limitations Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates or through a casual attitude toward machinery formed over a period of months or years Your employer probably has established a set of safety rules in your workplace Those rules this manual or any other safety information will not keep you from being injured while operating your equipment Learn and always use safe operation Cooperate with co workers to promote safe practices Immediately report any potentially dangerous situation to your supervisor or appropriate person 24 Pump 128 Station Con
17. Station n Operator Settings screen The Station n Setup screen appears 1 Press Name Line 1 at the bottom of the Station n Setup screen A keypad will pop up 24 Pump 128 Station Controller Chapter 3 Installation 42 2 You can enter a name of up to four 4 alpha numeric characters If you would like to enter a longer name you can go back to the Station n Setup screen and press Name Line 2 torepeatthe process Using Name Line 2 will allow you to enter up to four 4 more alpha numeric characters for a total of eight 8 characters The characters will appear as two four digit names on two separate lines Use lt to erase any mistakes Use to enter the value Note Make sure to choose different names as the system does not recognize duplicate names 3 You can scroll through the stations by scrolling through Back and Next at the top of the screen Copying Settings from One Station to Others If other stations at your facility will use the same settings as a station you have already set up you can copy the settings from this station to the others To do so 1 At the Station n Setup screen for the station you want to copy from touch Copy in the screen s upper right The Station Copy screen appears showing the station number for the station you are copying from Source Station 1 1 y 7 C T Copy to T Stations Single 5 Station 5 Pumps Copy to First Last Station E Station Station Setup Range of Stati
18. When this option is enabled the controller disabled disabled periodically sends compressed air backward enabled through the pump s air filter to dislodge accumulated dust and debris Enable this option if and only if the pump has the equipment for compressed air filter cleaning Every n loads Number of conveying cycles to stations between 1 99 5 filter cleanings Adjust this setting based on experience The more dust and debris in your material line the smaller this number needs to be 24 Pump 128 Station Controller Chapter 6 Configurable Settings 69 Name Description FC Options Default pulses Number of pulses of compressed air sent 1 99 5 through the pump s filter during cleaning If blowback is not working as desired the service department may ask you to change this setting On time Number of seconds that the air compressor 0 1 99 9 sec remains on for each pulse during filter cleaning If blowback is not working as desired the service department may ask you to change this setting Off time Number of seconds between air pulses during 0 5 99 9 sec filter cleaning If blowback is not working as desired the service department may ask you to change this setting Implosion with Seal When this option is enabled the controller Valve builds a vacuum in the filter chamber by isolating it from the rest of the system with the sealing valve The vacuum is then released to dislodge dust and debris Implosion without
19. company Substantiate the claim by referring to the agent s report A certified copy of our invoice is available upon request The original Bill of Lading is attached to our original invoice If the shipment was prepaid write us for a receipted transportation bill Advise customer service regarding your wish for assistance and to obtain an RMA return material authorization number If the Shipment is Not Complete Check the packing list as back ordered items are noted on the packing list In addition to the equipment itself you should have M Bill of lading M Packing list M Operating and Installation packet 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 24 Pump 128 Station Controller Chapter 1 Safety 2 Table of Contents CHAPTER 1 SAFETY atencions an 5 Te low to Use This M
20. 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 24 Pump 128 Station Controller Chapter 8 Appendix 78 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 XXX24 128 Serial No 31K0182 Control Voltage 24VDC 24 Pump 128 Station Controller Chapter 8 Appendix 79 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
21. 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 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 techni
22. shutdown delay the pump will turn off Pump s air filter is being cleaned by blowing compressed air backward through it lt Nell until the alarm is cleared Light Yellow Pump is waiting for material to become available Additional information about each pump including configuration settings and the number of hours the pump has been running is available at the Pump n Setup screen For details on configuration settings see page 42 For details on the hour meter see page 59 Logging On and Logging Off Your controller may be set up to require a password for any operation other than reviewing station and pump status silencing alarms reviewing the alarm log and looking at help screens If so a password entry screen will appear Password Entry A Password is required for the selected action Please press the button below to enter a password Enter Password Press the Enter Password button A keypad will appear 24 Pump 128 Station Controller Chapter 4 Operation 54 e Enter the alphanumeric password ag you touch it Press when complete Each digit appears as an If you have lost the password s contact the manufacturer for assistance Once you have logged on the password remains active until you log off or the password expires Setup personnel at your facility control the number of minutes before the password expires While the password is active you can continue to carry out password p
23. the setup for stations pumps and the system during operation See Chapter 4 System Setup for information on the procedures and options Reviewing and Resetting a Pump Hour Meter The controller keeps two meters for the length of time a pump has run One like a car s odometer keeps a running total and cannot be reset The other like a car s trip odometer counts the running time since the last reset To review and reset the hour meter 1 At any screen touch Pumps The Pump Status screen appears 2 Touch and hold the icon for the pump The Pump n Setup screen appears Pump Setup 1 Back Next gt Goto Copy Stations Pumps On off Pump Time Time Service 1 0 Sec 1 0 Sec 3 Pulse s gt Password Pump Pump ese Not Active Fault 1 Fault 2 Disabled Disabled Help The box labeled x Hours Resetable shows the running time since the last reset The box labeled x Hours shows total running time 3 To reset the resettable meter touch Hour Meter Reset The time above Hours Resetable changes to 0 Transferring Stations to a Standby Pump If a pump fails you can transfer all of the controller s station assignments for that pump to a standby pump To do this you must disable take offline both the source pump and the standby pump and the standby pump must have no stations already assigned to it The transfer operation at the controller s touch screen merely changes the pump assignment for
24. 1 x 4 wood supports Cut the steel banding 2 Use a pry bar to remove the blocks securing the unit to the skid 3 Lift unit from sides inserting forklift under the base The forks must be equidistant from the centerline of the unit and the unit must be balanced on the forks Lift slowly and only high enough to clear the skid Use a pry bar if necessary to carefully remove the skid from the unit 4 Lower slowly 3 2 Mounting the Control Panel Note Before you mount the panel consider how you run wiring to the KwikLink connectors ArmorBlocks vacuum hoppers the filter cham ber atmospheric valve if so equipped and the pump motor starter s vacuum switch es and vent valve s Mount the control panel on a flat vertical area It should be a visible area that gives your operator access to the control The panel requires a low voltage power drop as listed on the serial tag 3 3 System Installation Overview Installing the 24 pump 128 station controller is easy and straightforward Because the system uses networked distributed I O modules you ll only need to run two cables for the entire system The following is a typical installation sequence 1 Set up mounting plates with tubing clamps install KwikLink connectors and ArmorBlocks bases onto mounting plates as required 2 Install KwikLink connectors and ArmorBlock base plates to vacuum tubing at each node location just before a T fitting or valve 3 Run the
25. 1 to 32 Vacuum hopper receiver stations use a leading zero for numbers 01 to 09 e 33 to 44 Pump stations e 45 to 60 Central purge valves 24 Pump 128 Station Controller Chapter 3 Installation 17 e 61 to 63 Alarm stations Setting ArmorBlock Addresses Locate the rotary switches underneath the ArmorBlock The two switches are e MSD most significant digit for tens e LSD least significant digit for units ones For example if you wanted to set an address at 36 you set the MSD rotary switch at 3 and the LSD rotary switch at 6 To set an address of 8 set the MSD rotary switch at 0 leading zero then set the LSD rotary switch at 8 e Using a permanent black marker write the number of the address on the white label located on the bottom front of the ArmorBlock We suggest that you place numbered tags at node locations to ease installation and reduce any confusion of locations To set the node address e Use a small straight bladed screwdriver to rotate the switches Line up the small arrowhead on the switch with the number you want to select The following figure shows that the address is set at 01 the MSD rotary switch is set at 0 and the LSD rotary switch is set at 1 24 Pump 128 Station Controller Chapter 3 Installation 18 Figure 5 ArmorBlock Address Node Rotary Switches o o MAA o Set MSD 0 V a0 I P l aen IERS sl db 34 H eSa y
26. 26 Figure 11 Proper Vacuum Receiver Connections 8 INPUT 8 OUTPUT ARMORBLOCK ACS PART 40555192 ARMORBLOCK BASE ACS PART 40555191 OUTPUT POWER FLAT CABLE BLACK VACUUM PIPE NETWORK FLAT CABLE GREY Mx ARMORBLOCK MOUNTING PLATE KIT ACS PART A0556696 NOTE EACH MOUNTING PLATE REQUIRES 2 TUBING CLAMPS SIZED FOR THE CONVEYING SYSTEM VACUUM LINE PATCH CARD 20FT 6M YELLOW ACS PART A40555190 SEE DWG HA0563626 FOR CLAMP SIZING INFORMATION VACUUM HOPPER O VOLUME FILL PROXIMITY SWITCH OPTIONAL OS BOX DC MICRO RECEPTACLE ACS PART A0555194 24 Pump 128 Station Controller Chapter 3 Installation 27 Connecting Vacuum Pumps and Filter Chambers to the Network Connecting Vacuum Pumps Make sure that all previous installation steps have been done first before starting this task To connect a vacuum pump to the network 1 Attach patchcords from vacuum pump junction boxes to the appropriate ArmorBlock connectors See Figures 12 13 and 14 Figure 12 4 Vacuum Pump ArmorBlock Connections Note 1 The block shown is addressed 33 for the first 2 pumps The block addressed 34 would have connectors for pumps 3 and 4 etc Note 2 If a pump does not have Pump Fault 2 or a local pump alarm light the T connector is not required Connect the patchcord directly to the connector on the ArmorBlock 24 Pump 128 Station Controller Chapter 3 Installation 28 Figur
27. 847 439 5655 We have a qualified service department ready to help Service contracts are available for most products Sales Department Call 630 595 1060 Monday Friday 8am 5pm CST Our products are sold by a worldwide 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 24 Pump 128 Station Controller Chapter 8 Appendix 80
