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Sterling 882.00249.00 Home Theater Server User Manual

1. 14 Connecting the Control Panel to Vacuum 15 Connecting the Control Panel to the Pump Package 15 Main 17 ____________________ aia 17 Gaining Access to the Menu 18 Station Settings 19 Pump Settings Ee 27 System Sekmgs Tn 32 Service Settings 33 Saving Controller Settings to Flash 33 3 5 NTC 33 CHAPTER 4 OPERATION 34 4 A 34 Setting Load TIMES 34 Enabling and Disabling Individual Stations sess 35 2 Pump 12 Station Controllers Chapter 1 Safety 4 4 2 Controller Description and 35 35 Or Re m Ree 37 Status Indicators ssc 38 Controller m 39 4 3 sess p Rer te inen 40 Operation States 40 Lx H
2. 39558 gi JEEE z Lu 2 BLOWBACK 12 HIGH VACUUM 11 CHECK SYSTEM 3 1 2 2 2 12 Station Controllers Chapter 3 Installation 27 If you have a single pump system default 1 Press the YES key Selecting Single Pump mode requires the assignment of the default pump the screen then displays the following ON ON n 1 L3 z BLOWBACK 1 12 HIGH VACUUM 1 2 CHECK SYSTEM 11 2 Selecting Dual Pump mode requires ALL stations to be assigned to a pump Do so in Station Settings Menu The pump mode is now set To exit from the Pump Settings Menu 1 Press the CLEAR key Note You can always press the CLEAR key repeatedly to bring you up one level in the menu system Selecting the Dual Pump option immediately returns you to the Pump Settings menu Caution If you select Dual Pump mode you MUST assign each station to a pump Each station defaults to Pump 1 if not assigned Caution Not assigning a station to its related pump can cause damage to the loading system 2 Pump 12 Station Controllers Chapter 3 Installation 28 Changing Blowback Settings Pump Settings Menu As an option you can equip the conveying system filter chamber with a blowback feature to pulsate compressed air through the filter This function cleans the filter after a pre set number of load sequences To set up the controller blowback feature enter the Pump Setti
3. 0539383 BRIDGE 25 AMPS 2510 A0560956 ELEK RES 50 OHM 50 WATT CLEROSTAT A0539387 XFMR 16 VCT 112 VA MCI 4 07 8016 W00015057 SCR PAN HD SLTD PLT 4 40 X 1 6 2 Pump 12 Station Controllers Chapter 7 Appendix 55 7 4 Controller Identification Serial Number Located on the side of the controller box Street Address Town State Zip Code Telephone Number Fax Number XXX CONTROL PANEL Model No XXX2 12 Serial No 31K0182 Control Voltage 24VDC 7 5 Technical Assistance Contact Information Parts Department Call toll free 7am 5pm CST 800 423 3183 or call 630 595 1060 Fax 630 475 7005 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications which will maximize your equipment s performance and efficiency To assist in expediting your phone or fax order please have the model and serial number of your unit when you contact us A customer replacement parts list is included in this manual for your convenience ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service Service Department Call toll free 8am 5pm CST 800 233 4819 or call 630 595 1060 Emergencies after 5pm CST call 847 439 5655 We have a qualified service department ready to help Service contracts are available for most products Sales Department Cal
4. SECTION 1 SECTION 2 SECTION 3 SECTION 4 Fal Fel Fri Fel Fs Rs Fal Fa 1 2 3 START ST1 ST2 573 13 0 lt lt 4 14 0 33 0 cm a Se 35 6 cm 7 oN fca 5 7 8 8 8 9 PRIOR No 0 YES ENTER ST10 8 11 ST12 MENU x E 10 4 26 4 cm Depth dimension of subpanel 8 0 D 20 3 cm Also review electrical drawings supplied in the packet with this manual 2 Pump 12 Station Controllers Chapter 7 Appendix 51 7 3 Spare Parts List Figure 8 Typical 12 Station Controller Exterior Components Exploded View 12 EXE 10 NM 465 a an r places 4 0 om P RES 2 4 a places 5 4 2 1 4 1 places 16 A0560974 _ Power cord A0560954 2 Pump 12 Station Controllers Chapter 7 Appendix 52 Figure 9 Exterior Components Parts List Refer to Figure 8 on Page 51 when identifying parts 6 1 0560965 ENCL CARLON I2X OLID NHIZI0L 0560969 SPCR NYLON 0 091 ID 0 185 OD 1 8 1 0560967 SCR SLTD PLT 2 56 X 3 4 2 Pump 12 Station Controllers Chapter 7 Appendix 53 Figure 10 Typical 12 Station Controller Interior Components Exploded View 11 8 40560974 2 Pump 12 Station Controllers Chapter 7 Appendix 43 11 12 40 54 Figure 11 Interior Components Parts List Refer to Figure 10 on Page 53 when identifying parts
5. Press the YES key to enter the Ramp Up Time menu 86890 9585 0 N ON ON ON JN N B PUMP 1 2 BLOWBACK IET 12 HIGH VACUUM 1 2 1 2 ON ON ON Lu z BLOWBACK 4 12 HIGH VACUUM 1j 2 CHECK SYSTEM E 2 Using the keypad Enter the new time and press the ENTER key to save the new setting 2 Pump 12 Station Controllers Chapter 8 Service Only Information 57 Setting the Ramp Down Time Ramp down time 15 a delay that allows the pump to come to a full stop when needed The control cannot restart until this delay 15 completed This is also known as the Shutdown delay This delay defaults to 8 0 seconds and should not be altered unless instructed to do so by the Service Department jJ a e ON M 2 BLOWBACK i4 CHECK SYSTEM 11 2 At the above message prompt 1 Press the YES key to enter the Ramp Down Time menu 2 Select the pump for altering ramp down time gg ON ON ON ON ON ON 2 12 HIGH VACUUM 11 2 CHECK SYSTEM 1 5968 jl EE ON Ru 2 HIGH VACUUM 11 CHECK SYSTEM 1 2 Using the keypad 3 Enter the new time and press the ENTER key to save the new setting 2 12 Station
6. Although main controller power is 115 220 VAC control power is actually unregulated 24 VDC The 24 VDC control power supplies the power for all solenoids sensors and the controller itself The unregulated supply can deliver up to five 5 amps of continuous current to drive a very large system Inputs e Station connections e High vacuum connections e System error connections Outputs e Station connections Pump blowback e Spare 3 4 Setup This section provides the procedures for configuring your 2 pump 12 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 To help you set up the controller quickly this section walks you through the setup using the menu system This procedure will work for most applications but you may need to perform some minor adjustments afterwards to achieve the best conveying performance Note The controller must be in Offline mode to permit access to the menu system 2 Pump 12 Station Controllers Chapter 3 Installation 17 Gaining Access to the Menu System To enter the menu system make sure that the controller is in the OFFLINE state Press the MENU key t
7. Defective wiring Correct replace wiring Output icon comes on Defective terminal block bac defective terminal lenoid d Defective Replace defective Defective solenoid Replace defective solenoid Power supply shorting out Repair shorting circuit Excessive loading on solenoids VOU propel solaria Call Controller blows fuses 9 Engineering for assistance Replace fuse with one that has a Improper fuse installed 6 proper rating Cold boot the controller Restore the controller to factory defaults Erratic operation Corrupt RAM data see Section 8 5 on Page 75 for more information Replace PCB 2 Pump 12 Station Controllers Chapter 6 Troubleshooting 47 Controller Recovery using Flash Memory Technology Itis possible for a write error to occur while information 1s being saved in the controller s memory If this occurs the system always saves a backup of the data To recover from a write failure e Shut off the controller wait 15 seconds then restart the controller The boot sequence detects the write error and attempts to restore the backup file It is also possible although rare that the backup and original file could both become corrupt If this occurs then reset the controller to factory default parameters before proceeding However all parameters you ve previously stored are lost and you ll need to set up the controller from the beginning You should record what settings
8. 2 Press the YES key to alter the Idle Delay time 2 Pump 12 Station Controllers Chapter 3 Installation 31 The following screen displays N ON ON 1 r 1 z BLOWBACK 1 12 HIGH VACUUM CHECK SYSTEM 1 2 Each pump can have separate idle delay times To alter idle delay select a pump Using the keypad enter the pump number 1 or 2 The following screen displays J8BBE j 888 CHECK SYSTEM n PUMP 1 2 BLOWBACK HIGH VACUUM a Using the keypad enter the idle delay time The controller is now properly set up and ready for operation System Settings Menu Audio Alarm Time Video Alarm Time Password Enable Disable 2 Pump 12 Station Controllers Chapter 3 Installation 32 Service Settings Menu The settings in this menu are not meant to be modified by floor personnel operators See the section at the end of this manual for these settings Saving Controller Settings to Flash Memory Your 12 station controller uses a new technology called flash memory This type of memory writes and reads like normal memory but the advantage is that the data is retained after power is shut down If you alter any parameter the controller saves the new data to flash memory This procedure takes several seconds and takes all the processor time For this reason the controller does not write to flash memory while runni
