SCC 10-Pump 80-Station Controller Part Number: 882.00585.01 Bulletin Number: CV3-660 Effective: 8/7/07 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.
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 Shipping Information .............................................................................................................. 2 Unpacking and Inspection .....................................................................................2 In the Event of Shipping Damage..........................................................................2 If the Shipment is Not Complete............................................................................2 If the Shipment is Not Correct .
3-6 Setting Up Pumps ...............................................................................................43 Finishing Setup: Setting Up Passwords ..............................................................47 Save/Restore Settings.........................................................................................48 Initial Startup............................................................................................................... 49 CHAPTER 4: OPERATION ........................
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.
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. 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.
Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, and maintenance instructions for 10-Pump, 80Station 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.
Implosion Filter Cleaning. When this feature is enabled, the controller periodically pulls a vacuum on the filter chamber and then releases it to dislodge accumulated dust and debris. Grinder Empty. This feature allows a station to receive material from a grinder bin. The level of material in the bin is monitored to assure there is enough material to convey. Material Sharing. This feature allows multiple pumps (6 max.) to be connected to a material source.
• 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.
Chapter 3: Installation 3-1 Uncrating 10-Pump, 80-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.
8. Set up and connect vacuum receiver stations to ArmorBlocks installed in Step 3, using yellow patch cords. 9. Set up and connect vacuum pump stations and filter chambers to ArmorBlocks installed in Step 3, using yellow patch cords. 10. Determine location(s) of central alarm(s); set up and connect alarms using yellow patch cords. The following sections provide detailed information on these installation steps.
To install KwikLink cables: 1. Cut both black and grey cables to the proper length. 2. Use cable ties to attach KwikLink cables, black cable above grey cable, on the vacuum tubing. Attach cable to the tubing with cable ties at about three-foot (3 ft./ 1 m) intervals. Make sure that cable ties are snug, but not tightened enough to bend the flat cable. Caution! Install KwikLink cable on vacuum tubing only.
Figure 3: Side View of a Typical Mounting Plate Assembly with ArmorBlock Base Rotate 30º to 45º downward Installing Assembled Mounting Plates After you’ve set up the mounting plates: 1. Install them at each node location by clipping the tubing clamps onto the vacuum tube, just before the node area (such as a T-valve). 2.
Discard the standard resistor cap to eliminate confusion. 5. Mount the mounting plate assembly on the vacuum line at the end of the cable run. See Page 14 for more information. 6. Using the straight-blade cable cutter, carefully trim each flat cable so it sticks out past the final KwikLink connector by 1/4” to 3/8”. Place a dust cap over the end of the trimmed cable. 7. Lay the dust cap and cable into the KwikLink connector so the dust cap tabs engage in the connector slots.
The latch has two catches; the first loosely holds the connector on the cable, the second requires more pressure to close the connector tightly. The cable must be in the correct position for the connector to close properly. 3. Drive the two screws at the center points about halfway down; first on the latch side, then the hinge side. 4. Continue to tighten the screws a little at a time until fully tightened; no more than 15 inch-pounds (5.6 N•m) of torque. Note: You can only pierce the cable once.
• 61 to 63 — Alarm stations Setting ArmorBlock Addresses Locate the rotary switches underneath the ArmorBlock. The two switches are: • MSD (most significant digit) for tens • LSD (least significant digit) for units/ones For example, if you wanted to set an address at 36, you set the MSD rotary switch at 3 and the LSD rotary switch at 6. To set an address of 8, set the MSD rotary switch at 0 (leading zero), then set the LSD rotary switch at 8.
Figure 5: ArmorBlock Address Node Rotary Switches Installing ArmorBlocks The ArmorBlock cable base should already be attached to the mounting plate, aligned so it is perpendicular to the flat cables. If not, reinstall it with its proper alignment. To install the flat cables in the ArmorBlock cable base: 1. Lay the flat cable into the ArmorBlock cable base, grey data cable on the bottom and the black power cable on the top, making sure that the keyed edge is properly seated toward the top.
To secure the seal block: 1. Start the threads of each of the four captive screws into the cable base receptacle holes. 2. Drive each of the screws about halfway down, using the proper torque sequence: Bottom screw, top screw, left screw, right screw. Doing so insures that the cables are pierced evenly. 3. Using the proper torque sequence, tighten each screw, a little at a time, until the seal block is fully seated into the cable base. Tighten to no more than 8 to 10 inchpounds (3.0 to 3.7 N•m) of torque.
2. Making sure that the cable is completely straight, carefully close the hinged assembly, and apply firm, even pressure until the first latch locks into place. Note: Make sure that the flat cable is completely straight before continuing! The latch has two catches; the first loosely holds the connector on the cable, the second requires more pressure to close the connector tightly. The cable must be in the correct position for the connector to close properly. 3.