28. 9 for details 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 1 Touch Pumps The Pump Status screen appears Pump Status Siete Ln 1 Pmp Ln 2 Pmp Ln 3 Pmp La 4 Prop Loading a Filter Cleaning Alarm an ee Critical Alarm Es ke Bo Bo Ln 9 Pmp Ln10 Pmp System Setup Stations Alarms Push to Stop System Help The status of each pump is color coded as summarized in the upper right of the screen You can see a more detailed explanation of each status by using the online help To do so from this screen 24 Pump 128 Station Controller Chapter 4 Operation 53 2 Touch anywhere in the rectangle in the upper right of the screen or the Help button on the lower right side of the screen The Help Menu appears 3 In the section of the Help Menu labeled Screen Symbols Colors touch Pump The Pump Symbols help screen appears explaining the status represented by each color 4 When you are finished reviewing the information touch Pumps or Stations The Pump Status or Station Status screen appears The following table explains the status represented by each color at the Pump Status screen Pump is not enabled The controller ignores any alarms Pump is off waiting for demand from a station Light Green Pump is on waiting for demand from a station If there is no demand before the end of the auto
29. Goto and enter a pump number to go to that pump s setup screen 5 To save or restore settings go to the System Setup screen and touch Save Restore on the right side of the screen Naming Pumps To name a station go to the Pump Status screen Touch the icon for the pump you want to name and hold it for several seconds The Pump n Operator Settings screen for the selected pump appears Touch Pump Setup at the Pump n Operator Settings screen The Pump n Setup screen appears 3 Press Pump Name at the bottom of the Pump n Setup screen A keypad will pop up 6 You can enter a name of up to eight 8 alpha numeric characters Use lt to erase any mistakes Use to enter the value Note Make sure to choose different names as the system does not recognize duplicate names 6 You can scroll through the pumps by scrolling through Back and Next at the top of the screen Copying Settings from One Pump to Others If other pumps at your facility will use the same settings as a pump you have already set up you can copy the settings from this pump to the others The station name will not be copied To copy settings from one pump to others 1 At the Pump n Setup screen for the pump you want to copy from touch Copy in the screen s upper right The Pump Copy screen appears showing the pump number for the pump you are copying from Source Pump Pump 1 1 y y C T Copy to D Stations Single 2 Pump Pump 2 Pumps Copy to First Las
30. Password Duration as appropriate A keypad pops up with an entry of the current setting 2 Enter the number of minutes range 2 99 Use lt to erase any mistakes Use J to enter the value The keypad disappears and the new setting appears under Operator or Setup Password Duration Save Restore Settings To save settings go to the System Setup screen and touch Save Restore on the right side of the screen Touch Save Settings When the settings have been saved the controller will display Save Complete The date and time will appear under Restore Settings To restore old settings touch Save Restore TouchRestore Settings The controller will display the most recent date and time that the settings were restored 24 Pump 128 Station Controller Chapter 3 Installation 49 3 6 Initial Startup Once you have finished all the setup described above you are ready to start the system To do so 1 At any screen touch Stations on the right hand side of the screen The Station Status screen appears 2 For each station that you want to use briefly touch its icon The icon turns blue indicating that the station is ready or yellow indicating that the station needs material 3 Touch Pumps The Pump Status screen appears 4 For each pump that you want to use briefly touch its icon The icon turns blue indicating that the pump is ready 5 Touch Push to Start System in the lower right hand corner of the screen
31. REEN DISPLAY al H EN La 1 Ll de EAs VACUUM LINE SEQUENCE VALVE El POWER SURELY WITH VACUUM HOPPER 2 a OPTIONAL REMOTE JCH SCF N DISPLAY 8 4 Spare Parts List Quantity Part Number Description 1 A0569859 Fan grill vvith filter 1 739 00017 00 4A Power supply 1 A0542203 2A MDL fuse 1 A0568903 10A FNQ fuse 1 A0542205 2 5A MDL fuse 1 A0542209 4A MDL fuse 24 Pump 128 Station Controller Chapter 8 Appendix 77 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 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
32. The system starts If any alarm messages appear on the top of the screen see Section 3 5 on page 62 24 Pump 128 Station Controller Chapter 3 Installation 50 Chapter 4 Operation 4 1 Overview Your 24 128 controller electrically controls valves and solenoids to convey material from a central location to individual stations as needed The controller senses demands for material at the stations and responds to the demands in a timely fashion This section gives the procedures for using your controller and it covers tasks that can be carried out with no password or with an operator s password The section is divided into four sub sections e Starting and stopping the system e Basic tasks tasks normally carried out by a station operator e Advanced tasks tasks normally carried out by setup personnel e Alarms silencing and clearing alarms Before you carry out any of the procedures in this chapter the system must be set up as described in the previous chapter 4 2 Starting and Stopping the System In an emergency you can use the power switch on the upper right hand side of the controller cabinet if a password is required to stop the system and you do not know the password Normally all the stations and pumps you want to use should be enabled before you start the system When the system is stopped icons for enabled stations are blue when full and dark yellow when they need material Icons for enabled pumps are blue Enabling stati
33. When this option is enabled the controller Seal Valve builds a vacuum in the filter chamber by isolating it from the rest of the system by closing all the station sequence valves assigned to that pump The vacuum is then released to dislodge dust and debris Every n Loads 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 Pulse s Number of pulses of compressed air sent through the pump s filter during cleaning If blowback is not working as desired the service department may ask you to change this setting build up in the filter chamber the filter chamber to dissipate 24 Pump 128 Station Controller Chapter 6 Configurable Settings 70 Chapter 7 Troubleshooting 7 1 General Troubleshooting Problem_______ Possible cause J Solution The controller panel ie noi Plug in the controller panel ah connected to a power source The controller panel doesn t light Fuse circuit breaker in the power up at all l Replace reset drop is blown tripped Broken controller power switch Reset the circuit breaker and The motor circuit breaker check the motor for the proper A pump package doesn t run overload has tripped amp draw on tag though it i li it sl analis Main fuse in power drop circuit Replace the fuse reset circuit indicator is lit breaker ha
34. ____________ Options___ Default Conveying Options Convey time Length of time the station s vacuum valve 0 999 9 sec 30 sec remains open to allow material to be drawn in For a volume fill station the valve closes when material covers the station s volume fill proximity sensor or this time elapses whichever comes first Adjust this value to match the actual time needed to fill the station Last convey time Display only Length of time the station s vacuum valve was open for receiving material during the most recent convey This information is displayed for your reference when adjusting convey time and dump delay Dump delay Length of time allowed for material to drain from 3 99 sec 10 sec the station into the receiver The controller will not attempt to deliver more material to the station until this time has elapsed Adjust this value to match the actual time needed to drain the station If it is set too short the controller may attempt to refill the station before it is empty causing material to back up and or underusing the station s capacity If it is set too long the system may be unable to keep up with your equipment s demand for material 24 Pump 128 Station Controller Chapter 6 Configurable Settings 64 Name_________ Description_____________________ Options__ Default Conveying Options Assigned to pump n Name of the pump to which this station s vacuum line is connected Special con
35. ach the keyed round connector to the terminal of the controller marked DeviceNet Tighten the cord grip ring until snug 2 Align the square connector of the grey drop cable so the cable leads down from the connector Evenly press the square connector onto the top of the KwikLink connector It should make two audible snaps when properly seated 3 Dress the excess cable with cable ties so it does not interfere with operation and gives a pleasing appearance Connecting the Remote Interface to the Main Controller After selecting a location and installing the remote interface connect it to the main controller 1 Install the Ethernet switch in a location safe from electrical interference and physical damage 2 Install the remote interface s in their desired locations 24 Pump 128 Station Controller Chapter 3 Installation 21 3 Run the cables from the remote interface s to the switch and the main controller neatly dressing the cable with ties so that it does not interfere with system operation and it gives a neat appearance 4 Attach RJ45 connectors at each cable end following the connector manufacturers instructions 5 The Ethernet out connection on the main controller should connect to the Ethernet in connection on the switch 6 The Ethernet out connections on the switch should connect to the Ethernet in connections on the main controller and the remote interface s 24 Pump 128 Station Controller Ch
36. acturers 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 Additional audible visual alarm with silence button Alarm light and horn assembly that can be remote mounted and wired into the controller to indicate an alarm condition Remote Interface 24 Pump 128 Station Controller Chapter 8 Appendix 75 8 3 Drawings and Diagrams Figure 20 24 Pump 128 Station Controller with 10 Display Also review electrical drawings supplied in the packet with this manual Note Allow 12 of clearance on each side of the controller for ventilation and cables 24 Pump 128 Station Controller Chapter 8 Appendix 76 Figure 21 Typical System Installation Layout LE di q gl i Ex JE yl TT l a 2 A FE CENTRAL ALARM WITH i i IV SHUTOFF SWITC 06 MAIN CONTROL D 7 o TOUCH SC
37. anual tacita data 5 Safety Symbols Used in this Manual cut odo 5 1 2 Warnings And PrecaUtOnSs eina techies Agee leusigeds wei aetna awsdv avian neces 6 1 8 Responsibility ps mererin ierte alain 7 General ROSpOnSIDMY oi e ia 7 Operator Responsibility oooooococnccnnnccnnccononononononnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnss 7 Maintenance RespONSIDINV eiii te osas 8 Reporting a Safety Defeat dt A ia ated 8 CHAPTER 2 FUNCTIONAL DESCRIPTION sssceeeeeeees 9 2 1 Models Covered in This Manada illa 9 2 2 General Descriptions rrei a a a a aae dar A e a 9 2 Standard ESTOS as tam e ues ae RA E a A is 9 Mechanical Feature Ss issin olan pha inet eta oasi amat wal iaai 9 Electrical FOQtures ccccccccceceeeseeeseeeeeceneeseeeeeeseessseeseeeeteeseeeeeseeeeeeeseeeeeeeeeseeeees 10 E pinan pae a poea a eean 10 2 4 Optional Features seient ad 10 2 5 Safety Devices and InteriocRS ii concoconinconi cast dit 10 Safety Circuit STAN it A een contes 11 Fail Sale OPA Der eae dada aati ee 11 Safety Device LOCK OUES icono a a 11 CHAPTER 3 INSTALLATION sssseeeeeeeseseeeeeeseeaaeeeneeees 12 3 1 UnceratiNg eiss temes estretes Millet mts wedge towth tans 12 3 2 Mounting the A A ates 12 3 3 System Installation OvervieW seues meten ds 12 34 Electrical Connections mesmestema taments sotenmtomaotemmbmnmteetsncemdme iessor 13 Making Control Panel Power Drop Wiring Connections oooeoeeee