9. At the above message prompt 1 Press the YES key to enter the Hi Vacuum Load Count menu 5 Bt J m lt 7 ON ON 1 2 BLOWBACK 12 HIGH VACUUM 1 CHECK SYSTEM 1 2 At above screen prompt 2 Select the pump for altering the high vacuum load count The following screen displays E 16 5 F4 54 2 fol 11 2 BLOWBACK 12 HIGH VACUUM 1 CHECK SYSTEM 1 2 Using keypad 3 Enter the new time and press the ENTER key to save the new setting 2 12 Station Controllers Chapter 8 Service Only Information 63 Using the Installation Aids Menus Input Monitor Screen To assist in the installation process or to aid in problem diagnoses the controller uses two 2 OEM menu functions The Input Monitor screen displays all 20 inputs in real time 0 represents no input and 1 indicates an active input JEE E ON ON 2 BLOWBACK 1 2 HIGH VACUUM 1 2 CHECK SYSTEM 11 2 At the above message prompt 1 Press the YES key to enter the Input Monitor menu You now have access to the OEM menu system and Input Monitor menu The following screen displays ON ON ON ON ON ON a Lu 2 BLOWBACK 12 HIGH VACUUM 11 2 CHECK SYSTEM 1 2 The top row Bank 0 IN shows the input statu
10. SCC 2 Pump 12 Station Controllers Part Number 882 00249 00 Bulletin Number CV3 650 Effective 10 25 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 O Copyright 2005 rights reserved Please note that our address and phone information has changed Please reference this page for updated contact information These manuals are obsolete and are provided only for their technical information data and capacities AXCAUTION Portions of these manuals detailing procedures or precautions in the operation inspection maintenance and repair of the products may be inadequate inaccurate and or incomplete and shouldn t be relied upon Please contact the ACS Group for more current information about these manuals and their warnings and precautions Parts and Service Department The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications which will maximize your equipment s performance and efficiency To assist in expediting your phone or fax order please have the model and serial number of your unit when you contact us A customer replacement parts list is included in this manual for your convenience ACS welcomes inquiries on all your parts needs and is dedicated to providi
11. INTERNAL WIRING FU WIRE LUG 4 12 12 2 L3 FU e 0T e POWER WIRING 15 me Mee N 0 n FROM CONTROLLER OUTPUT 4 FOR MOTOR STARTER 96 95 FROM CONTROLLER OUTPUT n FOR VACUUM PUMP SOLENOID 1501 FROM CONTROLLER OUTPUT ro FOR PUMP BLOWBACK SOLENOID CONTROL WIRING 2 Pump 12 Station Controllers Chapter 3 Installation 5 HP PUMP TO CONTROLLER INPUT FOR PUMP HIGH VACUUM NEUTRAL VACUUM PUMP MOTOR STARTER VACUUM SOLENOID ON PUMP BLOWBACK SOLENOID ON PUMP 16 Power Your 12 station controller system can operate from a 115 220 VAC source at 50 Hz or 60 Hz The main power switch on the controller is located on the right side of the housing Built into the power switch are the controller fuses Also the configuration of the fuse holder determines the voltage setting of the controller 115 220 VAC Marked on the faceplate of the fuse holder shows the configuration for the desired voltage Using a small screwdriver remove the fuse holder To select the operating voltage align the arrow marker on the holder and the switch as shown in the following section The 12 station controller has a standard IEC power cord Plug the cord into any standard 115 VAC outlet If you selected the 220 VAC option remove the end connector and install a standard 220 VAC plug Doing so does NOT effect the controllers warranty DC Controller Power Sources
12. enter the new dump delay time in seconds into controller memory Keep in mind that the value shifts to the left as you enter Use the 0 key to shift to the next multiple of ten To exit from the Dump Delay menu and return to the Station Settings menu e Press the CLEAR key To save the new value and escape from the Dump Delay menu e Press the ENTER key To save the new value to the controller memory and increment to the next station in the sequence Press the SET key If you press the SET key without entering a value the original value is retained and the controller moves to the next station in the sequence Set Input Delay Station Settings Menu The third submenu under Station Settings is the Set Input Delay submenu To set input delay time Press the YES key The following screen displays ON ON aes 2 BLOWBACK i4 HIGH VACUUM 11 2 CHECK SYSTEM 2 The Input Delay function protects the system from erroneous inputs caused by noise or mechanical vibration The signal must be present for the input delay time setting duration for the input to be recognized To alter input delay time e Press the YES key The following screen displays Lu z BLOWBACK 12 HIGH VACUUM 1 2 CHECK SYSTEM MI 1 2 2 Pump 12 Station Controllers Chapter 3 Installation 22 To alter station input delay time e Select a station to al
13. 0 VDC BLACK 18 AWG _ DISPLAY 44 Maintenance Chapter 5 2 Pump 12 Station Controllers Figure 6 BIOS Connection Electrical Diagram Drawing 2 0 VDC 2 201 0 CONTROLLER AEC PIN A0560950 TB2 2L gt TB2 3L TB2 4L TB2 5L TB2 6L TB2 7L TB2 8L TB2 9L TB2 10L gt TB2 M1L TB2 14L TB2 15L gt TB2 16L gt TB2 17L TB2 18L TB2 19L gt TB2 20L 2 STATION 1 SENSORS 18 2 EMT di 2 STATION 2 SENSORS 1PRS as 2 me 12 STATION 3 SENSORS 2PRS 38 2 y As 2 STATION 4 SENSORS IPRS 45 2 zs No 4 2 STATION 5 SENSORS 4PRS 5 2 if 7 2 STATION 6 SENSORS 5PRS 65 2 3 2 5 7 SENSORS 6PRS 15 2 ES 12 STATION 8 SENSORS TPRS 815 2 a N C N O 4 2 STATION 9 SENSORS 8PRS 915 2 po 12 STATION 10 SENSORS 9PRS 1 fus 2 2 STATION 11 SENSORS 10PRS 115 2 T N C i 7 2 STATION 12 SENSORS 1PRS 115 2 i 12PRS 12 HIGH VACUUM SENSOR 1 1318 2 4 2 HIGH VACUUM SENSOR 2 1418 2 N 0 2 MACHINE ALARM SENSOR 1 1518 2 4 A 12 MACHINE ALARM SENSOR 2 115 2 4 12 MACHINE ALARM SENSOR 3 CET 115 2 12 MACHINE ALARM SENSOR 4 1815 2 5 2 SPARE 1 1915 2 12 SPARE2 2015 2 N 0 2 4 2 4 gt 2 A0560970 LEGEND FIELD WIRING OPTION SERVICE WIRING NOTE ALL WIRES ARE 18 AWG UNLES
14. Controllers Chapter 8 Service Only Information 58 Setting the Pump Stage Time Pump stage time is a delay that prevents both pumps from engaging at the same time Although rare in a two pump system both pumps can sometimes start at the same time This condition causes an excess of current on the electrical system from such a surge The pump stage time delay defaults to 3 0 seconds and should not be altered unless you are instructed to do so by the Service Dept Lu 2 BLOWBACK 12 HIGH VACUUM 1 CHECKSYSTEM 1 2 At the above message prompt 1 Press the YES key to enter the Pump Stage Time menu ON ON ON ON ON ON TETT AIF J fal 1 2 BLOWBACK 1 2 HIGH VACUUM 1 2 CHECK SYSTEM Using the keypad 2 Enter the new time and press the ENTER key to save the new setting 2 Pump 12 Station Controllers Chapter 8 Service Only Information 59 Setting the LCD Blink Delay LCD Blink Delay lets you alter the ON OFF time that the LCD blinks during an alarm This delay does not effect the Visual or Audible alarm outputs The delay defaults to 0 5 seconds and should not be altered unless you are instructed to do so by the Service Department JEESEEHSEES ON ON 1 r tJ 2 BLOWBACK 1 12 HIGH VACUUM B CHECK SYSTEM 1 7 2 At the above message prompt 1 Press the YES key to enter th
15. EI 57 Setting the Ramp Down 58 Setting ine PUMP TMG M 59 Setting The LCD Blink Delay 60 Setting the Hi Vacuum Sensor Delay ierit attorno 61 Setting the Hi Vacuum Vent sese esee een annia tnnt 62 Setting the Hi Vacuum Load Count 63 Using the Installation Aids Menus eiie 64 8 2 Other Controller Restricted 67 Using ihe OEM Service MOT iip da coto 67 Recovering P 68 Restoring the Controller to Factory 69 2 Pump 12 Station Controllers Chapter 1 Safety 5 Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining your equipment The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This manual covers only light corrective maintenance No other maintenance should be undertaken without first contacting a service engineer The Functional Description section outlines models covered standard features and optional features Additional sections within the manual provide instructions for installation pre operational procedures operation preventive maintenance and
16. familiarize themselves with the safety procedures and the proper use of any safety devices Fail Safe Operation If a safety device or circuit should fail the design must be such that the failure causes a Safe condition As an example a safety switch must be a normally open switch The switch must be held closed with the device it is to protect If the switch fails it will go to the open condition tripping out the safety circuit At no time should the safety device fail and allow the operation to continue for example if a safety switch 15 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 2 Pump 12 Station Controller Failure to do so may result in serious injury No one but the person who installed the lockout may remove it 2 Pump 12 Station Controllers Chapter 2 Functional Description 12 2 Pump 12 Station Controllers Chapter 2 Functional Description Chapter 3 Installation 3 1 Uncrating 2 Pump 12 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 skid
17. following screen displays 5 g ge D m 2 z 1j 2 BLOWBACK 1 12 HIGH VACUUM 1 CHECK SYSTEM 3 1 a 2 A cursor displays on the screen To move the cursor left Press the 4 key To move the cursor right Press the 6 key To move the cursor up Press the 2 key To move the cursor down Press the 8 key To toggle output ON or OFF e Press the START STOP key To exit this menu 2 Press the CLEAR key Caution Enabling the Pump output without opening any sequence valves can cause damage to the conveying system Caution Do not perform this action unless directed to do so by the Service Department 2 12 Station Controllers Chapter 8 Service Only Information 66 8 2 Other Controller Restricted Areas Using the OEM Service Menu The OEM service menu Original Equipment Manufacturer lets you set parameters not commonly used It also contains functions to aid in the installation of the controller Access to this menu should be restricted to setup and maintenance personnel only To gain access to the OEM service menu 1 Remove power from the controller 2 Press and hold the Zero 0 key and re apply power While holding the Zero 0 key allow the controller to initialize The controller displays the message below and permits access to the OEM service menu ON N 399599598 1j z BLOWBACK 1 12 HIGH VACUUM 1 8 CHECK
