4-Pump 38-Station Controllers Part Number: A0565547 Bulletin Number: SM2-615.1 Effective: 12/15/03 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing program of product improvement. Specifications, appearance, and dimensions described in this manual are subject to change without notice. DCN No.
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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.
Table of Contents CHAPTER 1: SAFETY ................................................................V 1-1 1-2 1-3 How to Use This Manual ............................................................................................. v Safety Symbols Used in this Manual ..................................................................... v Warnings and Precautions ......................................................................................... vi Responsibility ......................................
4-3 4-3 Reviewing Station Status ....................................................................................23 Reviewing Pump Status ......................................................................................25 Logging On and Logging Off ...............................................................................26 Enabling and Disabling Stations and Pumps.......................................................27 Starting and Stopping the System .......................................
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.
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 4-Pump, 38Station 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. The length of time allowed for material to drain from the station to its receiver. During this time, the controller does not attempt to deliver any more material to the station. Volume-fill Capability. The length of time a station’s vacuum valve remains open to allow material to be drawn in. The vacuum valve will close when material covers the station’s volume-fill proximity sensor or this time elapses, whichever comes first. Vent Valve Output.
2-4 Optional Features Options marked with “*” indicate options that can be factory installed or retrofitted in the field. 230/1/50 Operation. Required to operate with a 230/1/50 supply voltage. Audible/visual alarm. Alarm light and horn assembly that can be remote mounted and wired into the controller to indicate an alarm condition. Ethernet Capability. Enables controller to be connect to an ethernet network. Line Filter/Surge Suppressor.
Safety Device Lock-Outs Some safety devices disconnect electrical energy from a circuit. The safety devices that are used in this Controller are primarily concerned with electrical power disconnection. WARNING! Always disconnect and lockout all electrical power and pneumatic (i.e. compressed air) sources prior to servicing the 4-Pump, 38-Station Controller. Failure to do so may result in serious injury. No one but the person who installed the lockout may remove it.
Chapter 3: Installation 3-1 Uncrating 4-Pump, 38-Station Controllers are shipped mounted on a skid, enclosed in a plastic wrapper, and contained in a cardboard box. 1. Pry the crating away from the skid. Note: Remove the nails holding the box to the skid and lift the box off carefully; avoiding staples in the 1’ x 4’ wood supports. Cut the steel banding. 2. Use a pry bar to remove the blocks securing the unit to the skid. 3. Lift unit from sides, inserting forklift under the base.
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. Run two wires to each vacuum hopper: one each from the controller to the BinFull switch (LS) and to the Atmospheric/Sequence-T solenoid (SOL) valve. 3.
Setting the Number of Stations and the Number of Pumps Figure 1: Default “Station Status” Screen Before Setup 1. At the “Station Status” screen (Figure 1) or at the “Pump Status” screen, touch the SYSTEM SETUP button. The “Menu” screen opens. Figure 2: “System Setup” Screen Before Setup 2. At the “System Setup” screen, (Figure 2), touch STATIONS ACTIVE. A keypad pops up. 3. Enter the total number of stations (1-38) to be controlled by the system. Use CLR to erase any mistakes. Use ENT to enter the value.
Setting Up Alarm Silences When an alarm occurs, a horn sounds and a strobe light flashes at each installed central alarm. An alarm banner appears in the center of the screen. An alarm message and Silence button are on the banner. Touching this button silences the horn and turns off the lights for configurable periods of time and causes the alarm banner to disappear. You can set different lengths of time for keeping the horn silent and keeping the light turned off.
Setting Up Pump Staging To avoid an excessive power demand at your facility when the conveying system starts up, you can stagger the times at which pumps start. Whenever a demand would cause two pumps to start simultaneously, your choice for pump staging sets the delay between the start of one pump and the start of the next. The factory default is a delay of three seconds. You need to change this setting only if this delay is too long or too short for your facility.
Figure 5: “Station Operator” Screen Before Setup 3. On the “Station Operator” screen (Figure 5), touch the STATION SETUP button. The “Station Setup” screen opens. Figure 6: “Station Setup” Screen 4. On the “Station Setup” screen (Figure 6), adjust settings as required. Touching any box that appears in red (for “disabled”) toggles it to green (for “enabled”), and vice versa. Touching any white box gives you a keypad to enter a new value.