38. apter 3 Installation 22 Figure 8 Proper Controller and Remote Interface Connections POWER FLAT CABLE BLACK ARMORBLOCK MOUNTING PLATE KIT A ae ACS PART A0556696 ee eee NOTE EACH MOUNTING BLOCK REQUIRES 2 CLAMPS SPECIFIC TO THE PARTICULAR SIZE OF CONVEY PIPE VACUUM PIPE TSS USED SEE DWG A0563626 FOR CLAMP SIZING REQUIREMENTS NETWORK FLAT CABLE CREY 7 POWER OR NETWORK TAP CABLE DROP ACS PART A0555195 1 CORD IS REQUIRED amp IS CONNECTED AS SHOWN TO THE NETWORK FLAT CABLE GREY MAIN TOUCH SCREEN CONTROL DISPLAY CATS ETHERNET CABLE 1 CABLE IS NEEDED PER DISPLAY AS SHOWN CONNECTED TO ANYD TERMINAL OF THE ETHERNET SWITCH ETHERNET SWITCH ENS P REMOTE TOUCH SCREEN PA CONTROL DISPLAY Connecting the Power Supply Enclosure to the Network The power supply provides electrical power to make the system work Some network layouts require more than one power supply Location is also an important consideration when locating power supply enclosures on your network Contact the factory for determining how many power supply enclosures your system needs as well as where they need to be installed After you ve mounted the power supply enclosure s you can connect them to your network To connect a power supply to the network 24 Pump 128 Station Controller Chapter 3 Installation 23 1 Attach a KwikLink connector included in
39. ase itis the cable fully seated base To secure the seal block 1 Start the threads of each of the four captive screws into the cable base receptacle holes 2 Drive each of the screws about halfway down using the proper torque sequence Bottom screw top screw left screw right screw Doing so insures that the cables are pierced evenly 3 Using the proper torque sequence tighten each screw a little at a time until the seal block is fully seated into the cable base Tighten to no more than 8 to 10 inch pounds 3 0 to 3 7 Nem of torque The three seat lines on the seal block should meet the cable base indicating that the seal block is fully seated The seal block clips should also click into place onto the corresponding cable base slots Installing KwikLink Connectors KwikLink connectors let you connect the controller and the power supply to the system They are also used to electronically terminate power cable and data cable runs Just like ArmorBlocks KwikLink connectors are insulation displacement connectors IDCs Caution Exercise care when installing Kwiklink connectors IDC blades on KwikLink connectors are SHARP Gently push back any protruding IDC blades before installing flat cables inside The KwikLink connector should already be attached to the mounting plate so the hinge side is down If not reinstall it with its proper alignment along the correct flat cable See the installation drawing located in yo
40. atures Mechanical Features Time fill Capability The specific length of time allowed for material to convey to a station Volume fill Capability Allows for a station to be conveyed to until the prox at the top of the station detects material Vent Valve The vent valve unloads the vacuum pump motor and allows it to keep running during short periods when material conveying is not required Constantly starting and stopping the vacuum pump will damage it over time The vent valve also protects the conveying system from damage during high vacuum conditions The valve plunger will unseat itself and allow ambient air to leak into the vacuum lines when the vacuum climbs too high Central Purging This feature allows any remaining material to be cleaned out of the material line after every convey Local Blowback Filter Cleaning When this feature is enabled the controller periodically sends compressed air backward through the pump s air filter to dislodge accumulated dust and debris 24 Pump 128 Station Controller Chapter 2 Functional Description 9 Implosion Filter Cleaning When this feature is enabled the controller periodically pulls a vacuum on the filter chamber and then releases it to dislodge accumulated dust and debris Grinder Empty This feature allows a station to receive material from a grinder bin The level of material in the bin is monitored to assure there is enough material to convey Material Sharing This feature allow
41. black power and the grey network flat cables from the start of the system to the end attaching them to vacuum tubing with nylon cable ties 4 Install cable terminations 5 Determine location of network system nodes and set addresses for ArmorBlocks as required 6 Set up and connect to the controller and if purchased remote display Connect grey patch cords from controller terminals to KwikLink connectors installed in Step 3 7 After determining quantity and location s of where to install system power supply ies consult factory set up and connect to KwikLink connectors installed in Step 3 24 Pump 128 Station Controller Chapter 3 Installation 12 8 Set up and connect vacuum receiver stations to ArmorBlocks installed in Step 3 using yellow patch cords 9 Set up and connect vacuum pump stations and filter chambers to ArmorBlocks installed in Step 3 using yellow patch cords 10 Determine location s of central alarm s set up and connect alarms using yellow patch cords The following sections provide detailed information on these installation steps 3 4 Electrical Connections Refer to local electrical codes the schematic and connection diagrams supplied with this unit and the serial tag for wiring considerations Run all wiring in conduit if codes require it Making Control Panel Power Drop Wiring Connections Hardwire the input power at 115 1 50 60 VAC or 220 1 50 VAC depending on the specifications which are lo
42. cal 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 24 Pump 128 Station Controller Chapter 1 Safety 5 1 2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications following national and local safety codes This may include but is not limited to OSHA NEC CSA SPI and any other local national and international regulations To avoid possible personal injury or equipment damage when installing operating or maintaining this equipment use good judgment and follow these safe practices
43. cated on the Control Panel Serial Tag The control enclosure draws less than five 5 amps during normal operation at 115 1 50 60 VAC The main power switch is located on the right side of the enclosure Caution We recommend that you protect PLC memory by providing the control panel with a dedicated circuit a true earth ground and a spike surge protector Running KwikLink Cables About KwikLink Flat Cables KwikLink flat cable is physically keyed to prevent wiring mishaps This type of cable is unshielded and contains four conductors Use a long jawed straight bladed cable cutter at least 1 2 long to cut KwikLink flat cable You ll install two 2 colors of flat cable black and grey The black cable transmits output power and the grey cable transmits input power and data transmission Figure 1 KwikLink Cable Cross Section Edge Identification Cross Section Edge Identification de power pair 16 AWG red black 5 3 mm jun in O keyed edge sah mm white blue 0 10 in data pair 16 AWG 19 3 mm 0 76 In flat edge Installing KwikLink Cable Before you install flat cable determine how much length you need to install black power cable and grey data cable Typical installations have equal lengths of each This is a good time to plan for the future and run these cables to each possible location in the plant Use a straight blade cable cutter to make the cut at each end 24 Pump 128 Station Controll
44. de 2 Making sure that the cable is completely straight carefully close the hinged assembly and apply firm even pressure until the first latch locks into place Note Make sure that the flat cable is completely straight before continuing 24 Pump 128 Station Controller Chapter 3 Installation 16 The latch has two catches the first loosely holds the connector on the cable the second requires more pressure to close the connector tightly The cable must be in the correct position for the connector to close properly 3 Drive the two screws at the center points about halfway down first on the latch side then the hinge side 4 Continue to tighten the screws a little at a time until fully tightened no more than 15 inch pounds 5 6 Nem of torque Note You can only pierce the cable once Once pierced the KwikLock connector must not be removed This insures that the inner conductors are not exposed to the elements The system should now be properly terminated You can now continue to install components on the system Figure 4 Proper Termination Connections Addressing and Installing ArmorBlocks Addressing ArmorBlocks An ArmorBlock permits you to give it a number address so that the controller network system can recognize its location and function ArmorBlocks are used at vacuum hopper receiver pump and alarm node locations ArmorBlock Address Ranges The number range of ArmorBlock addresses are as follows e 0
45. e 13 Running KwikLink Cables ioga es tell 13 Setting Up and Installing Mounting Plates eeooooooooenneneeee 14 Terminating Cable RUS ci teta tiet 15 Addressing and Installing ArmorBIOCRS YN ooooooaaaannnnnmmmeiiaiiiaiiannnnnnn 17 Installing KWIKLINK Connectors iii iaa 20 Connecting the Controller to the N tWoOlk seccceeeeeeeenteneeeeeeeeeeeeenneneeneeeees 21 Connecting the Power Supply Enclosure to the Netvvorti 23 Connecting Vacuum Receivers to the Netvvorhi eeeeeeeeiiiiiiinennneneii 25 Connecting Vacuum Pumps and Filter Chambers to the Netvvort 28 Connecting Central Alarms to the Network cccccccccecceseccseceeeceeeceseeeaeeeaeeees 34 30 SEU ai sera ea E a asso ete eel 36 Setting UD the SVStOM cities es letres ASAS 37 Setting Up StQuions its teca ease ees Ai eee 41 Setting Up PUMPS EAE AE EE EEE EEN 44 Finishing Setup Setting Up Passwords 22222222222222naaanaaanananiinanna 48 Save Restore SettiNg Scar oiea e a a EAE 49 3 6 gt INIT Al Startup aii a i aa a ara ie sica Sede ari 50 CHAPTER 4 OPERATION ccccecsssseeeeeeeeeaaeeeneesseeaaenneesees 51 24 Pump 128 Station Controller Chapter 1 Safety 3 4 1 A O TO 51 4 2 Starting and Stopping the St Mistica na 51 4 3 BASIC FA SR Set a A A ii 52 Reviewing Station Status ies Ae nl ee
46. e 13 Proper Vacuum Pump Connections Standard XPD XPC Pumps ARMORBLOCK MOUNTING PLATE KIT sf ACS PART A0556696 POWER FLAT CABLE BLACK VACUUM PIPE DS EUR ECO anaes NOTE EACH MOUNTING BLOCK REQUIRES 2 CLANPS SPECIFIC TO THE PARTICULAR SIZE OF CONVEY PIPE USED SEE DWG A0563626 FOR CLAMP SIZING REQUIREMENTS x PATCH CORD 20FT 6M YELLOW ACS PART A0555190 lt 2 CORDS ARE REQUIRED x 8 INPUT 8 OUTPUT ARMORBLOCK ACS PART A0555192 r ARMORBLOCK BASE ACS PART A0555191 VACUUM PUMP DENOTES INCLUDED IN VACUUM PUMP DISTRIBUTIVE I O KIT 24 Pump 128 Station Controller Chapter 3 Installation 29 Figure 14 Proper Vacuum Pump Connections XPDB Pump OR INCLUDED RM KI CABLE BLACK VACUUM PIPE NETWORK FLAT CABLE OR 8 INPUT USED REQUIREMEN VIPB PUMP 24 Pump 128 Station Controller Chapter 3 Installation 30 Connecting Filter Chambers Make sure that all previous installation steps have been done first before starting this task To connect a filter chamber to the network 1 Attach patch cords from vacuum pump filter chamber to the appropriate connector s See Figures 9 12 15 and 16 connection is shown on first pump on the block only for clarity 24 Pump 128 Station Controller Chapter 3 Installation 31 Figure 15 Proper Filter Chamber Connections
47. e 52 Reviewing Pump Status il a ri 53 Logging On and Logging ini ti taainid amena ad 54 Enabling and Disabling Stations and PUMPS oooonciccnoncccccnncinnnnonaanannnnnnnnnnnnnnnns 55 Reviewing and Adjusting Basic Station Settings oooonniciicccinnnnoniccccccocccncncnononnnnn 56 AA AdVanCEd Tos RS tant i ae haan go A Ae esate een le i en ee 59 Reviewing and Resetting a Pump Hour Meter ooo022222e 59 Transferring Stations to a Standby PUMP oooocccccccccccocononccoccncnnnncnnnnnanoncnnnnnnnnnnnns 59 Dao ALANIS ES EE drac tanta setena testar da cata cate S CRC OE tons Penat Cant ea i Cas diada EE ai 62 Reviewing ANS as did 62 Silencing Alar MS ce he deg tad insta atc le SS cease tts A o Ai aa 62 CHAPTER 5 MAINTENANCE csccceeeeeeessseeneeeseeaaeeeeeeees 63 5 41 Preventative Malmenance s edita id 63 5 2 Corrective MAING an Cessament mente esermas meten senten a eeememtend 63 Network Scanner Module Considerations oooooo0unannanerananiiiianaann 63 CHAPTER 6 CONFIGURABLE SETTINGG cceeeeee 64 6 1 Memory Module Considerations c cccccceeeeeeeeeecnecceeeeendensneeeeneeeeeeeeeneeneseeseeee 64 6 2 Options for Station SGU eased ee bese Alencar cette e A teeter 64 6 3 Options for PUMP Setup cccccccccccncconnnonnnonononnnonnnonnnonnnnnnnnnnnnnnnononcnnnnnnnnnnnrnnnnnnnnnnonnns 69 CHAPTER 7 TROUBLESHOOTING