18. of ten 10 From the left character position S is read as Pump 0 Station Load Time This screen displays important information in an easy to read display The right ten 10 character group displays the status of the specific pump Again the different status displays are described on Pages 24 and 25 J EHE 12 ON ON 1 2 BLOWBACK 1 2 2 Pump 12 Station Controllers ON ON ON ON 2 i ON ON HIGH VACUUM 1 CHECK system 1 2 Chapter 4 Operation 36 Station Icons Below the text portion of the screen 12 station icons display the status of each station in the system Each station icon contains four segments Figure 3 Station Icon Segments ___ Segment 1 o Md et Segment 2 I 1 mg E b lun oe ANI Segment 3 OIN x Segment 4 Segment The top segment indicates the status of the valve above each station When the valve is open control output energized this icon highlights In Single Pump mode only one valve indicator is active at a time In Dual Pump mode up to two valve indicators can be active at a time When this indicator flashes it indicates the assignment of a priority convey Segment2 The center square segment indicates the existence of a station specific alarm condition The alarm is typically related to a No Convey condition but can also indicate the station wit
19. switch Reset the overload and check The motor overload has tripped the motor for the proper amp A pump package doesn t run draw on tag even though it is on line and its Main fuse in power drop indicator is lit optional fused disconnect has Replace the fuse blown Normal operation When the level drops material conveys to the hopper The hopper is off line ds the controller place the opper on line A vacuum hopper is being The convey time for the hopper Using the controller enter a bypassed in the loading cycle is set to zero reasonable convey time The field installed station bypass Normal operation Set the switch switch is simulating a Bin Full so the hopper is back in the condition loading sequence The field installed station bypass switch is bad or mis wired Conveying times are too lon Time the hopper s during Deng 9 loading and set conveying times Time Fill mode only to a few seconds less Check proximity sensors for Vacuum hoppers are over filling Maximum conveying times proper operation and proper too long and the PCB does not wiring to the PCB Repair as recognize the Hopper Full needed Reset the conveying proximity switch es times to a reasonable value and adjust as needed The bin below it is full if its amber indicator light is off Repair replace or rewire 2 Pump 12 Station Controllers Chapter 6 Troubleshooting 46 Possiblecause ___ _ Solution
20. you use in the controller system if this occurs The following screens display while the controller writes to flash memory Again do not cycle power while these two screens display 8E ji 9 58 BLOWBACK 12 HIGH VACUUM 1 CHECK SYSTEM 1 1 2 7996 gi SEHE N 2 BLOWBACK 1 12 HIGH VACUUM 1 CHECK SYSTEM 1 2 Note The controller needs about 30 seconds for saving to flash memory If the controller doesn t clear this display within 60 seconds you may need to cycle power This rare type of problem is caused by a write failure not detected by the controller This rare condition usually requires a complete factory default reset for full recovery 2 Pump 12 Station Controllers Chapter 6 Troubleshooting 48 Chapter 7 Appendix 7 1 Warranty Unless otherwise specified this product includes a Standard ONE YEAR PARTS AND LABOR WARRANTY Warranty Specifications The manufacturer hereby expressly warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions as set forth in the operating manuals for such equipment THE FOREGOING EXPRESS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES GUARANTIEES AGREEMENTS AND SIMILAR OBLIGATIONS OF THE COMPANY AND OR MANUFACTURER UNLESS OTHERWISE SPECIFIED IN THE SPECIFIC PRICE PAGE OR LIMITED BY THE MANUFACTURERS WARRANT
21. 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 2 Pump 12 Station Controllers Chapter 1 Safety 9 Chapter 2 Functional Description 2 1 Models Covered in This Manual This manual provides operation installation and maintenance instructions for 2 Pump 12 Station Conveying Controllers Model numbers are listed on the serial tag Make sure you know the model and serial number of your equipment before contacting the manufacturer for parts or service The 2 Pump 12 Station Conveying Controller is a programmable logic controller with 24 VDC or 115 VAC control circuit easy to
22. E 0 e S 42 CHAPTER 5 MAINTENANCE eere nnne nnn nnn 43 Updating BIOS Software C 43 CHAPTER 6 TROUBLESHOOTING 46 6 1 General Troubleshooting EE 46 Controller Recovery using Flash Memory 48 CHAPTER 7 APPENDIX 49 FUE 49 Warranty 5 HM 49 Warranty Restrictions 49 Warranty Liabilities en 50 Customer 4 50 7 2 Drawings and DiagramS svccrccceiccssassczostanosensassiacentirasdivaaduraada 51 7 3 Spare Parts 52 7 4 Controller Identification Serial Number 56 7 5 Technical Assistance 56 Parts Department s n e 56 Service 56 Sales Department 56 Contract 56 CHAPTER 8 SERVICE ONLY INFORMATION 57 8 1 Service Settings 57
23. 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 2 Pump 12 Station Controllers Chapter 1 Safety 6 Controller Safety Tags Read Operation and Installation High Voltage Inside Manual Enclosure 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 A RA ARA NX Read and follow these operation and installation instructions when installing operating and maintaining this equipment If these instructions become damaged or unreadable additional copie
24. Note Remove the nails holding the box to the skid and lift the box off carefully avoiding staples in the 1 x 4 wood supports Cut the steel banding 2 Usea pry bar to remove the blocks securing the unit to the skid 3 Lift unit from sides Lift slowly and only high enough to clear the skid Use a pry bar if necessary to carefully remove the skid from the unit 4 Lower slowly 3 2 Mounting the Control Panel Note Before you mount the panel consider how you run wiring to the vacuum hoppers the filter chamber atmospheric valve if so equipped and the pump motor starter s vacuum switch es and vent valve s Mount the panel on a flat vertical area It should be a visible area that gives your operator access to the control The panel requires a low voltage power drop as listed on the serial tag 3 3 Electrical Connections Refer to local electrical codes the schematic and connection diagrams supplied with this unit and the serial tag for wiring considerations Run all wiring in conduit if codes require it Making Control Panel Power Drop Wiring Connections Plug the power cord supplied with your unit into a properly grounded 3 slot 115 1 50 60 VAC or 230 1 50 60 VAC receptacle specified on the control panel serial tag The control enclosure draws less than five 5 amps during normal operation at 115 1 50 60 VAC Caution We recommend that you protect PLC memory by providing the control panel with a dedicated circuit a true e
25. RS 232 serial connection through the COMI serial port As shown in the electrical diagrams and the electrical diagram on the following page connect a serial cable as shown Follow the installation program instructions supplied with the software update The installation program automatically updates the BIOS 2 12 Station Controllers Chapter 5 Maintenance 43 1 ing Draw ical Diagram Electr ion BIOS Connecti Figure 5 LINE 1 6 FU 1 1 RED N 3 RED 3 9 E T GREENYELLOW L 1 f5 5 9 P RED POWER SWITCH W FILTER amp FUSE POWER TRANSFORMER ENCAPSULATED WIRING PIN A0560955 SCHAFFNER FN1394 10 05 11 MCI 4 07 8016 24 VDC FU1 amp FU2 AEC P N A0560957 Y 250 VAC 5 0 AMP 2 4 OPTIONAL RESET SWITCH ONLY sip lt CANIDEVICENET P FU 96 RS 485 SPI 20 10 CONTROLLER PIN A0560950 A0560970 2 1 24 ane BRIDGE RECTIFIER RED 6 AEC PIN A0539383 25 AMPS GBPC2510 RED NOTE ALL WIRES ARE 18 AWG UNLESS OTHERWISE NOTED OPTIONAL RS 232 COMMUNICATION PORT CPU PROGRAMMING PORT CUSTOMER SUPPLIED FUSE amp HOLDER RECOMMENDED 4 AMP FOR 12 STATION SYSTEM BLUE BLUE 50 OHM 50 WATT 5 BLUE MAMA RED 18 AWG _ 10 DISPLAY 4 FILTER CAPACITOR AEC P N A0539382 22000 UFD 40 VDC
26. RTING state and returns to load material into the hoppers BLOWBACK When enabled the controller enters the BLOWBACK state following user definable number of station loads The blowback function is to pulse air through the filter system to keep the filter from clogging The number and duration of the air pulses is also user definable see the Blowback menu on Pages 54 58 for more information LOADING IDLE In Dual Pump mode if you start the controller with demand from stations 2 Pump Mode assigned to both pumps both pumps start at the same time In many plants Only such a resulting power surge can momentarily exceed the electrical limits of the plant To prevent this condition the pumps are staged in sequence separated by a short duration Pump 1 always starts first followed by Pump 2 This state also applies when both pumps are in the OFFLINE state and demand occurs on both systems at the same time 2 Pump 12 Station Controllers Chapter 4 Operation 41 4 4 Shut Down 2 Pump 12 Station Controllers Chapter 4 Operation 42 Chapter 5 Maintenance Updating BIOS Software Occasionally BIOS software updates are available to enhance the operation of the controller These updates are available through the Service Deptartment or for download from the internet To find out what the current BIOS software version is call the Service Department for details You can update the software with a laptop computer and an