5. As appropriate, setup the rest of the stations using either of the following methods: • Use the PREVIOUS or NEXT buttons to navigate to other stations. Touch PREVIOUS to go to the previous “Station Setup” screen, or touch NEXT to go to the next “Station Setup” screen. Setting Up Pumps Before starting the system, you must define several settings for each pump, such as how quickly to shut it down when it is not in use. This section first discusses how to use the controller’s menu system to configure pumps.
Figure 8: Pump Setup Screen Before Setup 3. Adjust settings as required. Touching any box that appears in red (for “disabled”) toggles it to green (for “enabled”), and vice versa. Touching any box that appears in white gives you a keypad to enter a new value. Keypad entry works as with many ATM machines: the first digit you enter initially appears in the rightmost column and moves to the left as you enter more digits. You do not need to use the decimal point. Use CLR to erase any mistakes.
Operator Password If you define a password for operators, then a password will be required to carry out any function (other than reviewing station and pump status, silencing alarms, reviewing the alarm log, and looking at help screens).
To change the duration of the password, complete the following steps: 1. On the “System Setup” screen, touch the Operator Password Duration button or the Setup Password Duration button, depending on which password duration you want to change. A keypad pops up. 2. Enter the number of minutes (between 1 and 99) that you want to set as the password duration. Use CLR to erase any mistakes. Use ENT to enter the value. The keypad disappears, and the “System Setup” screen shows the new setting.
Chapter 4: Operation 4-1 Overview Your 4-pump, 38-station controller electrically controls valves and solenoids to convey material from a central location to individual stations as needed. The controller senses demands for material at the stations and responds to the demands in a timely fashion. This section gives the procedures for using your controller, and it covers tasks that can be carried out with no password or with an operator’s password.
The following table explains the status represented by each color at the “Station Status” screen. Color Gray outline Label Offline Green Yellow Blue Light blue Purple Blue, blinking Full Demand Convey Dry Air Convey Unload Priority Red Red outline Alarm Critical White Purge Description Station is not enabled. The controller ignores any demands or alarms. Station is enabled and idle (full). Station requires material. Station is being loaded with material.
Reviewing Pump Status The “Pump Status” screen is the counterpart of the “Station Status” screen. To reach the “Pump Status” screen from any other screen, touch PUMP STATUS on any screen. The “Pump Status” screen appears. Figure 10: “Pump Status” Screen During Operation The status of each pump is color-coded. You can see an explanation of each status by using the online help. To do so from this screen, complete the following steps: 1. Touch HELP button. The “HELP Menu” screen appears. 2. Touch PUMP STATES.
Logging On and Logging Off Your controller may be set up to require a password for any operation (other than reviewing station and pump status, silencing alarms, reviewing the alarm log, and looking at help screens). If so, touching a button will open the “Password Entry” keypad screen. Figure 11: “Password Entry” Screen Enter the four-digit password (including any leading zeros). For example, if the password is 1, enter 0001. * Each digit appears as an “ ” as you touch it.
Enabling and Disabling Stations and Pumps When a station or pump is disabled, the controller makes no attempt to use it and ignores any alarms that occur for it. Disabling a station or pump at the controller’s screen is similar to bypassing a station with its bypass switch. Enabling a station or pump makes it available for use. Note: For a station to be available for the system, it must be enabled at the controller’s screen and its bypass switch must be in the “Convey” position.
Reviewing and Adjusting Basic Station Settings The 4-pump, 38-station controller has a “Station Operator” screen for each station, as shown below. This screen enables you to review and adjust all basic settings for the station. To reach the “Station Operator” screen, complete the following steps: 1. Go to the “Station Status” screen, if needed. To reach this screen from any other screen, touch STATION STATUS button. 2.
Adjusting Convey Time and Dump Delay Convey time is the length of time the station’s vacuum valve remains open to allow material to be drawn in. (For a volume-fill station, the valve closes when material covers the station’s volume-fill proximity sensor or this time elapses, whichever comes first.) Unload time is the length of time allowed for material to drain from the station into its receiver. During this time, the controller does not attempt to deliver any more material to the station.