48. e 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 24 Pump 128 Station Controller Chapter 1 Safety 6 1 3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the machine All personnel engaged in the use of the machine should become familiar with its operation as described in this manual Proper operation of the machine promotes safety for the operator and all workers in its vicinity Each individual must take responsibility for observing the prescribed safety rules as outlined All warning and danger signs must be observed and obeyed All actual or potential danger areas must be reported to your immediate supervisor General Responsibility No matter who you are safety is important Owners operators and maintenance personnel must realize that every day safety is a vital part of their jobs If your main concern is loss of productivity remember that production is always affected in a negative way following an accident The following are some of the ways that accidents can affect your production e Loss of a skilled operator temporarily or permanently e Breakdown of shop morale e Costly damage to equipment e
49. ed 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 I Europe Middle East Africa ACS New Berlin Manufacturing Facility 2900 S 160 Street ACS Warsaw New Berlin WI 53151 Ul Dziatkowa 115 Phone 1 262 641 8600 eee Ed air 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
50. er Chapter 3 Installation 13 To install KwikLink cables 1 Cut both black and grey cables to the proper length 2 Use cable ties to attach KwikLink cables black cable above grey cable on the vacuum tubing Attach cable to the tubing with cable ties at about three foot 3 ft 1 m intervals Make sure that cable ties are snug but not tightened enough to bend the flat cable Caution Install KwikLink cable on vacuum tubing only DO NOT install KwikLink cable on material conveying tubing as static electricity formed at material lines could disrupt system operation Figure 2 Side View of a Typical Power Cable and Data Cable Installation Cable tie buckle ee Vacuum tube Black power cable De Grey data cable Pa Note When approaching a node location stop the attachment process Run the cables over the node area such as a T valve and make sure you create a slight amount of slack when continuing the attachment with cable ties Doing so lets you install KwikLink connectors or ArmorBlocks with greater ease with less stress on the cable Setting Up and Installing Mounting Plates Setting Up Mounting Plates It s a good idea to get all your mounting plates set up with KwikLink connector bases or ArmorBlock cable bases before installation as your system layout determines Note ArmorBlock cable bases are installed on mounting plates perpendicular in orientation to the flat cable runs Vacuum hoppers receiver stations and
51. erial number of your equipment before contacting the manufacturer for parts or service The 24 Pump 128 Station Conveying Controller is a programmable logic controller with 24 VDC control circuit easy to use touch screen operator interface terminal and optional audible visual alarm 2 2 General Description Our material conveying systems create vacuum for the automatic conveying of most free flowing dry pelletized or granular materials Material characteristics determine the type of equipment needed to convey the material A typical use for our equipment is an in plant distribution system for plastic processing plants Our central vacuum systems are as varied as the applications they service The tubing and equipment furnished in our system is designed to convey the material s specified at the time of purchase at specific rates and distances We can advise you on your system capabilities based on system makeup distance material and conveying rates you want System capacity is directly affected by the pressure drop in the overall system such as number of material line bends pipe length Y tubes T tubes etc Use the minimum effective amount of vinyl flex hose to maximize material line efficiency Keep material lines as straight as possible Refer to the Mechanical Components Product manual Part No A0536580 for installation recommendations Note Vacuum leaks occurring anywhere in your system reduce capacity Standard Fe
52. eturn to the Transfer to Standby Pump screen 1 Touch Transfer To Standby Pump Transfer in Progress appears briefly on the screen followed by Transfer Complete in place of the Transfer To Standby Pump button The controller switches the setting for Source Pump to the new pump and switches the setting for Standby Pump to 0 unassigned 2 Touch Return The Pump n Setup screen appears 3 Touch Pumps The Pump Status screen appears 4 Put the standby pump online by briefly touching its icon The icon changes color to show the new status and the system begins using the pump In addition all Station n Operator and Setup screens show the new pump assignment When the failed pump is operational again you can repeat this process this time using the standby pump s number as the setting for Source Pump the repaired pump s number as the setting for Standby Pump 24 Pump 128 Station Controller Chapter 4 Operation 61 3 5 Alarms Reviewing Alarms At the Station Status or Pump Status screen 1 Touch Alarms The Alarm Log screen appears with the newest alarm listed first Alarm Summary Stations Pumps System Setup Help To scroll up and down through the list e Touch A and Y at the bottom of the list Silencing Alarms Whenever a new alarm occurs your controller sounds the horn and turns on the strobe light at each central alarm If the alarm is for a specific station or pump and if the stati
53. every station on the failed pump It does not transfer any pumps settings for auto 24 Pump 128 Station Controller Chapter 4 Operation 59 shutdown delay alarms or blowback to the standby pump Mechanical connections must be changed manually To transfer stations from a pump to a standby pump 1 At any screen 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 greny Move the vacuum hose from the failed pump to the standby pump and carry out any other mechanical procedures needed to use the standby pump At the Pump Status screen touch and hold the icon for any pump until the Pump n Setup screen appears At the Pump n Setup screen touch Transfer Stations To Standby Pump The Transfer to Standby Pump screen appears Standby Pump Destination Pump None Return Stations Pumps Password Not Active Touch Source Pump A list of available pumps pops up Scroll through the list to choose a source pump Press Return once you have selected and highlighted your desired source pump The number appears under Source Pump Touch Destination Pump A list of available pumps pops up Scroll through the list of pumps to choose a destination pump Press Return once you have selected and highlighted your desired destination pump The number appears under Standby Pu
54. f 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 Go to the Station n Operator screen as described on p 56 or go to the Station n Setup screen 24 Pump 128 Station Controller Chapter 4 Operation 57 Touch Priority Convey Activate The button changes to Priority Convey Active and blinks until the station s demand has been satisfied or you stop the priority convey The controller begins filling the chosen station only after finishing any convey already in progress To stop a priority convey before the station is completely full Touch the blinking Priority Convey Active The button changes to Priority Convey Activate and stops blinking The controller finishes the current convey if any and resumes normal operation Changing the Mixture for a Remote Proportioning Valve A remote proportioning valve RPV mixes two different materials typically virgin and regrind materials during a convey cycle If
55. formation 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 24 Pump 128 Station Controller Chapter 2 Functional Description 10 e Identify and locate specific safety devices e Understand the proper use of the safety devices provided e Describe the function of the safety device Safety Circuit Standards Safety circuits used in industrial systems protect the operator and maintenance personnel from dangerous energy They also provide a means of locking out or isolating the energy for servicing equipment Various agencies have contributed to the establishment of safety standards that apply to the design and manufacture of automated equipment The Occupational Safety and Health Administration OSHA and the Joint Industrial council JIC are just a few of the organizations that have joined with the plastics industry to develop safety standards Every effort has been made to incorporate these standards into the design of the controller however it is the responsibility of the personnel operating and maintaining the equipment to familiarize themselves with the safety pr
56. g 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 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 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 locat
57. g this button silences the horn s and turns off the light s for configurable periods of time You can set different lengths of time for keeping the horn silent and keeping the light turned off If a new alarm occurs the horn sounds and the light turns on again To set the lengths of time for suppressing the alarm strobe and horn 1 Go to the System Setup screen To reach this screen from any other screen touch System Setup on the right hand side of the screen 24 Pump 128 Station Controller Chapter 3 Installation 39 System Setup Pumps Pump Present Staging 10 5 Sec Set Time amp Date Stations 14 09 6 23 2005 DeviceNet Nodes Name Purge Vlv Material Pumps Setup Password Operator Not Active Operator Password Setup Password Password Duration Password Duration 5 Min 5 Min Help The current settings are displayed under Alarm Strobe Suppression and Alarm Horn Silence 2 Touch Alarm Strobe Suppression or Alarm Horn Silence as appropriate A keypad pops up with the current setting 3 Enter the number of minutes you want the horn or light to be turned off once the alarm silence button is pushed range 0 99 If the alarm condition is not corrected or the defective device is not disabled through the touch screen the audible and visual alarms will reoccur after the times expire If you want the light or the horn to stay on as long as the alarm persists simply press 0 If you want the h
58. h the times actually required to fill and empty the station The following problems may occur if these settings are incorrect 1 Material is backing up and causing high vacuum alarms for time fill stations only Convey time is too long 2 System is not keeping up with the demand for material Convey time is too short or dump delay is too long For your reference the Station n Operator screen shows the length of time the controller actually spent conveying material during the most recent delivery under Last Convey Time To adjust a station s convey time or the dump delay 1 Go to the Station n Operator screen as described on p 56 or go to the Station n Setup screen 2 Touch Convey Time or Dump Delay A keypad pops up 3 Enter the number of seconds desired Use to erase any mistakes Use to enter the value The new setting appears under Convey Time or Dump Delay 4 If you change convey time by more than a few seconds for a station with a remote proportioning valve RPV notify the setup personnel at your facility The setting for the RPV s cycle time should be adjusted to divide evenly into the new convey time see page 41 Activating and Stopping Priority Convey for a Station Before activating priority convey make sure that all other stations using the same pump have adequate material in reserve to continue operation No material will be conveyed to these stations during priority convey I