3. Run the cables from the remote interface(s) to the switch and the main controller, neatly dressing the cable with ties so that it does not interfere with system operation and it gives a neat appearance. 4. Attach RJ45 connectors at each cable end following the connector manufacturers instructions. 5. The “Ethernet out” connection on the main controller should connect to the “Ethernet in” connection on the switch. 6.
Figure 8: Proper Controller and Remote Interface Connections Connecting the Power Supply Enclosure to the Network The power supply provides electrical power to make the system work. Some network layouts require more than one power supply. Location is also an important consideration when locating power supply enclosures on your network. Contact the factory for determining how many power supply enclosures your system needs, as well as where they need to be installed.
1. Attach a KwikLink connector included in the bag with power cables to the flat cables. One connector is used for the network grey cable and one connector is used for the auxiliary power black cable. 2. Align the square connector of the grey drop cable so the cable leads down from the connector. Evenly press the square connector onto the top of the bottom KwikLink connector. It should make two audible snaps when properly seated. 3.
Figure 9: Proper Power Supply Enclosure Connections Connecting Vacuum Receivers to the Network Make sure that all previous installation steps have been done first before starting this task. To connect a vacuum receiver to the network: 1. Attach patch cord from vacuum hopper junction box (station demand) to appropriate input connector. See Figures 10 and 11 (connection is shown on first hopper on the block only for clarity.) 2.
Figure 10: 10/80 4-Connector ArmorBlock Connections Note 1: The block shown is addressed 01 for the first (2) two hoppers. The block addressed 02 would have the connections for 3-4, etc. Note 2: If a hopper does not have an optional input or optional output, the T-connector is not required. Connect the patchcord directly to the connector on the ArmorBlock.
Figure 11: Proper Vacuum Receiver Connections Connecting Vacuum Pumps and Filter Chambers to the Network Connecting Vacuum Pumps Make sure that all previous installation steps have been done first before starting this task. To connect a vacuum pump to the network: 1. Attach patchcords from vacuum pump junction boxes to the appropriate ArmorBlock connectors. See Figures 12, 13, and 14.
Note 1: The block shown is addressed 41, for the first pumps. The block addressed 42 would have connectors for pumps etc. Note 2: If a pump does not have “Pump Fault #2” or a local pump alarm light, the T connector is not required. Connect the patchcord directly to the connector on the ArmorBlock.
Figure 13: Proper Vacuum Pump Connections, Standard XPD/XPC Pumps 10-Pump, 80-Station Controller Chapter 3: Installation 29
Figure 14: Proper Vacuum Pump Connections, XPDB Pump Connecting Filter Chambers Make sure that all previous installation steps have been done first before starting this task. To connect a filter chamber to the network: 1. Attach patch cords from vacuum pump filter chamber to the appropriate connector(s). See Figures 12, 15, and 16 (connection is shown on first pump on the block only for clarity.
Figure 15: Proper Filter Chamber Connections, Blowback XFC-S 10-Pump, 80-Station Controller Chapter 3: Installation 31
Figure 16: Proper Filter Chamber Connections, Implosion Type Note: Retain the terminal caps from the ArmorBlock. They may be used later. 2. Dress the excess patch cord cables with cable ties so they do not interfere with operation and to give a pleasing appearance.
Connecting Central Alarms to the Network Make sure that all previous installation steps have been done first before starting this task. First, determine where the best location for central alarms should be, and install the alarm module(s) there. You’ll use two yellow patch cords to connect. To connect an alarm module to the network: 1. Attach one connector of the first yellow patch cord to the terminal on the alarm module. Tighten the cord grip ring until snug. 2.
Figure 17: Proper Central Alarm Connections 3. Attach one connector of a yellow patch cord to the terminal on the alarm silence switch module. Tighten the cord grip ring until snug. 4. Attach the other connector to the upper left terminal of the ArmorBlock. Tighten the cord grip ring until snug. Note: Retain the terminal caps from the ArmorBlock. They may be used later.
Figure 18: 4-Connector ArmorBlock Connections for Central Alarms Alarm Silence Pushbutton (A-I0) Alarm Silence Pushbutton (A-I1) Alarm Silence Pushbutton (B-I2) Alarm Silence Pushbutton (B-I3) Alarm Strobe Light (C-O0) Alarm Horn (C-O1) Alarm Strobe Light (D-O2) Alarm Horn (D-O3) 4 Input / 4 Output ArmorBlock for Central Alarms 5. Dress the excess patch cord cables with cable ties so they do not interfere with operation and to give a pleasing appearance.