27. S OTHERWISE NOTED 2 Pump 12 Station Controllers Chapter 5 Maintenance TB2 21L TB2 22L TB2 23L TB2 12L TB2 13L TB2 12U TB2 13U TB2 2U TB2 3U 2 40 TB2 5U TB2 6U TB2 7U TB2 8U TB2 9U TB2 10U TB2 11U TB2 14U TB2 15U TB2 16U TB2 17U TB2 18U TB2 19U TB2 20U TB2 21U TB2 22U TB2 23U TB2 1U TB2 24U TB2 1L TB2 24L 1S0L 2501 3501 4501 5601 6501 7801 N O 8501 9801 10801 11501 12501 N 0 N 0 N 0 N 0 24 VDC 4 Station 1 sequence valve Station 2 sequence valve Station 3 sequence valve Station 4 sequence valve Station 5 sequence valve Station 6 sequence valve Station 7 sequence valve Station 8 sequence valve Station 9 sequence valve Station 10 sequence valve Station 11 sequence valve Station 12 sequence valve Pump 1 solenoid Pump 2 solenoid Vent solenoid 1 Vent solenoid 2 Blowback solenoid 1 Blowback solenoid 2 Audible alarm Visual alarm 45 Chapter 6 Troubleshooting 6 1 General Troubleshooting Problem Possible cause Solution The controller panel is not Plug in the controller panel plugged in The external disconnect The controller panel doesn t light recommended in the dedicated Close the switch on up at all circuit is open off drop is blown tripped Broken controller power
28. SYSTEM 3 1 71 2 Gain access to the OEM service menu by entering the menu system An additional menu screen is shown below ag g 5 E e D 8 1 x BLOWBACK 1 2 HIGHVACUUM 1 CHECK SYSTEM fa 2 2 Pump 12 Station Controllers Chapter 8 Service Only Information 67 Recovering Passwords By following this procedure passwords can be displayed should they be lost or forgotten Note In the interest of system security and integrity make sure that only setup people and supervisors know this procedure Follow these steps to recover passwords l 2 3 Remove power from the controller Press and hold the 3 key Reapply power as you continue to hold down the 3 key The screen displays up to four 4 password settings during controller initialization Note the sample screen below Press the CLEAR key to contine with initialization 2968 8 BE 79868 r 11 BLOWBACK 11 11 HIGH VACUUM 1 CHECK SYSTEM 111 1 2 Note Passwords shown on this screen are illustration only 2 Pump 12 Station Controllers Chapter 8 Service Only Information 68 Restoring the Controller to Factory Defaults Although rare you may experience a condition when you need to perform a total reset of the controller To do so perform the following procedure Note All parameters you set are lost when doing this procedure including passwords and OEM Service settings Follow t
29. WBACK 12 HIGH VACUUM 11 CHECK SYSTEM E 2 ON To move on to the individual settings screen Press the NO key The following screen displays EE ON ON ON ON 2 BLOWBACK IET 12 HIGH VACUUM 1 CHECK SYSTEM 1 2 Starting with Hopper 1 controller now lets you individually set operation mode of each station 1 Press the YES key to set the station to Normal mode 2 Press the NO key to set the station to the Sight Glass mode 3 Press the SET key to save the new setting into controller memory and increment to the next station in sequence 4 Press the CLEAR key to exit to the Station Settings menu 2 Pump 12 Station Controllers Chapter 3 Installation 20 Set Dump Delay Station Settings Menu The second submenu in Station Settings 15 the Set Dump Delay submenu ON ON 1 2 BLOWBACK 12 HIGH VACUUM 11 2 CHECK SYSTEM 2 To set dump delay time e Press the YES key After a hopper finishes loading the next hopper in the queue usually gets loaded The time it takes to load the new hopper s usually gives ample time for the first hopper to dump its material However in a situation where a single hopper 1s being loaded a demand may be generated during the dump cycle from material catching on the flapper switch This may cause an inadvertent load while the hopper is still dumping
30. Y FOR PARTS 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 Warranty Restrictions 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 immediately without any further use or handling 2 Pump 12 Station Controllers Chapter 7 Appendix 49 Warranty Liabilities THE COMPANY EXPRESSLY DISCLAIMS ANY AND ALL LIABILITY FOR ANY SPECIAL CONSEQUENTIAL OR INCIDENTAL DAMAGES OR EXPENSES THAT RESULT FROM THE USE OF THIS PRODUCT Some states do not allow the exclusion or limitation of special consequential or incidental damages so the above limitation may not apply to you The Company s obligation for parts not furnished as components of its manufactured equipment 15 limited to the warranty of the manufac
31. arth ground and a spike surge protector 2 Pump 12 Station Controllers Chapter 3 Installation 14 Connecting the Control Panel to Vacuum Hoppers Refer to the wiring connection diagram in Figure 1 on the next page that applies to your application Note Wire size depends on control voltage distance number of vacuum hoppers and the number of wires in each raceway Consult a qualified electrician On 24 VDC control voltage systems run a common 24 VDC wire and a common 0 zero VDC wire from the controller to each vacuum hopper in the system Note For safety make sure that the 24 volt line is fused The size of the fuse depends on the number of stations installed A 4 amp fuse is sufficient for a 12 station installation On all systems run two wires to each vacuum hopper one each from the controller to the Bin Full switch LS and to the Atmospheric Sequence T solenoid SOL valve Make sure that solenoid and the proximity switch if supplied on vacuum hoppers are the same voltage 24 VDC as the control panel voltage Consult the control panel serial tag and the solenoid valve nameplates Wire size depends on control voltage distance number of vacuum hoppers and the number of wires in each raceway Consult a qualified electrician Properly ground each hopper to reduce static build up generated by material conveying Connecting the Control Panel to the Pump Package 1 Wire pump package motor starter
32. cated 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 Europe Middle East Africa ACS New Berlin Manufacturing Facility 2900 S 160 Street ACS Warsaw New Berlin 53151 Ul Dzialkowa 115 Phone 1 262 641 8600 eae as as Phone 48 22 390 9720 Fax 48 22 390 9724 Shipping Information Unpacking and Inspection You should inspect your equipment for possible shipping damage Thoroughly check the equipment for any damage that might have occurred in transit such as broken or loose wiring and components loose hardware and mounting screws etc In the Event of Shipping Damage According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment Notify the transportation company s local agent if you discover damage Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods before the transportation company s inspection and authorization File a claim with the trans
33. coil M to terminal provided in control panel enclosure Wire the pump package vacuum relief valve solenoid SOL A to the terminal provided in the control panel enclosure Wire the pump package vacuum switch VS to the terminal located in the control panel enclosure On vacuum pumps with blowback wire the pump package blowback solenoid SOL B to the terminal located in the control panel enclosure On 24 VDC control voltage systems run a common 24 VDC wire and a common 0 zero VDC wire from the controller to each pump package in the system 2 Pump 12 Station Controllers Chapter 3 Installation 15 Figure 1 Typical 24 Volt Junction Box Wiring Diagram SOL KAY VALVE LOCATED ON GRD PUMP 1 FROM CONTROLLER OUTPUT _ ARUM NEUTRAL amp 24VDC FOR VACUUM SOLENOID E 1 TO TERMINAL At NEUTRAL 24vDC _ 0 2 mE COMMON ON MOTOR STARTER M Sad Z FROM CONTROLLER OUTPUT non BLOWBACK 1171 FOR BLOWBACK SOLENOID Box M TO UPPER VALVE PROCESS AIR CONNECTION 1 RESET TRIPPED 97 E 298 FROM CONTROLLER OUTPUT FOR PUMP MOTOR STARTER Ds ees 1 TO MOTOR 5 MTR 115VAC 0VDC vs TO CONTROLLER INPUT FOR EE PUMP HIGH VACUUM 6 3 PHASE 4 WIRE SERVICE AND SUBPANEL LAYOUT AND CONNECTION DIAGRAM A0544675 FUSED DISCONNECT SWITCH TO LEGEND 115V AC AND 24V DC BE PROVIDED BY CUSTOMER FIELD WIRING DISC
34. 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 15 intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service Preventive maintenance sections are included to ensure that your equipment provides excellent long service The Troubleshooting chapter serves as a guide for identification of most common problems Potential problems are listed along with possible causes and related solutions The Appendix contains technical specifications drawings schematics and parts lists A spare parts list with part numbers specific to your machine is provided with your shipping paperwork package Refer to this section for a listing of spare parts for purchase Have your serial number and model number ready when ordering Safety Symbols Used in this
35. e LCD Blink Delay menu E Ep 2 BLOWBACK 12 HIGH VACUUM 11 2 CHECK SYSTEM 11 2 Using the keypad 2 Enter new time and press the ENTER key to save the new settings 2 Pump 12 Station Controllers Chapter 8 Service Only Information 60 Setting the Hi Vacuum Sensor Delay Hi vac sensor delay is the time that a high vacuum condition must exist before it 1s sensed by the controller This delay eliminates the annoying Hi Vacuum errors which self clear or are erroneous This delay defaults to 3 0 seconds and should not be altered unless you are instructed to do so by the Service Department 5 SEE M BLOWBACK 1 12 HIGH VACUUM 1 CHECK SYSTEM 1 2 At the above message prompt 1 Press the YES key to enter the Hi Vacuum Sensor Delay Time menu 38 ELLE N ON ON m 1 z BLOWBACK 2 HIGH VACUUM f cHEck system 1 2 At the above message prompt 2 Select the pump for altering vacuum sensor delay The following screen displays 79988091 ON ON rA at z BLOWBACK 12 HIGH VACUUM 1 CHECK SYSTEM Using the keypad 3 Enter the new time and press the ENTER key to save the new setting 2 12 Station Controllers Chapter 8 Service Only Information 61 Setting