59. his time has elapsed the pump shuts down to save power and to prevent wear on the pump Adjust this setting to fit the needs of your facility in trading off the savings against the costs associated with waiting for a pump to start up when there is a demand for material Alarm Options Local alarm When this option is enabled the controller turns disabled disabled on the local alarm light for any alarm at this enabled specific pump Enable this option if and only if your facility has installed a local alarm light for this pump Pump fault 1 The ArmorBlock for each pump has two inputs disabled disabled that you can wire to generate alarms for enabled situations of your choosing These alarms can be configured as standard or critical Standard means that the pump continues to operate Critical means that the pump is disabled For example you may have a sensor that turns on when material reaches the top of a filter chamber waste bin When this option is enabled the controller issues an alarm if the sensor wired to the input for Pump Fault 1 turns on Enable this option if and only if your facility has installed a miscellaneous alarm on the input for Pump Fault 1 for this pump Pump fault 2 See the explanation for Pump fault 1 above disabled disabled Enable this option if and only if your facility has enabled installed a miscellaneous alarm on the input for Pump Fault 2 for this pump Filter Cleaning Options Blow back
60. ight of the screen or the Help button on the lower right side of the screen The Help Menu appears 3 In the section of the Help Menu labeled Screen Symbols Colors touch Station The Station Symbols help screen appears explaining the status represented by each color 4 When you are finished reviewing the information touch Stations or Pumps The Station Status or Pump Status screen appears 24 Pump 128 Station Controller Chapter 4 Operation 52 The following table explains the status represented by each color at the Station Status screen Station is not enabled The controller ignores any demands or alarms White Blow Back Station s air filter is being cleaned by blowing compressed air A Or tra ng comprar station Station is in priority convey mode Its pump will be temporarily Green Convey dedicated to filling it as soon as possible Critical Station is in critical alarm The controller has disabled the station ee until the alarm is cleared Purple Closed Station is in closed loop convey Loop Light Yellow Waiting Station is waiting for material to become available Station is being loaded Additional basic information about each station convey time dump delay pump assignment and if enabled RPV setting purge settings etc is available at the Station n Operator screen See page 56 for details Detailed configuration settings for each station are available at the Station n Setup screen See page 3
61. is too short Partial convey Vacuum line has a leak Volume fill prox Is not calibrated properly Note As a stopgap measure you can disable the partial convey alarm for this station until the problem can be remedied See pp 41 and 659 Output power failure Critical 24 Pump 128 Station Controller Chapter 7 Troubleshooting 72 Pump X Option Output Conflict An assigned station has closed loop enabled and the pump has either implosion with sealing valve or Local Alarm enabled i Patch cord is cut or disconnected Purge Valve X Failure Solenoid has failed ArmorBlock is not installed properly Purge Valve X Not Present ArmorBlock is not addressed correctly ArmorBlock is defective ArmorBlock base is defective Patch cord is cut or disconnected Purge Valve X Power Failure Solenoid has failed Pick up wand is not positioned properly Receiver Level Take off compartment is not adjusted properly I Patch cord is cut or disconnected RPV Fail Patch cord is cut or disconnected i IS Solenoid has failed Sequence Valve Failure Patch cord is cut or disconnected Solenoid has failed Slide Gate Failure Patch cord is cut or disconnected Solenoid has failed 24 Pump 128 Station Controller Chapter 7 Troubleshooting 73 Pump Alarms Blowback Solenoid Failure Patch cord is cut or disconnected Critical Solenoid has failed z Patch cord is cut or disconnected Clearing Valve Failure I Solenoid has failed Pump d
62. isconnect is off Failure Patch cord is cut or disconnected Pump contactor has malfunctioned General Fault 1 The alarm is user configured General Fault 2 The alarm is user configured High vacuum switch is maladjusted High Vacuum Switch Failure High vacuum switch is wired incorrectly High vacuum switch is defected ArmorBlock is not installed properly Not Present ArmorBlock is not addressed correctly Critical ArmorBlock is defective Base of ArmorBlock is defective Patch cord is cut or disconnected Output Failure Pump disconnect is off Contactor has failed Power supply is not turned on Output Power Failure Power supply is not connected properly Critical Power supply fuse blown Pump ArmorBlock not installed properly ArmorBlock is defective i i EE R System Alarms The alarm horn silence duration time has passed and at least one Alarm Horn Silence Expired OS alarm is still present on the system Alarm Strobe Suppress Expired The alarm beacon suppress duration time has passed and at least one alarm is still present on the system Control panel is not connected to flat cable Control panel network cable not installed correctly DeviceNet Scanner P I tt d Communications Failure Ower SUPP noces on Power supply not connected properly Power supply fuse blown Main Control Panel Power Panel power supply fuse blown Supply Failure Panel power supply has failed Control panel is not connected to flat cable
63. mp and a button labeled Press to Move Stations appears on the screen 24 Pump 128 Station Controller Chapter 4 Operation 60 Standby Pump Source Destination Pump Pump eS Ln 1 Pmp Ln10 Pmp Stations Pumps Press to Move Stations a be Password 10 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 Press To Move Stations button If you get an error message first check to make sure that you have entered the correct numbers and reenter if necessary If the error message tells you to disable the source pump and or the standby pump touch Return at this screen then Pumps at the Pump n Setup screen Take the pumps offline and then return to the Transfer to Standby Pump screen If the error message tells you that the standby pump has stations assigned you must either use a different standby pump or you must remove the pump assignment for all stations assigned to the standby pump To remove the assignments touch Return at this screen then Stations at the Pump n Setup screen Hold a station icon to go to its Station Operator screen then touch Setup to go to the Station n Setup screen Use Back and Next P to review all pump assignments and where necessary choose Assigned to Pump x to set station assignments to O unassigned Then r
64. mp n alarm text Any alarm that does not start with Station or Pump is a system alarm The following tables list all alarms alphabetically together with possible causes A critical alarm is one that causes the affected device to stop 2 You can also see a list of alarms and their causes in the controller s online help To display this information touch the color key of statuses in the upper right hand corner of either the Station Status or the Pump Status screen or touch Help at any other screen When you are finished reviewing the help touch Return Station Alarms Blowback solenoid failure Critical Vacuum line is blocked I Closed Loop Pump X Failure Vacuum line is blocked High vacuum cleared when the controller has conveyed a full load to this station No convey Material line is disconnected from source Vacuum line is disconnected from station Note As a stopgap measure you can disable the no convey alarm for this station until the problem can be remedied See pp 41 and 65 ArmorBlock is not installed properly Not present ArmorBlock is not addressed properly Critical ArmorBlock is defective ArmorBlock base is defective Power supply is not turned on Power supply is not connected properly Power supply fuse blown Station ArmorBlock is not installed properly ArmorBlock is defective Take off compartment is not adjusted properly Pick up wand is not positioned properly Convey time
65. names Use lt to erase any mistakes Use J to enter the value Checking Addressing and Wiring for System Components Once you have set the number of stations and pumps as described previously you should verify that the controller is communicating with all stations pumps and central alarms and with the ArmorBlocks for all central purge valves To do so 1 Atthe System Setup screen touch DeviceNet Nodes on the right side of the screen The DeviceNet Status screen appears 24 Pump 128 Station Controller Chapter 3 Installation 38 DeviceNet Status Station Node and Input Status Node Station C A ED 570 Demand E ees More Option il EE AS Stations Node SMC ESS CSS I TE CC veep Station IZ EE EM EU ES 2 ES El El ES ead E EEE ue Demand HEE E os LL LL A E Option DES pe ve vn er ll Node Station EE EL Ell El En El Ell ES EH EH El CES ESC ES System OE UA A A LA SL LL LS E A L Setup Option AA e AA a IA nl Node Models modets Motels Melo Pl vasos Station E OS Dern A DS EE ES LS ES A SL ES ES ES Option MS A SS O SS 0 A G Pumps 2 Check that the expected components are shown as present green and not present grey Disregard any error messages For example if you have 18 stations boxes 01 through 18 in the Stations section should be green and boxes 19 through 128 should be grey For central purge valves you should see a green box for each ArmorBlock installed If the screen display is not as e
66. ncluded in the mix This setting applies only when RPV is enabled with PLC control The system is set up so that if there are any inaccuracies in the proportions the mix will contain more Material A and less Material B than specified here Cycle time Number of seconds for each cycle in depositing 5 100 sec 10 sec Material A and Material B during the convey time This setting applies only when RPV is enabled with PLC control Example If you set convey time to 30 seconds cycle time to 10 seconds and Material B to 30 so Material A is 70 the system will convey as follows Material A for 7 seconds Material B for 3 seconds end cycle 1 Material A for 7 seconds Material B for 3 seconds end cycle 2 Material A for 7 seconds Material B for 3 seconds end cycle 3 In a volume fill station a cycle will be truncated before completion if the station becomes full The cycle time should divide evenly into the convey time 24 Pump 128 Station Controller Chapter 6 Configurable Settings 68 6 3 Options for Pump Setup Several of the items in this screen are not setup options but are instead intended for use during operation These items hour meter and transferring stations to a standby pump are described in Chapter 4 Operation Name sd Description CL Options Default Idle Time Options Auto Shutdown Delay Length of time the pump continues to run 0 999 sec 45 sec unloaded without demand from any station After t
67. nge keyed edge toward the latch Make sure that the cable and dust cap are properly seated inside 9 Making sure that the cable is completely straight carefully close the hinged assembly and apply firm even pressure until the first latch locks into place Note Make sure that the flat cable is completely straight before continuing The latch has two catches the first loosely holds the connector on the cable the second requires more pressure to close the connector tightly The cable must be in the correct position for the connector to close properly 10 Drive the two screws at the center points about halfway down first on the latch side then the hinge side 11 Continue to tighten the screws a little at a time until fully tightened no more than 15 inch pounds 5 6 Nem of torque Note You can only pierce the cable once Once pierced the KwikLock connector must not be removed This insures that the inner conductors are not exposed to the elements Installing Inside KwikLink Connectors with Blank Caps Once installed on the grey data cables these connectors permit you to measure voltage in the system so you can analyze how it is working The system cannot work properly unless these inside mounted connectors have the blank non conductor caps installed 1 Lay the cable in the hinged base noting the correct keyed profile flat edge toward the hinge keyed edge toward the latch Make sure that the cable is properly seated insi