Activating and Stopping Priority Convey for a Station Note: Before activating priority convey, make sure that all other stations using the same pump have adequate material in reserve to continue operation. No material will be conveyed to these stations during priority convey. If you want the controller to fill a specific station with material immediately, you can activate “priority convey” for that station.
4-3 Adjusting Advanced Settings This section describes the procedures carried out during operation that are normally reserved for setup personnel. These procedures require use of the setup password (if your facility has defined one). The procedure for logging on and off with the setup password is the same as for logging on with the operator password; see p. 26 for step-by-step instructions for logging on and off.
Transferring Stations to a Standby Pump If a pump fails, you can transfer all of the controller’s station assignments for that pump to a standby pump. To do this, you must disable (take offline) both the source pump and the standby pump, and the standby pump must have no stations already assigned to it. The transfer operation at the controller’s touch screen merely changes the pump assignment for every station on the failed pump.
Figure 15: Transfer To Standby Pump Button Note: When you enter the second pump number, the controller checks to make sure that both pumps are offline and that the standby pump has no stations assigned to it. If these conditions are not all met, error messages appear on the screen instead of MOVE button. If you get an error message, first check to make sure that you have entered the correct numbers and reenter if necessary. If another error occurs, see the Standby Pump Errors section on page 33. 7.
Filter cleaning Our pumps have two options available for filter cleaning; these are vacuum pulse or compressed air filter cleaning. Touching the ENABLE/DISABLE button located in the lower left hand corner of the pump setup screen will allow the operator to turn on/off these two options or disable the filter cleaning option altogether. Note: Each type of filter cleaning requires optional equipment that must be purchased and installed prior to enabling this option.
Chapter 5: Maintenance No Periodic maintenance is required on this unit.
Chapter 6: Configurable Settings This section describes the proper setup of the 4 pump, 38-station control system parameters. These parameters are operator changeable; however, these items should require setup only during the initial installation. Only authorized personnel should change them. Many of the variables and setup parameters have been preset at the factory and do not need to be changed.
Name Description Options Default Special convey When this option is enabled, the station’s vacuum valve remains open for the convey time, even if the station is not demanding material and is indicating that it is full. When disabled, the station’s vacuum valve opens when there is demand from the station, and it remains open until the convey time has elapsed or material trips the volume-fill proximity switch. Enable this option if and only if the station has no flapper.
6-2 Options for Pump Setup Several of the items in this screen are not setup options but are instead intended for use during operation. These items (hour meter and transferring stations to a standby pump) are described in Chapter 4, which cover operation procedures. Name Idle Time Options Description Options Default 1 Idle time Length of time the pump continues to run unloaded without demand from any station.
Chapter 7: Troubleshooting 7-1 General Troubleshooting Problem The control panel doesn’t light up at all The touch screen display doesn’t come on when the control panel is powered up. 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. Fuse/circuit breaker in the power drop is blown/tripped. Control power switch is broken.
7-2 Alarms The format for all station alarms is “Station n [alarm text],” for example, “Station 12 receiver low level.” The format for all pump alarms is “Pump 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 The Manufacturer warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions. The Company’s obligation is limited to repair or replace FOB the factory any parts that are returned prepaid within one year of equipment shipment to the original purchaser, and which, in the Company’s opinion, are defective. Any replacement part assumes the unused portion of this warranty.
8-3 Drawings and Diagrams Figure 17: 4 pump 38 station Controller with 6" Display 24” 6” 30” * Depth dimension is 10” Also, review electrical drawings supplied in the packet with this manual.
8-5 Returned Material Policy Credit Returns Prior to the return of any material, authorization must be given by the manufacturer. A RMS number will be assigned for the equipment to be returned. Reason for requesting the return must be given. All returned material purchased from the manufacturer is subject to 15% ($75.00 minimum) restocking charge. All returns are to be shipped prepaid. The invoice number and date or purchase order number and date must be supplied.
8-7 Controller Identification (Serial Number) Tag (Located on the side of the controller box) Street Address Town, State, Zip Code Telephone Number Fax Number XXX CONTROL PANEL Model No. XXX4-38 115 Volt Serial No.