Setting Up the System Setting the Number of Stations and the Number of Pumps 1. Touch System Setup at the Station Status (or Pump Status) screen. The System Setup screen appears: Note: Touching Help in the lower right of this screen gives you a menu of online help for the choices in this screen. 2. Touch Stations Present in the upper left of the System Setup screen. 3. This will take you to the Stations Installed screen. A screen showing a list of stations appears.
4. Press System Setup to return to the System Setup screen. 5. Touch Pumps Present in the upper part of the System Setup screen. 6. This will take you to the Pumps Installed screen. The screen shows a list of pumps. The pumps that are not installed are red. The pumps that are installed are green. Briefly touching the icon for a pump toggles between not installed and installed. 7. Press System Setup to return to the System Setup screen. 8.
2. Check that the expected components are shown as present (green) and not present (grey). (Disregard any error messages.) For example, if you have 18 stations, boxes 01 through 18 in the Stations section should be green and boxes 19 through 80 should be grey. For central purge valves, you should see a green box for each ArmorBlock installed. If the screen display is not as expected, either a component’s ArmorBlock has an incorrect address or the ArmorBlock is not correctly wired to the network.
1 station per Block Configuration The current settings are displayed under Alarm Strobe Suppression and Alarm Horn Silence. When a station node is configured for the default 2 stations per block (see Setting up the System on page 37), one option input and one option output per station is available. When a station node is configured for 1 station per block, three option inputs and three option outputs are available for the station. 2. Touch Alarm Strobe Suppression or Alarm Horn Silence, as appropriate.
Setting Up Stations Before starting the system, you must define several settings for each station, such as which pump conveys material to it and whether the station has a slide gate. This section first discusses how to use the controller’s menu system to configure stations. The table on pp. 63– 67 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 Stations on the right-hand side of the screen.
3. Touching Help in the lower right of this screen gives you a menu of online help for the choices in this screen. 4. Adjust settings as required. Touching any box that appears in red (for “disabled”) toggles it to green (for “enabled”). Many boxes have more than one embedded state. Touching any box that appears in light gray gives you a keypad to enter a new value.
2. You can enter a name of up to four (4) alpha-numeric characters. If you would like to enter a longer name, you can go back to the Station n Setup screen and press Name Line 2 to repeat the process. Using Name Line 2 will allow you to enter up to four (4) more alpha-numeric characters, for a total of eight (8) characters. The characters will appear as two four-digit names on two separate lines. Use ← to erase any mistakes. Use ↵ to enter the value.
4. As appropriate, either continue copying to other stations, or touch Station Setup to go back to the Station n Setup screen. To copy the selected station’s settings to a range of other stations 1. Touch First Station button next to the green button labeled “Copy to Range of Stations.” The keypad pops up. 2. Enter the station number for the hopper at the lower end of the range you are copying to. Use ← to erase any mistakes. Use ↵ to enter the value.
2. Touch the icon for the pump you want to set up, and hold it for several seconds. The Pump n Setup screen appears: 3. Touching Help in the lower right of this screen gives you a menu of online help for the choices in this screen. 4. 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 light gray gives you a keypad to enter a new value.
d. Touch Goto and enter a pump number to go to that pump’s setup screen 5. To save or restore settings, go to the System Setup screen and touch Save/Restore on the right side of the screen. Naming Pumps To name a station, go to the Pump Status screen. Touch the icon for the pump you want to name and hold it for several seconds. The Pump n Operator Settings screen for the selected pump appears. Touch Pump Setup at the Pump n Operator Settings screen. The Pump n Setup screen appears. 3.
To copy the selected pump’s settings to one other pump 1. Touch the gray Copy to Pump button next to the green Copy To Single Pump button. The keypad pops up. 2. Enter the pump number for the pump you are copying to. Use ← to erase any mistakes. Use ↵ to enter the value. The keypad disappears and the Pump Copy screen shows the pump number you entered under Copy to Pump. 3. Touch the green Copy To Single Pump button. “Copy Complete” briefly appears at the top of the screen. 4.
Finishing Setup: Setting Up Passwords You can set up passwords for two levels of security: for operators and for setup personnel. The controller comes from the factory with neither password set. This allows every user access to all functions. Setup Password. If you define a password for setup personnel, then most settings can be changed only after entering the password.
2. Touch Operator Password or Setup Password, as appropriate. A keypad pops up. 3. Enter up to eight (8) alpha-numeric characters. If you want to remove the password protection, simply leave the entry blank. Use ← to erase any mistakes. Use ↵ to enter the value. The keypad disappears and the new setting appears under Operator (or Setup) Password. In addition, if you have added a password, a new button appears on the screen, labeled Log Off Operator.