68. ocedures and the proper use of any safety devices Fail Safe Operation If a safety device or circuit should fail the design must be such that the failure causes a Safe condition As an example a safety switch must be a normally open switch The switch must be held closed with the device it is to protect If the switch fails it will go to the open condition tripping out the safety circuit At no time should the safety device fail and allow the operation to continue for example if a safety switch is guarding a motor and the safety switch fails the motor should not be able to run Safety Device Lock Outs Some safety devices disconnect electrical energy from a circuit The safety devices that are used in this Controller are primarily concerned with electrical power disconnection WARNING Always disconnect and lockout all electrical power and pneumatic i e compressed air sources prior to servicing the 24 Pump 128 Station Controller Failure to do so may result in serious injury No one but the person who installed the lockout may remove it 24 Pump 128 Station Controller Chapter 2 Functional Description 11 Chapter 3 Installation 3 1 Uncrating 24 Pump 128 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
69. on 24 Figure 9 Proper Power Supply Enclosure Connections UUIPUT FUNER FLAT CABLE ie a ee VACUUM ee el se Y NETWORK FLAT CABLE GREY Aa ARMORELOCK MOUNTING PLATE KIT ACS PART No 40556696 NOTE EACH MOUNTING BLOCK REQUIRES lt 2 CLAMPS SPECIFIC TO THE PARTICULAR SIZE OF CONVEY PIPE USED quel x POWER TAPDROP CABLE ACS PART No 0555195 22 CORDS ARE REQUIRED POWER SUPPLY e D LL i e Connecting Vacuum Receivers to the Network Make sure that all previous installation steps have been done first before starting this task To connect a vacuum receiver to the network 1 Attach patch cord from vacuum hopper junction box station demand to appropriate input connector See Figures 10 and 11 connection is shown on first hopper on the block only for clarity 2 Dress the excess patch cord cable with cable ties so it does not interfere with operation and gives a pleasing appearance 24 Pump 128 Station Controller Chapter 3 Installation 25 Figure 10 24 128 8 Connector ArmorBlock Connections Note 1 The block shown is addressed 01 for the first 4 four hoppers The block addressed 02 would have the connections for 5 8 etc Note 2 If a hopper does not have an optional input or optional output the T connector is not required Connect the patchcord directly to the connector on the ArmorBlock 24 Pump 128 Station Controller Chapter 3 Installation
70. on or pump has a local alarm the controller also turns on the local alarm light In addition a banner appears on the touch screen displaying an alarm message anda Push To Silence button To silence the alarm 1 Touch Push to Silence on the alarm banner The horns and lights at the central alarms turn off The local alarm light stays on The banner will close Your controller has separate configurable settings for how long the horns should remain silent and how long the lights should remain off If the alarm condition still exists when either of these times elapses the corresponding devices horns or lights turn on again If a new alarm occurs both the horns and the lights turn on 24 Pump 128 Station Controller Chapter 4 Operation 62 Chapter 5 Maintenance 5 1 5 2 Preventative Maintenance No preventative maintenance is required on this unit Corrective Maintenance Network Scanner Module Considerations The manufacturer includes a network scanner software diskette with your controller this diskette and instructions are located in your Customer Information Packet Keep this diskette and the instructions in a safe place Should the network scanner module require replacement use the scanner software to restore the program You can e Purchase a programmed replacement scanner module from the manufacturer e In extreme cases you can purchase the module from your local Allen Bradley dealer and program it yourself wi
71. ons 5 10 System Setup Copy to All Stations Password Not Active Help 2 Follow the directions on the following pages to copy settings to one other station a range of stations or all stations To copy the selected station s settings to one other station 1 Touch the gray Copy to Station button next to the green button labeled Copy To Single Station The keypad pops up 2 Enter the station number for the station you are copying to Use lt to erase any mistakes Use J to enter the value The keypad disappears and the Station Copy screen shows the station number you entered under Copy to Station 3 Touch the green Copy to Single Station button Copy Complete briefly appears at the top of the screen 24 Pump 128 Station Controller Chapter 3 Installation 43 4 As appropriate either continue copying to other stations or touch Station Setup to go back to the Station n Setup screen To copy the selected station s settings to a range of other stations 1 Touch First Station button next to the green button labeled Copy to Range of Stations The keypad pops up 2 Enter the station number for the hopper at the lower end of the range you are copying to Use to erase any mistakes Use to enter the value The keypad disappears and the Station Copy screen shows the station number you entered under First Station 3 TouchLast Station button next to the light grey button labeled First Sta
72. ons and pumps is described on p 55 A button to start and stop the system is located in the lower right of the Station Status Pump Status and Alarm Log screens When the system is off the button is red and reads Push to Start System When the system is on the button is green and reads Push to Stop System Depending on the setup at your facility the system may prompt for a password when you touch this button If conveying does not begin when you start the system check to make sure that all needed pumps are enabled If they are check that all needed stations are enabled 24 Pump 128 Station Controller Chapter 4 Operation 51 4 3 Basic Tasks This section covers tasks that can be carried out with no password or with an operator s password Reviewing Station Status The starting point for all operations is the Station Status screen To reach this screen from any other screen 1 Touch Stations The Station Status screen appears Depending on which model you have your screen will appear as one of the cali Station Status EPR EL E ERRE ES Yu USO qe peque geo El P9 9999 99 Es The status of each station is color coded as summarized in the upper right of the screen Pumps Pumps Alarms Alarms Push to Stop System Help BLD9 System VGN Setup You can see an explanation of each status by using the online help To do so from this screen 2 Touch anywhere in the rectangle in the upper r
73. or or Pump n Setup screen appears when you touch the icon then you have kept your finger on the screen too long Touch Stations or Pumps to return to the Status screen and try again 24 Pump 128 Station Controller Chapter 4 Operation 55 Reviewing and Adjusting Basic Station Settings Reaching and Reading the Station Operator Screens The 24 128 Controller has a Station Operator Settings screen for each station as shown below This screen enables you to review and adjust all basic settings for the station To reach the Station n Operator screen 1 Go to the Station Status screen if needed To reach this screen from any other screen touch Stations on the right hand side of the screen 2 Touch and hold the icon for the station until the controller either prompts for the password or displays the Station n Operator screen Once you have entered the password if needed the Station n Operator screen appears Operator Settings Back Next lt gt Stations Pumps Station Setup System Priority Setup Convey Activate Password Not Active Help Settings in the box labeled Convey the red Priority Convey Activate button and the menu controls on the right hand side of the screen appear for all stations The other options in this screen appear if and only if the station has these features enabled Buttons in light gray are settings that you can adjust at this screen Boxes in dark gray are for display only If a pum
74. orn or the light to stay off until a new alarm occurs use 99 for its entry Use to erase any mistakes Use J to enter the value The keypad disappears and the new setting appears under Alarm Strobe Suppression orAlarmHorn Silence 4 Repeat for the other device strobe or horn as appropriate Setting Up Pump Staging To avoid an excessive power demand at your facility when the conveying system starts up you can stagger the times at which pumps start Whenever a demand would cause two pumps to start simultaneously your choice for pump staging sets the delay between the start of one pump and the start of the next The factory default is a delay of five seconds You need to change this setting only if this delay is too long or too short for your facility To set the delay between the start of one pump and the next 1 Go to the System Setup screen if needed The current delay is displayed under Pump Staging 2 Touch Pump Staging A keypad pops up with the current setting 3 Enter the number of seconds range 0 99 Use lt to erase any mistakes Use to enter the value The keypad disappears and the new setting appears under Pump Staging 24 Pump 128 Station Controller Chapter 3 Installation 40 Setting Up Stations Before starting the system you must define several settings for each station such as which pump conveys material to it and whether the station has a slide gate This section first discusses how to use the cont
75. p assignment or purge setting needs to be changed this must be done at the Station n 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 1 To display the screen for the next lower numbered station for example to move from the screen for Station 15 to the screen for Station 14 touch lt Back 2 To display the screen for the next higher numbered station for example to move from the screen for Station 15 to the screen for Station 16 touch Next PD 3 To display the screen for a specific station touch Goto A keypad pops up Enter the number for the desired station Use lt to erase any mistakes Use J to enter the value 4 To exit to the Station Status or Pump Status screen touch Stations or Pumps 24 Pump 128 Station Controller Chapter 4 Operation 56 Adjusting Convey Time and Dump Delay Convey time is the length of time the station s vacuum valve remains open to allow material to be drawn in For a volume fill station the valve closes when material covers the station s volume fill proximity sensor or this time elapses whichever comes first Dump delay is the length of time allowed for material to drain from the station into its receiver During this time the controller does not attempt to deliver any more material to the station The settings for convey time and dump delay should matc
76. present this valve may be set up so that you control the mix with a timer at the station or it may be set up so that you control the mix with the controller s touch screen The instructions here apply only for controlling the mixture from the touch screen The controller refers to the two materials as Material A primary and Material B additive The system is set up so that if there are any inaccuracies in the proportions the mix will contain more Material A and less Material B To change the mixture for the remote proportioning valve 1 Go to the Station n Operator screen as described on page 56 or go to the Station n Setup screen 2 Touch RPV Material B A keypad pops up 3 Enter the desired percentage for the additive material Use lt to erase any mistakes Use 4 to enter the value The new setting appears under RPV Material B 24 Pump 128 Station Controller Chapter 4 Operation 58 4 4 Advanced Tasks This section describes the procedures carried out during operation that are normally reserved for setup personnel These procedures require use of the setup password if your facility has defined one The procedure for logging on with the setup password is the same as for logging on with the operator password see page 45 Logging off is also the same except that operators can log off only at the Station n Operator screen while most screens accessible to setup personnel offer Log Off as an option You can also change