36. e safety program can be continually reviewed maintained and improved Keep minutes or a record of the meetings Hold daily equipment inspections in addition to regular maintenance checks You will keep your equipment safe for production and exhibit your commitment to safety Please read and use this manual as a guide to equipment safety This manual contains safety warnings throughout specific to each function and point of operation 2 Pump 12 Station Controllers Chapter 1 Safety 8 Operator Responsibility The operator s responsibility does not end with efficient production The operator usually has the most daily contact with the equipment and intimately knows its capabilities and limitations Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates or through a casual attitude toward machinery formed over a period of months or years Your employer probably has established a set of safety rules in your workplace Those rules this manual or any other safety information will not keep you from being injured while operating your equipment Learn and always use safe operation Cooperate with co workers to promote safe practices Immediately report any potentially dangerous situation to your supervisor or appropriate person Maintenance Responsibility Proper maintenance is essential to safety If you are a maintenance worker you must make safety a priority to effectively repair and maintain equipment
37. e screen depends on the setting of the Pump mode BE gi 38858 1 2 1 2 BLOWBACK IET HIGH VACUUM CHECK SYSTEM n 2 2 Pump 12 Station Controllers Chapter 4 Operation 35 Pump Modes Single Pump Mode In Single Pump mode the screen displays as shown below The upper left corner displays the active station being loaded If the system has no active station two 2 hyphens in the station area display The lower left corner displays the load time in seconds When a station is loading this area displays how much time elapses during the load cycle If no station is active three 3 hyphens display The upper right area displays the status of the control This section displays the condition of the controller and what action 15 occurring in the loading sequence The different status displays are described on Pages 24 and 25 The lower right section of the display is not used in Single Pump mode It simply displays the manufacturer s logo 3EBggH EE ON ON ON IN 2 BLOWBACK 1 2 t Dual Pump Mode Oh ON ON ON 2 HIGH VACUUM 1 2 In Dual Pump mode the screen displays as shown on the following page The first line of screen displays information for Pump 1 and the second line of the screen displays information for Pump 2 Each line has twenty 20 characters divided into two 2 groups
38. ettings are saved and the station number increments to the next station in sequence Press the SET key without entering a value to retain the original value in controller memory The load time range of the station is from 1 to 360 seconds Entering values beyond this range result in the screen displaying three 3 question marks To abort this erroneous entry and return to normal operation mode 1 Press the CLEAR key Enabling and Disabling Individual Stations Except while you are in the menu system and when you are altering system parameters you can enable or disable any station in the system To enable or disable a loading station 1 Press STnn key where nn is the station number you want to toggle between station enable or disable mode 4 2 Controller Description and Operation Your 12 station controller system has been designed for quick setup and easy low maintenance operation Before you begin operation make sure you become familiar with the functions and features of your controller The controller screen displays the status of the controller at any given time By a simple glance you can know exactly what the controller is doing The screen has three areas e Text area a 2 line 20 character screen e Station icons for displaying the status of each individual station e Status indicators for displaying the operation of the pump Text Area The text area 1s separated into four 4 sections The appearance of th
39. h a high vacuum condition the load cycle and should be considered normal Segment4 Segment 4 is the indicator word ON located below the station icon When ON displays the related station loads when the system senses a demand signal When ON does not display the station demand input signal is Segment3 Located on the bottom of the station icon the lower segment indicates the station demand input This is a real time indicator displaying when the station demand input is active This indicator may toggle on and off during ignored and the related station does not load Segment 4 blinks with Segment 2 in a high vacuum condition 2 Pump 12 Station Controllers Chapter 4 Operation 37 Status Indicators Four 4 status indicators are located below the station icons at the bottom of the display These indicators include PUMP BLOWBACK HIGH VACUUM and SYSTEM Each icon word has a 1 and a 2 icon with it indicating Pump 1 or Pump 2 Figure 4 Status Indicator Icons Pump Status The PUMP status indicator specifies an active pump Indicator PUMP displays when any pump is active and the 1 or 2 icon indicates which or both pump 15 active Blowback When enabled during the Blowback sequence the Indicator icon displays The 1 or 2 icon indicates the activity of the blowback solenoid HIGH VACUUM High The High Vacuum indicator displays when a high vacuum Vacuum condition is prese
40. hat station sequence valve opens This is the LOADING state You can define load times for each station The controller loads the station in demand until one of the two events below occur 1 The volume fill sensor becomes active 2 The load time is exhausted At the end of the LOADING cycle the controller closes the sequence valve and continues to the next station in the queue If all stations are satisfied the controller enters the IDLE No Activity state IDLE The IDLE No Activity state acts as an energy saver and pump lifetime No Activity extender During this state the atmospheric valve is open allowing the vacuum to be vented sequence valves are closed and all inputs are monitored for demand activity This feature reduces repeated starting and stopping of pumps extending pump operation life If the controller senses a demand during the IDLE No Activity state the controller re enters the LOADING state by closing the vent valve and opening the sequence valve of the station in demand If no demand exists in the system for the duration of the IDLE No Activity time setting the controller then enters the READY state Note IDLE is any condition in the conveying system when the pump runs but no station loads READY The READY state is a monitoring function All outputs are off and the controller waits for a demand signal to be fulfilled If the controller senses a demand condition the controller then re enters the STA
41. hese steps to restore the controller to factory defaults 1 Remove power from the controller 2 Press and hold the CLEAR key 3 Re apply power while holding down the CLEAR key During initialization the screen displays a message indicating that factory default settings are set Verifying Software Checksums Follow these steps to verify software checksum values 1 Remove power from the controller 2 Press and hold the SET key 3 Re apply power while holding down the SET key During initialization the screen displays a message while the controller calculates the software check sum This number is in hexadecimal format Base 16 and displays in numbers and letters Example Ox1FCO9 is a valid checksum format E jt j 5 T E JE jt E z LU BLOWBACK 5 2 HIGH VACUUM 1 2 CHECK SYSTEM 3 1 1 2 2 Pump 12 Station Controllers Chapter 8 Service Only Information 69
42. it the menu system Caution You must assign the correct pump to a hopper before starting the conveying process Failure to properly assign pumps can result in damage to the conveying system 2 Pump 12 Station Controllers Chapter 3 Installation 26 Pump Settings Menu The Pump Settings menu lets you set all pump parameters These include e Pump Mode e Blowback Delay Time Setting the Pump Mode The first setting to be configured 1s the Pump mode This function tells the controller how many pumps are connected to the system and how the pumps are to be controlled You can select two pump modes Single Pump mode and Dual Pump mode In Single Pump mode default one 1 pump is used to convey material to all 12 stations In Dual Pump mode two 2 pumps are used simultaneously resulting in a more efficient conveying process From the main operating display OFFLINE 1 Press the MENU key repeatedly until the screen displays the following ac j 888 38998 TI 2 LS 2 BLOWBACK 12 HIGH VACUUM 1 CHECK SYSTEM 11 2 To enter the Pump Settings menu 1 Press the YES key 2 Press the NO or MENU key repeatedly until the screen displays the following g B I E 5 PUMP BLOWBACK 12 HIGH VACUUM 11 2 CHECK SYSTEM 1 To enter Pump Mode setting menu 1 Press the YES key The screen displays the following
