-Pump 9-Station Controller Part Number: 882.00193.00 Bulletin Number: CV3-615 Effective: 10/27/05 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing program of product improvement. Specifications, appearance, and dimensions described in this manual are subject to change without notice. DCN No.
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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.
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 given by the manufacturer. A RMA 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 returned is subject to 15% ($75.00 minimum) restocking charge. ALL returns are to be shipped prepaid.
Table of Contents CHAPTER 1: SAFETY ...............................................................VI 1-1 1-2 1-3 How to Use This Manual ............................................................................................ vi Safety Symbols Used in this Manual .................................................................... vi Warnings and Precautions ........................................................................................viii Responsibility ......................................
CHAPTER 6: CONFIGURABLE SETTINGS............................. 31 6-1 6-2 Options for Station Setup .......................................................................................... 31 Options for Pump Setup ............................................................................................ 32 CHAPTER 7: TROUBLESHOOTING ........................................ 33 7-1 7-2 General Troubleshooting...........................................................................................
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.
Controller Safety Tags Tag Description Tag Read Operation & Installation Manual PE 1 –Pump 9-Station Controller Protected Earth Ground Description High Voltage Inside Enclosure Earth Ground Chapter 1: Safety vii
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.
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.
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.
Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, and maintenance instructions for 1-Pump, 9Station 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.
2-3 Standard Features Mechanical Features Time-fill Capability. A station’s vacuum valve remains open for a specific period of time to allow material to be drawn in. Volume-fill Capability. The vacuum valve will close when material covers the station’s volume-fill proximity sensor or a specific period of time elapses, whichever comes first. Vent Valve.
2-4 Optional Features Options marked with “*” indicate options that can be factory installed or retrofitted in the field. CE Package for 220/1/50 Operation. Required in Europe and other areas that need 220/1/50 supply voltage. *Remote audible/visual alarm. Alarm light and horn assembly that can be remote mounted and wired into the controller to indicate an alarm condition.
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 1-Pump, 9-Station Controller. Failure to do so may result in serious injury. No one but the person who installed the lockout may remove it.
Chapter 3: Installation 3-1 Uncrating 1-Pump, 9-Station Controllers are shipped mounted on a skid, enclosed in a plastic wrapper, and contained in a cardboard box. 1. Pry the crating away from the skid. Note: Remove the nails holding the box to the skid and lift the box off carefully; avoiding staples in the 1’ x 4’ wood supports. Cut the steel banding. 2. Use a pry bar to remove the blocks securing the unit to the skid. 3. Lift unit from sides.
Connecting the Control Panel to Vacuum Hoppers Note: Wire size depends on control voltage, distance, number of vacuum hoppers, and the number of wires in each raceway. Consult a qualified electrician. 1. On 24 VDC control voltage systems, run a common +24 VDC wire and a common 0 (zero) VDC wire from the controller to each vacuum hopper in the system. 2.
3-4 Setup This section provides the procedures for configuring your 1-pump, 9-station controller. Configuration of your controller includes setting the number of stations and pumps, setting variables such as convey time and blow-back intervals. 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 Conveying Systems manual.
Viewing System Status The station and pump status screen (Shown below) can be viewed by pressing the F2 key on the controller keypad. Figure 3: Status Screen This screen will show whether stations 1-9 and the pump (shown in the bottom right of the screen- “P1”) are Ready or Offline. For a list of additional station and pump status names and their description which may be displayed on this screen, see below.
Station Setup To set the station settings and features of your conveying system, press the F4 key on the controller keypad while in the Main Menu screen. The initial (of three) Station Setup screen will be shown (below): Figure 6: Initial Station Setup Screen This screen will allow you to set the following features: • Convey time - Convey time is the length of time the station’s vacuum valve remains open to allow material to be drawn in.
Entering Values Into Controller Fields When it is necessary to change the settings for a particular feature, you will need to do the following: 1. Use the arrow keys to select the value. 2. Select the value in the field to be changed by pressing the SET key. 3. Press the numbers you want to enter into the field from the numeric keypad (Shown below). 4. Press the green ENT (Enter) key to enter those values or the red ESC (Escape) key to return the values back to their original setting. 5.
Second Station Setup Screen Once the settings have been entered into the initial Station Setup Screen, press F3 to access the next set of configurable station settings. The second station setup screen (Figure 8) will be shown. Figure 8: Second Station Setup Screen This screen will allow you to set/activate the following features: • Purge Time – this is the length of time allowed for material to be cleaned out of the system. Purge time duration is displayed in seconds and can be set from 1-999.
Third Station Setup Screen Once the settings have been entered into the second Station Setup Screen, press F3 to access the next set of configurable station settings. The third station setup screen (Figure 9) will be shown. Figure 9: Third Station Setup Screen This screen will allow you to set/activate the following features: • No CNVY F2 – This feature allows you to enable or disable the station no convey alarm.