77. re copying to Use lt to erase any mistakes Use J to enter the value The keypad disappears and the Pump Copy screen shows the pump number you entered under Last Pump Touch the green Copy button labeled Copy To Range of Pumps Copy Complete briefly appears at the top of the screen As appropriate either continue copying to other pumps or touch Pump Setup to go back to the Pump n Setup screen To copy the current pump s settings to all other pumps 1 2 Touch the green Copy To A11 Pumps button Copy Complete briefly appears at the top of the screen Touch Pump Setup to go back to the Pump n Setup screen 24 Pump 128 Station Controller Chapter 3 Installation 47 Finishing Setup Setting Up Passwords You can set up passwords for two levels of security for operators and for setup personnel The controller comes from the factory with neither password set This allows every user access to all functions Setup Password If you define a password for setup personnel then most settings can be changed only after entering the password The password will be required to display the following screens e System Setup to review and change system wide settings and go to the network status screens e Station Setup to review and change settings for all station options e Pump Setup to review and change settings for all pump options Operator Password If you define a password for operators then a password will be
78. 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 to adjust a station s convey time and dump delay activate priority convey and review the station s last convey time and pump assignment depending on the options installed the screen may also enable the operator to adjust the mixture percentage for a remote proportioning valve change the purge time and purge valve and set the intended material line for manifold sharing Entering the setup password will give the user access to all functions To set or remove password protections 1 Press System Setup on the right side of the screen to go to the System Setup screen if needed The System Setup screen appears System Setup SYSTEM PARAMETERS Stations Pumps Pump Present Present Staging i 1 5 Sec ALARN Set Time amp Date Stations 13 47 6 23 2005 Save Restore DeviceNet Nodes Alarm Strobe Alarm Horn Name Suppression Silence Purge Vlv 0 Min 10 Min Material Pumps Password Not Active Operator Setup Operator Password Setup Password Password Duration Password Duration
79. roller s menu system to configure stations The table on pp 64 68 discusses the individual choices Setting Up a Single Station 1 Go to the Station Status screen if needed To reach this screen from any other screen touch Stations on the right hand side of the screen The Station Status screen appears Depending on which model you have your screen will appear as one of the following lt a m mM mm mm n I 4 I System Setup Setup Pumps Pumps mi mM mm mM mm mM a E E Alarms Alarms ma mm mm mM mm mm mm mm mM mm Push to Start System Help 2 Touch the icon for the station you vvant to set up and hold it for several seconds The Station n Operator Settings screen for the selected station appears Back Next app Goto Stations Pumps Station rd Not Active Help Touch Station Setup at the Station n Operator Settings screen The Station Setup screen appears 24 Pump 128 Station Controller Chapter 3 Installation 41 Station Setup 1 Back Next gt Goto Copy Convey Dump Assigned Special Closed Delay to Convey Loop 10 Sec None Disabled Disabled Stations Pumps OPTION INPUT No Partial 3 Optional SN Attempts UNES CAN Attempts Input DS B4 Alarm PM B4 Alarm Disabled Priority Convey Activate Station Service System 3 Touching Help in the lower right of this screen gives you a menu of online help for the choices in this screen 4
80. rotected 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 1 Go to System Setup 2 Touch Log Off on the right of the screen The Station Status screen appears Enabling and Disabling Stations and Pumps When a station or pump is disabled the controller does not attempt to use it and ignores any alarms that occur for it Disabling a station or pump at the controller s screen is similar to bypassing a station with its bypass switch Enabling a station or pump makes it available for use For a station to be available for the system it must be enabled at the controller s screen and its bypass switch if present must be in the 0 position To enable or disable a station or pump 1 Go to the Station Status or Pump Status screen if needed To reach this screen from any other screen touch Stations or Pumps on the right hand side of the screen Each disabled station or pump has an icon with a status of offline silver All other statuses are enabled statuses 2 Touch the icon for the station or pump briefly The station or pump switches to the new state as indicated by the color of its icon 3 Ifthe Station n Operat
81. s blown breaker Motor contact is faulty Repair or replace as required The bin below it is full if its Nomaloperation When the Aa XS level drops material conveys to amber indicator light is Off the hopper The hopper is off line Using the controller place the A vacuum hopper is being pp j hopper on line bypassed in the loading cycle The field installed station bypass Normal operation Set the switch switch is simulating a Bin Full so the hopper is back in the condition loading sequence The field installed station EEES del R balt replace ortewita EEES del is bad or mis wired Dep 7 Time the hopper s during loading and set conveying times to a few seconds less Check proximity sensors for proper operation Repair as needed Reset the conveying times to a reasonable value and adjust as needed Power supply shorting out Repair shorting circuit Controller blows fuses Replace fuse with one that has a Improper fuse installed Improper fuse installed installed a proper rating Conveying times are too long Time Fill mode only Vacuum hoppers are over filling Maximum conveying times are too long and or the controller does not recognize the Hopper Full proximity switch es 24 Pump 128 Station Controller Chapter 7 Troubleshooting 71 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 Pu
82. s multiple pumps 6 max to be connected to a material source The controller will let one pump at a time draw from the material source Electrical Features e 115 1 60 or 220 1 50 supply voltage e 24 VDC control voltage e Lockable ON OFF switch e Branch circuit fusing e Fully accessible NEMA 12 style electrical control enclosure Controller Features e Allen Bradley Compact Logix programmable controller with 10 color touch screen operator interface e Diagnostics operating instructions and parts information are built into the interface e Controls up to one hundred twenty eight 128 stations and up to twenty four 24 Vacuum Power Units e Controls up to three central alarms e Allows operator to transfer stations to a standby pump when a pump fails e Electronic time delay between pump startups to prevent an excessive power demand at your facility 2 4 Optional Features Noise Filter Surge Suppressor Provides protection to electronic devices in the control panel from power surges and electrical noise Closed Loop Conveying This feature allows material to be conveyed and processed without being contaminated by outside influences such as dust other materials etc Additional audible visual alarm with silence button Alarm light and horn assembly that can be remote mounted and wired into the controller to indicate an alarm condition Remote Interface 4 max 2 5 Safety Devices and Interlocks This section includes in
83. s on the System Setup screen Setting the Date Time You can set the current date and time by going to the System Setup screen and pressing Set Time amp Date 1 To set the time touch Hour A keypad will pop up and you will be able to enter the current hour The controller uses military time You can repeat this process for the minutes by pressing Minute 2 To set the date touch Month A keypad will pop up for you to enter the number of the current month i e May 5 You can repeat this process to set the current day and year by pressing Day and Year as appropriate Use lt to erase any mistakes Use to enter the value The keypad disappears and the new setting appears under Set Time amp Date Naming Purge Valves and Materials You can assign purge valves and materials names rather than keep them assigned by numbers You can name stations and pumps as well Refer to the Setting Up Stations and Setting Up Pumps sections later in this chapter 1 Go to the System Setup screen and touch Name Purge Vlv Material and scroll through the list of purge valve materials and find the one you want to rename 2 Use the up and down arrows to select the purge valve material you would like to name 3 Select Press to Change at the bottom of the list A keypad will pop up 3 You can then type in a name of up to eight alpha numeric characters Make sure to choose different names as the system does not recognize duplicate
84. t Pump mists Pump Pump Setup Range of 2 5 Pumps Pump 2 Pump 5 Password Not Active Copy to All Pumps Help 2 Follow the directions below to copy settings to one other pump a range of pumps or all pumps 24 Pump 128 Station Controller Chapter 3 Installation 46 To copy the selected pump s settings to one other pump 1 Touch the gray Copy to Pump button next to the green Copy To Single Pump button The keypad pops up Enter the pump number for the pump you are copying to Use to erase any mistakes Use J to enter the value The keypad disappears and the Pump Copy screen shows the pump number you entered under Copy to Pump Touch the green Copy To Single Pump button Copy Complete briefly appears at the top of the screen As appropriate either continue copying to other pumps or touch Pump Setup to go back to the Pump n Setup screen To copy the selected pump s settings to a range of other pumps 1 Touch First Pump next to the green button labeled Copy To Range of Pumps button The keypad pops up Enter the number for the pump at the lower end of the range you are copying to Use lt to erase any mistakes Use J to enter the value The keypad disappears and the Pump Copy screen shows the pump number you entered under First Pump Touch Last Pump next to the light grey button labeled First Pump The keypad pops up Enter the number for the pump at the upper end of the range you a
85. th the scanner software diskette you can also have your A B dealer do that for you We suggest that you have a preprogrammed spare network scanner module on hand for such conditions 24 Pump 128 Station Controller Chapter 5 Maintenance 63 Chapter 6 Configurable Settings This section describes the proper setup of the 24 pump 128 station control system parameters These parameters are operator changeable however these items should require setup only during the initial installation Only authorized personnel should change them Many of the variables and setup parameters have been preset at the factory and do not need to be changed However this section of the manual will address all of the setup parameters that were available at the time of printing The purpose of this is to familiarize the reader with all the setup parameters and their usage Memory Module Considerations The operator interface and the PLC central processing unit use memory modules to store the operating program and user settings The module is installed in the front of the PLC CPU card The memory module returns the controller to the factory default settings if an electrical fault occurs or if the hardware is replaced Keep in mind that this condition is extremely rare You will then need to restore saved settings or set up the controller once again with the settings you programmed in this chapter Options for Station Setup Name_______ Description_________