43. l 630 595 1060 Monday Friday 8am 5pm CST Our products are sold by a world wide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Contract Department Call 630 595 1060 Monday Friday 8am 5pm CST Let us install your system The Contract Department offers any or all of these services project planning System packages including drawings equipment labor and construction materials and union or non union installations 2 Pump 12 Station Controllers Chapter 7 Appendix 56 Chapter 8 Service Only Information Note Hidden programmable features and hidden menu pages should not be made available to floor operators These pages include the Service Information located in this section Unauthorized changes to these factory settings by inexperienced operators may prevent the controller from operating properly and may void part or all of the warranty Note If this manual is to be used on the floor by the operator keep this section separate from the rest 8 1 Service Settings Menu Setting the Ramp Up Time Ramp up time 15 a delay that allows the pump to establish full speed before the valve opens This delay defaults to 1 5 seconds and should not be altered unless instructed to do so by the Service Department 30006066 5 BLOWBACK E 12 HIGH VACUUM 1 CHECK SYSTEM 1 2 At the above message prompt
44. material To prevent this from occurring a dump delay timer starts after each hopper loads The controller then waits until the timer elapses before loading the station Setting this timer is critical to an efficiently operating conveying system If you set the timer too short inadvertent loads result If you set the timer too long unneccessary sequence delays occur To determine the proper setting fill the hopper with material and measure the time it takes to dump the material Add one second 1 sec for smaller hoppers and three seconds 3 sec for larger hoppers to this time Enter the setting into controller memory using the following procedure You may have to adjust the time setting for the best overall system efficiency ON z Lu 2 BLOWBACK 12 HIGH VACUUM 11 CHECK SYSTEM 1 2 2 To alter station dump delay time Select the station requiring the dump delay time change and press the related Station STan key nn is the number of the station you want to alter The following screen displays 2 1 2 BLOWBACK 1 2 HIGH VACUUM 1 2 CHECK system 1 2 2 Pump 12 Station Controllers Chapter 3 Installation 21 The screen displays station you selected 11 in above example and current dump delay time setting Using number keys 1 to 0
45. n by the manufacturer A RMS number will be assigned for the equipment to be returned Reason for requesting the return must be given returned material purchased from the manufacturer is subject to 1596 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 1s not within the manufacturer s warranty period and or in new and unused condition suitable for resale Warranty Returns Prior to the return of any material authorization must be given by the manufacturer A RMS number will be assigned for the equipment to be returned Reason for requesting the return must be given All returns are to be shipped prepaid The invoice number and date or purchase order number and date must be supplied After inspecting the material a replacement or credit will be given at the manufacturer s discretion if the item is found to be defective in materials or workmanship Purchased components are covered under their specific warranty terms 2 Pump 12 Station Controllers Chapter 1 Safety 3 Table of Contents CHAPTER 1 SAFETY 6 1 41 How to Use This Manual NE 6 Safety Symbols Used in this 6 1 2 Warnings and 7 l3 8 Gene
46. ng Any changes to load times are saved when you press the STOP key and the controller shuts down completely Note Let the controller save parameter changes to flash memory completely before you shut down the controller Itis also possible for a write error to occur during this operation If this occurs the system always saves a backup of the data See the Maintenance Section for instructions on how to restore the previous settings 3 5 Initial Startup 2 Pump 12 Station Controllers Chapter 3 Installation 33 Chapter 4 Operation 4 1 Startup 299999999999999 Setting Load Times You can alter load times anytime while not in the menu system by pressing the SET key The controller screen then prompts you to select the station you want to alter ON ON r1 11 z BLOWBACK 4 i2 HIGHVACUUM 1 CHECK SYSTEM To select a station to alter 1 Press the related station ST key of the station you want to alter The screen prompts you to enter a load time in seconds B g 5 ju gg J 9 E E ON C i E l PUMP 1 BLOWBACK E 12 HIGH VACUUM 1 2 CHECK SYSTEM 1 a 2 Pump 12 Station Controllers Chapter 4 Operation 34 2 Using number keys 1 to 0 enter new time 3 Press the ENTER key to save the new setting into controller memory If several stations require altering 1 Press the SET key instead of the ENTER key The new s
47. ng excellent customer service For immediate assistance please contact North Central and South America 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 Africa 48 22 390 9720 Email acseuropecustserv corpemail com India 91 21 35329112 Email acsindiacustserv corpemail com 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 lo
48. ng the number keys enter the new blowback pulse setting then press ENTER to save the new value To save the current set value and move to the next menu item e Press ENTER without entering a value If a value 15 entered beyond the limits such as less than or greater than 99 the screen displays question marks in the settings area If this happens e Simply re enter the new value or press CLEAR to restore the value to the original setting If you ve properly entered the value the following screen displays jg EE ON ON ON ON ON ON ti 2 BLOWBACK 5 HIGH VACUUM 11 2 CHECK SYSTEM 1 2 Next set the Pulse On time value This is the duration that the blowback solenoid is turned ON Using the number keys enter the new On Time setting then press ENTER to save new value To save the current On Time setting and move to the next menu item e Press ENTER without entering a value The following screen displays 9 ggi D 588 5 C ON Lu 2 BLOWBACK E 12 HIGH VACUUM 11 CHECK SYSTEM 1 2 E 2 12 Station Controllers Chapter 3 Installation 30 Next set the Pulse Off time value This is the duration that blowback solenoid is turned OFF Using the number keys enter the new Off Time setting then press ENTER to save new value To save the current Off Time se
49. ngs menu then Press the MENU key until the Blowback Settings prompt screen displays 5 JEEE 2 BLOWBACK 1 HIGH VACUUM 2 3 2 ON Press the YES key to alter the blowback settings The following screen displays ale E 5 B 358 58 1j BLOWBACK 1 12 HIGH VACUUM 11 12 CHECK SYSTEM 1 2 2 Each pump can have separate blowback settings To alter pump settings select a pump Using the keypad enter the pump number 1 or 2 The following screen displays 38888 ji JEEE ON E M 2 BLOWBACK 2 HIGH VACUUM 1 CHECK SYSTEM 11 2 To disable the blowback feature Press the NO key The screen returns to the Pump Settings menu If you want to enable the blowback feature Press the YES key 2 Pump 12 Station Controllers Chapter 3 Installation 29 The screen continues to next prompt ON 3g 5 Lu z BLOWBACK IET 12 HIGH VACUUM 1 CHECK SYSTEM 1 2 The first setting for blowback feature is number of blowback pulses This setting determines the number of pulses of air that will be pushed through the filter during the blowback cycle It has a range of 1 to 99 with a factory default of ten 10 pulses Usi
50. nt The 1 or 2 icon indicates the pump Indicator that has the high vacuum condition The Alarm icon Segment 2 and the ON icon Segment 4 flash at the hopper with the high vacuum condition CHECK SYSTEM Check The Check System indicator displays any system errors System Three input for each pump when active prompts the Indicator CHECK SYSTEM icon to display The 1 or 2 icon indicates which pump has the System input s active System errors can include Dirty Filter are common uses for these inputs 2 Pump 12 Station Controllers Chapter 4 Operation 38 Controller Keypad Your 12 station controller has a 16 position keypad to let you operate and alter controller parameters With the exception of the SET key each key has at least two functions The status of the controller determines what function 15 recognized Figure 4 Controller Keypad ST 7 ST 8 exc dap START ST2 ST3 stop SET 5 st6 CLEAR ST9 PRIOR f lt m eo ST 10 ST 11 PPPE DPE E ST 12 MENU 7 Key Descriptions Description Number Use the ten 10 numeric keys marked 1 to 0 to enter numerical information Keys on the controller Station Keys Press one of the 12 station keys marked ST1 to ST12 to select or activate the specific station or hopper you want Start Stop Pre
51. nt manner In Standard mode a flapper sensor detects a demand on the system The volume fill sensor senses when the hopper is filled with material These two 2 sensors are wired in series and a single input of the controller reads them The controller determines the difference in the signals depending on load sequence timing In Sight Glass mode only one single sensor detects demand This mode has no volume fill operation and you ll need to disable that function Properly setting the operation mode lets the controller correctly sequence station loading Upon entering the Operation Mode menu the controller prompts you to set all 12 stations to Normal default mode 2 12 Station Controllers Chapter 3 Installation 19 To set all the stations to Normal mode and return to Station Settings menu e Press the YES key at the following screen prompt ON ON C ON J3gEgEBgEEGBEE 1 FL 1 11 2 BLOWBACK 12 HIGH VACUUM 11 2 CHECK SYSTEM 11 2 This function lets you use the fast setup feature of the controller Normal mode is the factory default so if no sight glass loaders are on your system you won t need to alter this setting Pressing the NO key moves to the All Sight Glass Mode screen Again this function lets you quickly change all stations to Sight Glass mode if all stations have sight glass loaders 5 j 38 JBBTE EA Lu z BLO
52. o initiate the menu system The menu has three 3 top level menus 1 Station Settings 2 Pump Settings 3 System Settings Press the CLEAR key in the menu system to bring you up one level Figure 2 Menu Tree Structure 2 12 Station Controllers Chapter 3 Installation 18 Station Settings Menu To access the Station Settings menu place the controller in the OFFLINE state 1 Press the ENTER MENU key to enter the menu system 2 Continue to press the ENTER MENU key until the following screen displays a e 0 x ON cHEcksvsrEM 1 2 To enter the Station settings menu Press the YES key To bring you up one level within any menu e Press the CLEAR key Operation Mode Station Settings Menu In most applications each loading station can use different types of hoppers The two common types are standard hoppers and sight glass loaders You ll need to set up your controller for the type of hopper you are using for each of the 12 loading stations The first submenu in the Station Settings menu is the Operation Mode To enter the Operation Mode submenu Press the YES key at the following screen prompt g 5 E 2 r LS z BLOWBACK 1 12 HIGH VACUUM 11 CHECK SYSTEM IN Each station in the conveying system can be a standard configuration or a sight glass configuration Each hopper design operates in a slightly differe
53. ollers Chapter 2 Functional Description 11 2 5 Safety Devices and Interlocks This section includes information on safety devices and procedures that are inherent to the Controller This manual is not intended to supersede or alter safety standards established by the user of this equipment Instead the material contained in this section is recommended to supplement these procedures in order to provide a safer working environment At the completion of this section the operator and maintenance personnel will be able to do the following e Identify and locate specific safety devices Understand the proper use of the safety devices provided Describe the function of the safety device Safety Circuit Standards Safety circuits used in industrial systems protect the operator and maintenance personnel from dangerous energy They also provide a means of locking out or isolating the energy for servicing equipment Various agencies have contributed to the establishment of safety standards that apply to the design and manufacture of automated equipment The Occupational Safety and Health Administration OSHA and the Joint Industrial council JIC are just a few of the organizations that have joined with the plastics industry to develop safety standards Every effort has been made to incorporate these standards into the design of the conveying system however it is the responsibility of the personnel operating and maintaining the equipment to
54. or dump material after a user definable number of load attempts the controller activates an alarm condition Perform the following procedure to set alarm conditions To alter the Input Delay time e Press the YES key The following screen displays ON JE Ej E 981 5 1 1 2 BLOWBACK 1 12 HIGH VACUUM 1 2 CHECK SYSTEM To alter stations alarm settings e Select a station to alter then press the related Station STan key nn is the station number you selected The screen displays the selected station 11 in the following example and the current station alarm setting 3 i j ON E 1 2 BLOWBACK 2 HIGHVACUUM 1 cueck system 1 2 To enable the alarm e Press the YES key The alarm is enabled on the station you selected If you want to disable the alarm e Press the NO key The alarm is disabled on the station you selected The controller increments to the next station in sequence To retain the original setting e Press the SET key The next station in the sequence displays 2 Pump 12 Station Controllers Chapter 3 Installation 24 To exit from Alarm Setting time menu and return to Station Settings menu e Press the CLEAR key JUUUSBEE ON ON d Lu z BLOWBACK 12 HIGH VACUUM 1 2 CHECK SYSTEM 1 2 Assigning a Pump to a Station This function lets yo
55. portation 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 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 Bill of lading Packing list Operating and Installation packet Electrical schematic and panel layout drawings 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 15 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 2 Pump 12 Station Controllers Chapter 1 Safety 2 Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department Credit Returns Prior to the return of any material authorization must be give
56. ral rcs mm 8 Operator Responsibility tnn tnn nnn nna 9 Maintenance Responsibilily iei 9 Reporting a Safety Defect E 9 CHAPTER 2 FUNCTIONAL DESCRIPTION 10 2 1 Models Covered in This 10 2 2 General 10 2 3 Standard _______ __ _ _ _ _ 11 Mechanical Features T 11 Electrical FRIIS T V 11 Controller T tes 11 2 4 Optional 11 2 5 Safety Devices and lInterlocks 12 cer 2 I m 12 Fail Safe Operation 12 Safety Device Lock QU IS deno dese 12 CHAPTER 3 INSTALLATION 14 14 3 2 Mounting the Control 14 3 3 Electrical OTM CONS rcs nodi rale axo aum RR AT 14 Making Control Panel Power Drop Wiring
57. rmal load operation is 1 Sense the demand from a station Add that station demand into the queue When required remove the station from the queue If required start the vacuum pump Open the sequence valve Load the station until the volume sensor activates or load time expires Close the sequence valve Continue on to load the next station in the queue Iob CON due ues CUIDA If no demand is present in system after a short delay then shut down the system vacuum pump Operation States OFFLINE The OFFLINE operation state 15 the default state at the point when you apply power to the controller While in this state all outputs in the system are deactivated and access to the menu system 15 permitted station demands are ignored IDLE Startup If you press the START STOP key in the OFFLINE state the controller enters the IDLE Startup state If no demand is on the system the controller immediately enters the READY state With a valid demand the IDLE Startup state allows the pump to get up to speed before starting to load a station While in the IDLE Startup state all station sequence valves are closed and the vent valve is open The vent valve allows the vacuum pump to vent to atmosphere keeping the system from becoming depressurized 2 Pump 12 Station Controllers Chapter 4 Operation 40 LOADING Following the IDLE Startup state the vent valve is closed and the first station in demand loads when t
58. s 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 fuses and carry them with you Make sure the equipment and components are properly GROUNDED before you switch on power Use extreme caution when working with your conveying system HIGH VACUUM can be dangerous Keep body parts tools clothing and debris away from vacuum inlets When welding or brazing in or around this equipment make sure VENTILATION is ADEQUATE PROTECT adjacent materials from flame or sparks by shielding with sheet metal An approved FIRE EXTINGUISHER should be close at hand and ready for use if needed Do not restore power until you remove all tools test equipment etc and the equipment and related components are fully reassembled Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration We expect you as a user to abide by the foregoing recommendations in order to make operator safet
59. s of the first ten 10 inputs The bottom row shows the status of inputs 11 20 Bank 1 IN BNK0 To exit this menu 2 Press the CLEAR key 2 Pump 12 Station Controllers Chapter 8 Service Only Information 64 Output Control Menu The Output Control menu gives you direct access to all 20 outputs of the controller The menu has two 2 modes Manual and Automatic Automatic mode cycles each output on and off Manual mode gives you access to each individual output 9891 J JEEE ON i rst 1 2 1 2 HIGHVACUUM 1 CHECK SYSTEM 1 2 At the above message prompt 1 Press the YES key to enter the Output Control menu The following screen displays ON ON ON ON ON c ON pes 1 z BLOWBACK 1 2 HIGH VACUUM system 1 2 To start automatic cycle Press the NO key To increase speed Press the START STOP key To decrease speed Press the SET key To exit the Output Control menu and turn all outputs OFF 2 Press the CLEAR key Caution Automatically cycling outputs with the pump in Active mode can damage the conveying system Caution Do not perform this action unless directed to do so by the Service Department 2 12 Station Controllers Chapter 8 Service Only Information 65 To access the outputs manually at the AUTOMATIC OR MANUAL screen prompt 1 Press the YES key The
60. ss the START STOP key once to start the loading sequence Press the Key START STOP key again to stop the loading sequence Set Key Press the SET key to set hopper loading times Using the SET key also permits you to increment through each of the twelve 12 stations hoppers when setting loading times Press the SET key to save the updated value of the parameter you set then increments to the next station Clear Prior Press the CLEAR PRIOR key to initiate the priority convey sequence this Key key also acts much like an escape key No Yes Press the NO or YES keys to answer questions or prompts while you are Keys using the menu system Enter Menu Press the ENTER MENU key to save any data you entered in the controller Key memory You can also press the key to let you enter the menu system 2 Pump 12 Station Controllers Chapter 4 Operation 39 4 3 Operation Your 12 station controller electrically controls valves and solenoids to convey material from a central location to individual stations as needed The controller works within this process by sensing a material demand and responds in a timely fashion to that demand An active signal sent from a demand sensor prompts the controller to place the station in a demand queue The controller responds to this condition by loading the stations in a first come first served basis This 15 the most efficient manner of conveying material to different sized stations The basic sequence of a no
