2-Pump 18-Station Controllers Part Number: A0573713 Bulletin Number: SM3-655 Effective: 4/7/04 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.......................................................26 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 2-Pump, 18Station 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 2-Pump, 18-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 2-Pump, 18-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), touch the MENU button. The “Main Menu” screen opens. 2. Once in the Main Menu Screen, press the SYSTEM SETUP button. The “System Setup” screen opens. Figure 2: “System Setup” Screen 3. At the “System Setup” screen, (Figure 2), touch STATIONS ACTIVE, or PUMPS ACTIVE. A keypad pops up (Shown below) once that particular button is pressed.
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 Stations Before starting the system, you must define several settings for each station, such as which pump conveys material to it. This section first discusses how to use the controller’s menu system to configure stations. The table on pages 35–36 discusses the individual choices. To set up each station, perform the following: 1. Go to the “Station Status” screen if needed. To reach this screen press station status button on the Main Menu.
3. On the “Station Operator” screen (Figure 5), touch the SETUP button. The “Station Setup” screen opens. Figure 6: “Station Setup” Screen On the “Station Setup” screen (Figure 6), adjust settings as required. Touching any white box in the lower half of the screen provides you with a keypad to set new values (See page 15 for keypad entry instructions).
Setting Up Pumps Before starting the system, you must define several settings for each pump, such as how quickly to shut it down when it is not in use. This section first discusses how to use the controller’s menu system to configure pumps. The table on page 37 discusses the individual choices. In order to setup up the pumps properly, perform the following: 1. Go to the “Pump Status“ screen if needed. To reach this screen, touch the PUMP STATUS button on the Main Menu.
Figure 11: Third Pump Setup Screen The screen shown above allows you to set the number of times the system will convey material before cleaning, the number of cleaning pulses that will be sent, the amount of time (in seconds) that the vacuum will remain on, and the amount of time that the vacuum will vent the system. When pressed individually, the keypad will come up allowing you to enter the necessary values for each feature. 6. Press BACK to return to the second Pump Setup screen, then BACK again.
Setup Password If you define a password for setup personnel, then all settings can be changed only after entering the password. The password will be required to display the following screens: • System Setup (to review and change system-wide settings). • Station Setup (to review and change settings for all station options). • Pump Setup (to review and change settings for all pump options).
4. Enter up to four digits. If you want to remove password protection, enter 0 as the password. Use CLR to erase any mistakes. Use ENT to enter the value. The keypad disappears, and the “System Setup” screen shows the password you entered. Note: When entering a password, all four digits must be supplied. For example, if you enter a password of 2 here, you will need to enter 0002 when the controller prompts for the password.
Chapter 4: Operation 4-1 Overview Your 2-pump, 18-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 icon on the “Station Status” screen. Icon Label Offline Description Station is not enabled. The controller ignores any demands or alarms. Ready Station is enabled and idle (full). Demand Station requires material. Convey Station is being loaded with material. Dry Air Convey Air to convey material is coming from dry air source, rather than ambient air. Unload Station is dumping material into its receiver.
Reviewing Pump Status The “Pump Status” screen is the counterpart of the “Station Status” screen. To reach the “Pump Status” screen, touch the MENU button. Once in the Main Menu, touch PUMP STATUS. The “Pump Status” screen appears. Figure 14: “Pump Status” Screen During Operation The status of each pump is coded and has a label indicating its’ status in the bottom-left of the button. The following table explains the status represented by each icon at the Station Status screen.
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 15: “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.
Starting and Stopping the System WARNING! In an emergency, you can use the power switch on the front of the controller cabinet if a password is required to stop the system and you do not know the password. Note: Normally, all the stations and pumps you want to use should be enabled before you start the system. When the system is stopped, icons for enabled stations and pumps have the word READY at the top of their icons. Enabling stations and pumps is described on p. 26.
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.
9. Put the standby pump online by briefly touching its icon. The icon changes codes to show the new status, and the system begins using the pump. In addition, all “Station Operator” and “Station Setup” screens show the new pump assignment. Standby Pump Errors If the error message tells you to disable the source pump and/or the standby pump, touch RETURN at this screen, then PUMP STATUS at the “Pump Setup” screen. Take the pumps offline and then return to the “Transfer to Standby Pump” screen.
4-4 Alarms Reviewing Alarms To review your system’s alarms, touch ALARM HISTORY on the Main Menu. The “Alarm Log” screen appears, with the newest alarm listed first. Figure 19: Alarm Log Screen To scroll up and down through the list, touch DOWN or UP at the bottom of the screen. Press MENU to return to the Main Menu screen. Silencing Alarms Whenever a new alarm occurs, your controller sounds the horn and turns on the strobe light at each central alarm.
Chapter 5: Maintenance Although no periodic maintenance is required on this unit, the Service Menu screen provides information on accessing components of the conveying system to perform maintenance on them. To gain access to the Service Menu screen, press the SERVICE MENU button in the Main Menu. Note: This service menu screen is PASSWORD PROTECTED and meant for manufacturer personnel use only. Contact manufacturer for assistance.
Chapter 6: Configurable Settings This section describes the proper setup of the 2 pump, 18-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 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 22: 2 pump 18 station Controller with 6-1/2" Display 24” 5” 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. XXX2-18 115 Volt Serial No.