86. the bag with power cables to the flat cables One connector is used for the network grey cable and one connector is used for the auxiliary power black cable 2 Align the square connector of the grey drop cable so the cable leads down from the connector Evenly press the square connector onto the top of the bottom KwikLink connector It should make two audible snaps when properly seated 3 Align the square connector of the black drop cable so the cable leads down from the connector Evenly press the square connector onto the top of the upper KwikLink connector It should make two separate audible snaps when properly seated 4 Attach the keyed round connectors to the receptacles on the side of the power supply enclosure marked 24 VDC POWER SUPPLY Tighten the cord grip ring until snug 5 Dress the excess cables with cable ties so they do not interfere with operation and to give a pleasing appearance If more than one power supply is required to properly energize the grey network flat cable 1 Remove the terminal block jumpers on all but the most centrally located network power supply enclosures For locations of jumpers refer to the drawing shipped inside the power supply enclosure Note Only one power supply should be connected to each section of the black auxiliary power flat cable Do not remove any jumpers on power supplies that transmit energy to the black flat power cable 24 Pump 128 Station Controller Chapter 3 Installati
87. tion The keypad pops up 4 Enter the station number for the hopper at the upper end of the range you are copying to Use to erase any mistakes Use to enter the value The keypad disappears and the Station Copy screen shows the station number you entered under Last Station 5 Touch the green Copy To Range of Stations button Copy Complete briefly appears at the top of the screen 6 As appropriate either continue copying to other stations or touch Station Setup to go back to the Station n Setup screen To copy the current station s settings to all other stations 1 Touch the green Copy To All Stations button Copy Complete briefly appears at the top of the screen 2 Touch Station Setup to go back to the Station n Setup screen Setting Up Pumps Before starting the system you must define several settings for each pump such as how quickly to shut it down when it is not in use and whether the pump has a local alarm This section first discusses how to use the controller s menu system to configure pumps The table on page 77 discusses the individual choices Setting Up a Single Pump 1 Goto the Pump Status screen To reach this screen from any other screen touch Pumps on the right side of the screen The Pump Status screen appears 24 Pump 128 Station Controller Chapter 3 Installation 44 baa P 1 P 2 P 3 Pump 4 lo lo amp eo Rian Ci E Pump 5 E Pump 6 E Pump 7 Be Pump 9 Pump 11 System Se
88. troller Chapter 1 Safety 7 Maintenance Responsibility Proper maintenance is essential to safety If you are a maintenance worker you must make safety a priority to effectively repair and maintain equipment Before removing adjusting or replacing parts on a machine remember to turn off all electric supplies and all accessory equipment at the machine and disconnect and lockout electrical power Attach warning tags to the disconnect switch Be sure that all non current carrying parts are 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 24 Pump 128 Station Controller Chapter 1 Safety 8 Chapter 2 Functional Description 2 1 Models Covered in This Manual This manual provides operation installation and maintenance instructions for 24 Pump 128 Station Conveying Controllers Model numbers are listed on the serial tag Make sure you know the model and s
89. tup Stations Alarms Push to Start System Help 2 Touch the icon for the pump you want to set up and hold it for several seconds The Pump n Setup screen appears Pump Setup 1 Back Next gt Goto Copy Hour Meter Stations Pumps Filter Every 5 On off Pump Cleaning 5 Pulse s Time Time Service Disabled Loads 1 0 Sec 1 0 Sec System Pump Pump Fault 1 Fault 2 Disabled Disabled Defaults 3 Touching Help in the lower right of this screen gives you a menu of online help for the choices in this screen 4 Adjust settings as required Touching any box that appears in red for disabled toggles it to green for enabled and vice versa Touching any box that appears in light gray gives you a keypad to enter a new value Keypad entry works as with many ATM machines the first digit you enter initially appears in the rightmost column and moves to the left as you enter more digits Use lt to erase any mistakes Use J to enter the value The keypad disappears and the Pump n Setup screen shows the new value in the selected gray box See page 64 for details on the options and their default settings 5 As appropriate a Copy this pump s settings to one or more other pumps as described below or b Touch Back lt to go to the Pump n 1 Setup screen 24 Pump 128 Station Controller Chapter 3 Installation 45 c Touch Next P to go to the Pump 1 Setup screen or d Touch
90. ur Customer Information Packet for further details To install flat cable inside KwikLink connectors 1 Lay the cable in the hinged base noting the correct keyed profile flat edge toward the hinge keyed edge toward the latch Make sure that the cable is properly seated inside 24 Pump 128 Station Controller Chapter 3 Installation 20 keyed edge is a toward the latch latch 2 Making sure that the cable is completely straight carefully close the hinged assembly and apply firm even pressure until the first latch locks into place Note Make sure that the flat cable is completely straight before continuing The latch has two catches the first loosely holds the connector on the cable the second requires more pressure to close the connector tightly The cable must be in the correct position for the connector to close properly 3 Drive the two screws at the center points about halfway down first on the latch side then the hinge side 4 Continue to tighten the screws a little at a time until fully tightened no more than 15 inch pounds 5 6 Nem of torque Note You can only pierce the cable once Once pierced the KwikLink connector must not be removed This insures that the inner conductors are not exposed to the elements Connecting the Controller to the Network To connect the controller to the network make sure that the KwikLink connector is properly installed on the flat grey data cable To connect 1 Att
91. vacuum pumps require 8 connector ArmorBlocks central alarm stations require 4 connector Armor Blocks Make sure that each mounting plate has properly attached tube clamps as required Each mounting plate requires two 2 tube clamps Always use locking washers especially in high vibration environments 24 Pump 128 Station Controller Chapter 3 Installation 14 Figure 3 Side View of a Typical Mounting Plate Assembly with ArmorBlock Base Ny Rotate 30 to 45 downward Installing Assembled Mounting Plates After you ve set up the mounting plates 1 Install them at each node location by clipping the tubing clamps onto the vacuum tube just before the node area such as a T valve 2 Orient the mounting plate parallel with the flat cables and at a 30 to 45 angle so the KwikLink connector or ArmorBlock faces the operator on the floor torque the tubing clamp fasteners until tight The flat cable will be installed inside KwikLink connectors and ArmorBlocks as described in the following sections of this chapter Terminating Cable Runs After you ve run the black and grey network cables you need to properly terminate the ends of the cables By doing so you ll insure that the network runs properly You will also have the benefit of being able to measure voltage in the system without disrupting operation This section lists procedures for terminating these cables To properly terminate a cable run 1 Mount three standard K
92. vey When this option is enabled the station s disabled disabled vacuum valve remains open for the convey enabled time even if the station is not demanding material and is indicating that it is full When disabled the station s vacuum valve opens when there is demand from the station and it remains open until the convey time has elapsed or material trips the volume fill proximity switch Enable this option if and only if the station has no flapper Closed Loop This option allows material to be conveyed and processed without being contaminated by outside influence such as dust other materials etc Alarm Options No convey When this option is enabled the controller disabled disabled issues a no convey alarm if it has repeatedly enabled attempted to convey material to the station but the flapper never opened during the dump delay The number of attempts is controlled by the next setting Usually this option should be enabled At times you may wish to disable it during operation as a stopgap measure for dealing with an alarm attempts B4 alarm Number of attempts before alarm the number of times the controller will attempt to convey material to a station before it issues a no convey alarm The setting for this option depends on a how much material your mold uses to make each part compared with the capacity of the receiver and b how important it is to keep your mold from running out of material and shutting down
93. wikLink connectors to a mounting plate in a triangle configuration See Figure 4 on Page 19 for an illustration Make sure that each connector is installed with the hinge side down 2 Mount the tubing clamps to the mounting plates Each mounting plate requires two 2 tubing clamps 3 Mount the standard resistor cap from the KwikLink connector kit on the top center KwikLink connector for the black power flat cable The standard resistor cap has metal prongs in the center Repeat for the outside end KwikLink connector on the grey data flat cable 4 For the inside KwikLink connector next to the outside end on the grey cable mount a separately packaged blank cap on it instead of the standard resistor cap in the KwikLink connector kit 24 Pump 128 Station Controller Chapter 3 Installation 15 Discard the standard resistor cap to eliminate confusion 5 Mount the mounting plate assembly on the vacuum line at the end of the cable run See Page 14 for more information 6 Using the straight blade cable cutter carefully trim each flat cable so it sticks out past the final KwikLink connector by 4 to 34 Place a dust cap over the end of the trimmed cable 7 Lay the dust cap and cable into the KwikLink connector so the dust cap tabs engage in the connector slots The dust cap tabs should fit into the connector slots perfectly Left 8 Lay the cable in the hinged base noting the correct keyed profile flat edge toward the hi
94. xpected either a component s ArmorBlock has an incorrect address or the ArmorBlock is not correctly wired to the network When you have verified that the controller is communicating with the other system components you should verify that the inputs on all ArmorBlocks for stations and pumps are wired correctly and are working correctly To do so Station numbers are stacked vertically as column headings in this screen 3 Check that all inputs are on green or off grey as expected and that they switch on and off as required a Station demand switch In a new installation the box labeled Demand Switch should be green for every station vacuum hopper in the system All other boxes for demand switches will be grey In a retrofit at an existing installation each station s Demand Switch box should be green unless the receiver bin under the station is in fact full b Option input The proper status of this input will be dictated by the option installed If any input does not operate as expected check the wiring on the ArmorBlock If this does not solve the problem phone the Service Department for assistance Setting Up Alarm Silences When an alarm occurs a horn sounds and a strobe light flashes at each installed central alarm An alarm window will also appear in the center of the operator interface screen s The window will display a description of the alarm the time and date it occurred and a Push To Silence button Touchin

Sterling 882.00255.00 CV3-655 Musical Table User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents