SCC 2-Pump 20-Station Controllers Part Number: 882.00251.00 Bulletin Number: CV3-630 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.
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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.
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.
Table of Contents Hopper Loaders with/without Sight Glasses iv
CHAPTER 1: SAFETY ................................................................ 3 1-1 1-2 1-3 1-4 How to Use This Manual ............................................................................................. 3 Safety Symbols Used in this Manual .....................................................................3 Controller Safety Tags…………………………………………………………………vii Safety Circuit Standards......................................................................................
4-3 4-3 Enabling and Disabling Stations and Pumps.....................................................303 Starting and Stopping the System .....................................................................313 Reviewing and Adjusting Basic Station Settings ...............................................314 Navigating Among the Station Operator Screens..............................................324 Adjusting Convey Time and Dump Delay..........................................................
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 High Voltage Inside Enclosure 1-2 Read Operation and Installation Manual 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 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.
1-4 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.
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.
Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, and maintenance instructions for 2-Pump, 20Station 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.
• Non-fused disconnect switch, lockable • Branch circuit fusing • Fully accessible NEMA 12-style electrical control enclosure Controller Features • Allen-Bradley PLC with 6” color touch screen display • 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 2-4 Optional Features Options marked with “*” indicate options that can be factory installed
Chapter 3: Installation 3-1 Uncrating 2-Pump, 20-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.
Figure 1: 2 Pump 20 Station Controller with 6" Display 24” 6” 30” * Depth dimension is 12” 2–Pump 20-Station Controllers Installation 11 of 51
3-3 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. XXX2-20 115 Volt 60 Serial No.
3-4 Electrical Connections Refer to local electrical codes, the schematic and connection diagrams supplied with this unit and the serial tag for wiring considerations. Run all wiring in conduit if codes require it. Making Control Panel Power Drop Wiring Connections Hardwire the input power at 110/1/50-60 VAC or 230V/1/50-60 VAC, depending on the specifications, which are located on the Control Panel Serial Tag. The main power switch is located on the front of the enclosure.
5. On 115 VAC control voltage systems, run a common hot (115 VAC) wire and a common neutral wire from the controller to each pump package in the system. 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. Note: Reference “Mechanical Components Operation and Installation manual” for more details on component locations (manual part # A0536580).
Figure 3: “Menu” Screen 2. At the “Menu” screen, (Figure 3), touch the System Setup button. The “System Setup” screen opens. Figure 4: “System Setup” Screen Before Setup Stations 19-20 3. At the “System Setup” screen, (Figure 4), touch Stations Present. A keypad pops up. 4. Enter the total number of stations (1-20) to be controlled by the system. Use (Enter Key) to enter the value. The (Backspace Key) to erase any mistakes. Use keypad disappears, and the new setting appears under Stations Present. 5.
6. Enter the total number of pumps (1-2) to be controlled by the system. Use (Enter Key) to enter the value. The (Backspace Key) to erase any mistakes. Use keypad disappears, and the new setting appears under Pumps Present. Setting Up Alarm Duration When an alarm occurs, a horn sounds and a strobe light flashes at each installed central alarm. An alarm banner screen appears. An alarm message and Alarm Silence button are on the banner.
5. Enter the number of minutes (between 0 and 99) that you want the horn to stay off. If you want the horn to stay on as long as the alarm persists, leave the setting at 0. If you want the horn to stay off until a new alarm occurs, enter 99 in the keypad. Use (Enter Key) to enter the value. The (Backspace Key) to erase any mistakes. Use keypad disappears and the new setting appears under Horn Silence.
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 40–41 discusses the individual choices. Setting Up a Single Station 1. Go to the “Station Status” screen if needed. To reach this screen from any other screen, touch Menu on the right hand side of the screen, and then touch Stations.
Figure 8: “Station Setup” Screen 4. On the “Station Setup” screen (Figure 8), 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. Touching Reset To Defaults in the lower right of the screen changes all the settings for this station back to their factory defaults. See pp. 382–42 for details on the options and their default settings. 5.
Figure 9: “Station Copy” Screen Last Station 19 Last Station 20 Follow the directions below to copy settings to one other station, a range of stations, or all stations: Copying to One Other Station: 1. On the “Station Copy” screen (Figure 8), touch the gray Copy to Station button. The keypad pops up. 2. Enter the station number for the station you are copying to. Use (Backspace (Enter Key) to enter the value. The keypad Key) to erase any mistakes.
value. The keypad disappears, and the “Station Copy” screen shows the station number you entered under Last Station. 5. Touch the green Copy to Range of Stations button. Complete briefly appears on the screen. 6. As appropriate, either continue copying to other stations, or touch Return to go back to the “Station Setup” screen. Copying to All Other Stations: 1. On the “Station Copy” screen (Figure 9), touch the green Copy to All Stations button. Complete briefly appears on the screen. 2.
Figure 11: Pump Setup Screen Blowback 5 Pulses 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. See page 422 for details on the options and their default settings. 4.
Figure 12: Pump Copy Screen Copy to Pump 2 Last Pump 2 Last Pump 2 Follow the directions below to copy settings to one other station, a range of stations, or all stations: • Copying to One Other Pump: 1. On the “Pump Copy” screen (Figure 12), touch the gray Copy to Pump button. The keypad pops up. 2. Enter the pump number for the station you are copying to. Use (Backspace (Enter Key) to enter the value. The keypad Key) to erase any mistakes.
3. Figure 12) touch the gray First Pump button. The keypad pops up. 4. Enter the pump number for the lower end of the range you are copying to. Use (Enter Key) to enter the value. (Backspace Key) to erase any mistakes. Use The keypad disappears, and the “Pump Copy” screen shows the pump number you entered under First Pump. 5. On the “Pump Copy” screen (Figure 12), touch the gray Last Pump button. The keypad pops up. 6. Enter the pump number for the upper end of the range you are copying to.
the options installed, the screen may also enable the operator to adjust the mix percentage for a remote proportioning valve, review the last purge time and purge valve, and set the intended material line for material proofing). Entering the setup password will give the user access to all functions. Note: If you want to protect the operator’s functions with a password, you must also define a setup password. If you leave the setup password undefined, then all users will have access to all functions.
to enter the value. The keypad disappears, and the “System Setup” screen shows the new setting. 3-6 Initial Startup Once you have finished all the setup described above, you are ready to start the system. To start your system, complete the following steps. 1. At any screen, touch Menu on the right side of the screen. The “Menu” screen appears (Figure 3). 2. Touch Stations. The “Station Status” screen appears (Figure 6). 3. For each station that you want to use, briefly touch its icon.
Chapter 4: Operation 4-1 Overview Your 2-pump, 20-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.
4. When you are finished reviewing the information, touch Return. The “Help Menu” screen opens. 5. Touch Menu to return to the “Menu” screen. The following table explains the status represented by each color at the “Station Status” screen. Color Gray outline Label Offline Blue Yellow Green Light blue Green, blinking Ready Demand Loading Dumping Priority Red, blinking Red outline, blinking Alarm Critical Description Station is not enabled. The controller ignores any demands or alarms.
1. Touch Menu. The “Menu” screen appears. 2. Touch Help. The “Help Menu” screen appears. 3. Touch Pump States. The “Pump Symbols Help” screen appears, explaining the status represented by each color. 4. When you are finished reviewing the information, touch Return. The “Help Menu” appears. 5. Touch Menu to return to the “Menu” screen. The following table explains the status represented by each color at the Station Status screen.
Enter the four-digit password (including any leading zeros). For example, if the password is 1, enter 0001. Each digit appears as an “X” as you touch it. When you touch the fourth digit, the controller carries out your request. For example, it enables or disables the requested pump or station, or it goes to the “Station Operator” screen. If you did not enter the correct password, the controller erases the entry. You can then try again. To give up, touch Return.