Pump Setup To set the pump settings and features of your conveying system, press the F5 key on the controller keypad while in the Main Menu screen. The initial (of three) Pump Setup screen will be shown (below): Figure 10: Initial Pump Setup Screen This screen will allow you to set the following features: • FC ENABLE F2 – Pressing F2 allows you to enable or disable the filter cleaning feature. • FC TYPE F5- This feature allows you to toggle between blowback and implosion cleaning (Press F5).
Second Pump Setup Screen Once the settings have been entered into the initial Pump Setup Screen, press F3 to access the next set of configurable pump settings. The second pump setup screen (Figure 11) will be shown. Figure 11: Second Pump Setup Screen This screen will allow you to set the following features: • CLEAN PULSES – This is the number of blowback/implosion pulses allowed during filter cleaning. This value can be set between 1 and 99.
Third Pump Setup Screen Once the settings have been entered into the second Pump Setup Screen, press F3 to access the next set of configurable pump settings. The third pump setup screen (Figure 12) will be shown. Figure 12: Third Pump Setup Screen This screen will allow you to set the following features: • RAMP UP TIME- This is the delay in seconds from when the pump starts till the conveying system starts. This value can be entered between 1 and 99.
System Setup To set the system settings and features of your conveying system, press the F6 key on the controller keypad while in the Main Menu screen. The initial (of three) System Setup screen will be shown (below): Figure 13: Initial System Setup Screen This screen will allow you to set the following features: • INSTALLED HOPPERS – This will allow you to input the number of stations present in the system. Values can be entered between 0 and 9 total hoppers.
Second System Setup Screen Once the settings have been entered into the initial System Setup Screen, press F3 to access the next set of configurable system settings. The second system setup screen (Figure 14) will be shown. Figure 14: Second System Setup Screen This screen will allow you to set the following feature: • Station Demand Debounce- This is the minimum amount of time in seconds before the demand signal is recognized by the system. Values can be set between 0.5 and 2.0.
Chapter 4: Operation 4-1 Overview Your 1-pump, 9-station controller electrically controls valves and solenoids to convey material from a central location to individual stations as needed. The controller senses demands for material at the stations and responds to the demands in a timely fashion. This section provides the procedures necessary for using your controller. Note: 4-2 Before you carry out any of the procedures in this chapter, the system must be set up as described in Chapter 3.
Pump Fault If the pump verify signal is not present after the pump is started, the alarm horn/light will activate. The pump will be stopped and set to an offline condition. The Status screen will display “PMP FLT.” Pressing F2 while the status screen is displayed will silence the alarm. Filter Can If the filter can limit switch signal is not present after the pump is started, the alarm horn/light will activate. The Status screen will display “FLTR CAN”.
Chapter 5: Maintenance No Periodic maintenance is required on this unit.
Chapter 6: Configurable Settings This section describes the proper setup of the 1-pump, 9-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.
6-2 Options for Pump Setup The ramp time represents the amount of time it takes for the vacuum blower to come up to full speed once it has been turned on. The ramp down time represents the amount of time it takes the blower to stop once it has been turned off. The ramp up time lets the blower reach full speed unloaded. When the ramp up time is reached, the vent valve will open and allow the pump to draw a vacuum on the main vacuum line.
Chapter 7: Troubleshooting 7-1 General Troubleshooting Problem The control panel doesn’t light up at all A pump package doesn’t run, even though it is on-line and its indicator is lit. A vacuum receiver is being bypassed in the loading cycle. Vacuum receivers are overfilling. Possible Cause The control panel is not turned on. Solution Turn on the control panel. The external disconnect (recommended) in the dedicated circuit is open (off). Fuse/circuit breaker in the power drop is blown/tripped.
7-2 Alarms The format for all station alarms is “Station n [alarm text],” for example, “Station 9 receiver low level.” The format for all pump alarms is “Pump n [alarm text].” Any alarm that does not start with “Station” or “Pump” is a system alarm. The following tables list all alarms alphabetically, together with possible causes. A “critical” alarm is one that causes the affected device to stop. Note: You can also see a list of alarms and their causes in the controller’s online help.
Chapter 8: Appendix 8-1 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.
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 is limited to the warranty of the manufacturers of said parts.
8-3 Drawings and Diagrams Figure 1: 1-Pump 9 Station Controller 16” 3.30” 6” Display 4.69” 16” * Depth dimension is 8” Also, review electrical drawings supplied in the packet with the manual. 8-4 Spare Parts List Quantity 2 2 1 1 1 1 2 1 1 –Pump 9-Station Controller Part Number A0569870 A0569859 A0540997 A0542210 A0544790 A0542203 A0542200 A0542207 Description Relay Air Grill with Filter Fuse, MDL –1 Fuse, MDL – 5 Fuse, MDL – 8 Fuse, MDL – 2 Fuse, MDL – 1.
8-5 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. XXX1-9 115 Volt Serial No.