61. ter then press the related Station STan key is the station number you selected The screen displays the selected station 11 in the following example and the current input delay time setting 388 5 B E 8 BLOWBACK 12 HIGH VACUUM 1 CHECK SYSTEM Using number keys 1 to 0 enter the new time in seconds into controller memory Keep in mind that the value shifts to the left as you enter it Use the Zero 0 key to shift to the next multiple of ten To exit from the Input Delay time menu and return to the Station Settings menu e Press the CLEAR key To save the new value and escape from the Input Delay menu e Press the ENTER key To save the new value to the controller memory and increment to the next station in the sequence Press the SET key If you press the SET key without entering a value the original value 15 retained and the controller moves to the next station in the sequence Set Station Alarms Station Settings Menu The fourth submenu under Station Settings 15 the Set Station Alarms submenu To set station alarms e Press the YES key The following screen displays SEE j gg ON Lu z BLOWBACK 12 HIGH VACUUM 1 CHECK SYSTEM 1 2 2 Pump 12 Station Controllers Chapter 3 Installation 23 Each station has its own No Convey alarm settings You can enable or disable alarms as needed If a station doesn t receive
62. the Hi Vacuum Vent Delay Hi vacuum vent delay 15 the vent time initiated by a high vacuum condition This delay defaults to 10 0 seconds and should not be altered unless you are instructed to do so by the Service Department jEBSESEE i BLOWBACK HIGH VACUUM fj f CHECK SYSTEM 1 2 At the above message prompt 1 Press the YES key to enter the Hi Vacuum Vent Delay Time menu 11 z BLOWBACK 2 HIGH VACUUM 1 CHECK SYSTEM 1 Sa At the above screen prompt 2 Select the pump for altering vacuum vent delay The following screen displays jg gi 3988 J 7 1 1 2 BLOWBACK 2 HIGH VACUUM 1 CHECK SYSTEM 1 2 Using the keypad 3 Enter the new time and press the ENTER key to save the new setting 2 12 Station Controllers Chapter 8 Service Only Information 62 Setting the Hi Vacuum Load Count Hi vacuum load count sets the maximum number of loads on a station in a high vacuum condition If a station repeatedly experiences high vacuum condition for the selected number of loads without being cleared or attended to it goes off line to prevent damage to the conveying system This parameter defaults to 7 loads and should not be altered unless you are instructed to do so by the Service Department 38 j j m 1 r BLOWBACK 12 HIGH VACUUM 1 CHECK SYSTEM 1 2
63. tting and move to the next menu item e Press ENTER without entering a value The following screen displays g I ON Lu z BLOWBACK 12 HIGH VACUUM CHECK SYSTEM 1 2 The last blowback setting tells the controller how many loads on stations assigned to the selected pump must be completed before starting a blowback cycle After you define this setting the controller returns to the Pump Settings menu screen Idle Delay Time Settings Pump Settings Menu After a station load is complete the controller looks for a new demand on the system If all stations are satisfied with material the controller enters IDLE No Activity state During this state the atmospheric vent valve is open and vacuum vents During IDLE No Activity state time the controller monitors inputs looking for a demand on the system Eventually if no demand is on the system the controller shuts down the pump s and waits for a demand signal This process saves energy and prolongs the life of the vacuum pump The Idle time is the length of time in which the controller waits with no demand until the pump is turned off To set up the controller Idle Delay time enter the Pump Settings menu then Press the MENU key until the Idle Delay Time prompt screen displays as follows M 2 BLOWBACK 2 HIGHVACUUM 1 2 CHECK SYSTEM
64. turers of said parts 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 No person agent manufacturer distributor dealer installer or company is authorized to change modify or extend the terms of this warranty in any manner whatsoever The time within which an action must be commenced to enforce any obligation of the Company s arising under this warranty or under any statute or law of the United States or any state thereof is hereby limited to the duration of this warranty Some states do not permit this limitation so the above may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state For transactions involving the potential applicability of international law or that of a foreign country this warranty policy and the procedures hereunder shall be governed by applicable federal and state law but not by the United Nations Convention on Contracts for the Sale of Goods Customer Responsibilities Any sales use or other tax incident to the replacement of parts under this warranty is the responsibility of the purchaser 2 Pump 12 Station Controllers Chapter 7 Appendix 50 7 2 Drawings and Diagrams Figure 7 2 pump 12 station Controller Control Panel 8 0 20 3 cm i
65. u easily set all 12 stations From the main operating screen 1 Press the MENU key until the following screen displays PERELE N Lu 2 BLOWBACK IET j 2 HIGH VACUUM 11 CHECK SYSTEM 1 2 To enter Station Settings menu 1 Press the YES key 2 Press the MENU key again until the following screen displays ON ON ON Lu z BLOWBACK 12 HIGH VACUUM CHECK SYSTEM 1 2 To assign pumps to stations 1 Press the YES key The following screen displays 99909099608 r 11 2 BLOWBACK 11 HIGH VACUUM a 2 CHECK SYSTEM 1 2 2 Pump 12 Station Controllers Chapter 3 Installation 25 To assign a station to a pump 1 Press the related station ST key The following menu screen displays 99288 j gg 1905 ON i PUMP 1 2 BLOWBACK 1 12 HIGH VACUUM 0 CHECK SYSTEM 1 To assign Pump 1 to station you selected Press 1 Instead of assigning Pump 1 to station you selected you can assign Pump 2 Press 2 To save the new setting and display the Station Assignment screen e Press the ENTER key To save the new pump assignment and increment to the next station sequence Press the SET key To exit the Station Settings menu 1 Press the CLEAR key 2 Press the CLEAR key repeatedly to exit to the next higher menu or to ex
66. use 16 key operator interface keypad and optional audible visual alarm 2 2 General Description Our systems create vacuum for the automatic pneumatic conveying of most free flowing dry pelletized or granular materials in a central material handling system 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 Note Vacuum leaks occuring anywhere in your system reduce capacity 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 2 Pump 12 Station Controllers Chapter 2 Functional Description 10 2 3 Standard Features Mechanical Features Time fill Capability The length of time a station s vacuum valve remains open to allo
67. w material to be drawn into its receiver Volume fill Capability The length of time a station s vacuum valve remains open to allow material to be drawn in The vacuum valve will close when material covers the station s volume fill proximity sensor or this time elapses whichever comes first Pump Blowback Filter Cleaning Outputs When this feature is enabled the controller periodically sends compressed air backward through the pump s air filter to dislodge accumulated dust and debris Electrical Features e 115 1 60 supply voltage e 24 VDC control voltage e Single point power and ground connection Non fused disconnect switch lockable Branch circuit fusing Fully accessible NEMA 12 style electrical control enclosure Controller Features Monitors Station status and Pump status Allows operator to transfer stations to a standby pump when a pump fails Electronic time delay between pump startups to prevent an excessive power demand at your facility 2 A Optional Features Options marked with indicate options that can be factory installed or retrofitted in the field 230 1 60 Operation Required to operate with a 230 1 60 supply voltage Audible visual alarm Alarm light and horn assembly that can be remote mounted and wired into the controller to indicate an alarm condition CE Package for 220 1 50 Operation Required in Europe and other areas that need 220 1 50 supply voltage 2 Pump 12 Station Contr
68. y a reality 2 Pump 12 Station Controllers Chapter 1 Safety 7 1 3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the machine 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 warning and danger signs must be observed and obeyed actual or potential danger areas must be reported to your immediate supervisor General Responsibility No mater who you are safety 1s important Owners operators and maintenance personnel must realize that every day safety 15 a vital part of their jobs If your main concern is loss of productivity remember that production 15 always affected in a negative way following an accident The following are some of the ways that accidents can affect your production Loss ofa skilled operator temporarily or permanently Breakdown of shop morale Costly damage to equipment Downtime An effective safety program 15 responsible and economically sound Organize a safety committee or group and hold regular meetings Promote this group from the management level Through this group th

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