Starting and Stopping the System WARNING! In an emergency, you can use the power switch at 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 are blue and icons for enabled pumps are yellow. Enabling stations and pumps is described on p. 303.
Navigating Among the Station Operator Screens The controls in the upper right-hand corner of the screen enable you to move among the “Station Operator” screens: • To display the screen for the next lower-numbered station (for example, to move from the screen for Station 15 to the screen for Station 14), touch ◄ Back. • To display the screen for the next higher-numbered station (for example, to move from the screen for Station 15 to the screen for Station 16), touch Next ►.
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.
Figure 17: Pump Setup Screen The box labeled x Hours Resettable shows the running time since the last reset. The box labeled x Hours shows total running time. To reset the resettable meter, touch Hour Meter Reset. The time above Hours Resettable changes to 0. Transferring Stations to a Standby Pump If a pump fails, you can transfer all of the controller’s station assignments for that pump to a standby pump.
Figure 18: “Transfer To Standby Pump” Screen 6. Touch Source Pump. The keypad pops up. 7. Enter the number of the failed pump. Use mistakes. Use Source Pump. (Backspace Key) to erase any (Enter Key) to enter the value. The number appears under 8. Touch Standby Pump. The keypad pops up. 9. Enter the number of the standby pump. Use (Backspace Key) to erase any (Enter Key) to enter the value. The number appears under mistakes.
If these conditions are not all met, error messages appear on the screen instead of a Transfer to Standby Pump 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 below. 10. Touch Transfer To Standby Pump. “Transfer in Progress” appears briefly on the screen, followed by “Transfer Complete,” in place of the Transfer To Standby Pump button.
Figure 20: Alarm Log Screen To scroll up and down through the list, touch ▲ and ▼ at the bottom of the list. Silencing Alarms Whenever a new alarm occurs, your controller sounds the horn and turns on the strobe light at each central alarm. Touch Alarm Silence on the alarm message banner that appears when a new alarm occurs or press the physical push button included in the central alarm option. The horns and lights at the central alarms turn off.
Chapter 5: Restoring a Lost or Corrupt Program 5-1 Corrective Maintenance PLC Memory Module A PLC memory module (ACS Part# A0567138) loaded with the appropriate program for the system purchased is provided as both a backup in the event of a catastrophic failure and as a means to upgrade the PLC program. Depending on the system purchased, the memory module will contain: 1. A0573702 VTC 2/20 AC Inputs 2.
2. Insert the memory module. Note: this step can be preformed while the unit is powered, however care should be taken not to contact any wiring within the control cabinet. 3. Cycle power to the control cabinet allowing approximately 30 seconds for the DC power supply (if provided) to fully discharge. 4. After approximately 30 seconds, the PLC’s green RUN indicator will flash indicating the PLC is reading the memory module.
Chapter 6: Configurable Settings/Defaults This section describes the proper setup of the 2 pump, 20-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 Alarm Options Description Options Default No convey When this option is enabled, the controller issues a “no convey” alarm if it has repeatedly attempted to convey material to the station but the flapper never opened during the dump delay. (The number of attempts is controlled by the next setting.) Usually this option should be enabled. At times, you may wish to disable it during operation as a stopgap measure for dealing with an alarm.
6-2 Pump Setup - Factory Presets 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 Auto shutdown delay 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. 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].” 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 Spare Parts List AC Voltage Quantity 1 1 1 1 1 1 1 2 1 4 1 1 1 1 1 1 Part Number A0563932 A0559862 A0572817 A0569858 A0565880 A0573717 A0573702 A0569859 A0541611 A0540997 A0540993 W00020354 A0563910 A0558091 A0530479 A0572812 Description 2.1A Power Supply for touch screen Input Card Output Card PLC.Base PLC CPU (request Pre-programmed) 6” Touch screen (Pre-programmed) Program, Memory Module, AC inputs Air Grill with Filter Fuse, MDL – .75 Fuse, MDL – 1 Fuse, MDL – .5 Fuse, MDL – 1.
8-4 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.