3-6 Initial Startup Once you have finished all the setup described above, you are ready to start the system. To do so: 1. At any screen, touch Stations on the right-hand side of the screen. The Station Status screen appears. 2. For each station that you want to use, briefly touch its icon. The icon turns blue, indicating that the station is ready or yellow, indicating that the station needs material. 3. Touch Pumps. The Pump Status screen appears. 4.
Chapter 4: Operation 4-1 Overview Your 10/80 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.
4-3 Basic Tasks This section covers tasks that can be carried out with no password or with an operator’s password. Reviewing Station Status The starting point for all operations is the Station Status screen. To reach this screen from any other screen: 1. Touch Stations. The Station Status screen appears. Depending on which model you have, your screen will appear as one of the following: The status of each station is color-coded, as summarized in the upper right of the screen.
The following table explains the status represented by each color at the Station Status screen. Color Silver Label Offline Blue Dark Yellow Light Green Brown White Ready Demand Purging Dumping Blow Back Dark Grey Bypass Medium Green Orange Red Priority Convey Alarm Critical Purple Closed Loop Waiting Convey Light Yellow Dark Green Description Station is not enabled. The controller ignores any demands or alarms. Station is enabled and idle (full). Station requires material.
2. Touch anywhere in the rectangle in the upper right of the screen or the Help button on the lower right side of the screen. The Help Menu appears. 3. In the section of the Help Menu labeled Screen Symbols/Colors, touch Pump. The Pump Symbols help screen appears, explaining the status represented by each color. 4. When you are finished reviewing the information, touch Pumps (or Stations). The Pump Status (or Station Status) screen appears.
• Enter the alphanumeric password. Each digit appears as an “*” as you touch it. Press ↵ when complete. If you have lost the password(s), contact the manufacturer for assistance. Once you have logged on, the password remains active until you log off or the password expires. (Setup personnel at your facility control the number of minutes before the password expires.) While the password is active, you can continue to carry out password-protected tasks without reentering the password.
Reviewing and Adjusting Basic Station Settings Reaching and Reading the Station Operator Screens The 10/80 Controller has a Station Operator Settings 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 n Operator screen: 1. Go to the Station Status screen, if needed. To reach this screen from any other screen, touch Stations on the right-hand side of the screen. 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.) Dump delay 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.
The button changes to Priority Convey Active and blinks until the station’s demand has been satisfied (or you stop the priority convey).The controller begins filling the chosen station only (after finishing any convey already in progress). To stop a priority convey before the station is completely full: Touch the blinking Priority Convey Active. The button changes to Priority Convey Activate and stops blinking. The controller finishes the current convey, if any, and resumes normal operation.
4-4 Advanced Tasks 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 with the setup password is the same as for logging on with the operator password; see page 45.
shutdown delay, alarms, or blowback to the standby pump. Mechanical connections must be changed manually. To transfer stations from a pump to a standby pump: 1. At any screen, touch Pumps. The Pump Status screen appears. 2. Both the source pump and the standby pump must be offline. If either pump is any other state, disable it by touching its icon briefly. The icon becomes grey. 3.
10. 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 a Press To Move Stations button. If you get an error message, first check to make sure that you have entered the correct numbers and reenter if necessary.
3-5 Alarms Reviewing Alarms At the Station Status or Pump Status screen: 1. Touch Alarms. The Alarm Log screen appears, with the newest alarm listed first: 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.
Chapter 5: Maintenance 5-1 Preventative Maintenance To maintain cooling fan, check and clean and/or replace filter.
Chapter 6: Configurable Settings This section describes the proper setup of the 24-pump 128-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 Conveying Options Assigned to pump n Special convey Closed Loop Alarm Options No convey # attempts B4 alarm Description Options Default 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.
Name Partial convey # attempts B4 alarm Option Input Receiver low level Bypass switch Grinder empty Grinder empty with Alarm Option output Local alarm Blow back Description When this option is enabled, the controller issues a “partial convey” alarm if it has repeatedly attempted to convey material to the station, and material has moved from the station into the receiver, but the volume-fill proximity sensor has never signaled that the station is full.
Name Every n loads # pulses On time Off time Slide gate Purge Purge duration Purge valve Material set to n Description Number of conveying cycles between filter cleanings. Adjust this setting based on experience. The more dust and debris in your material line, the smaller this number needs to be. Number of pulses of compressed air sent through the station’s filter during cleaning. If blowback is not working as desired, the service department may ask you to change this setting.
Name RPV (Remote Proportioning Valve) RPV material B Cycles Description This option allows the system to use a remote proportioning valve to mix two different materials, typically virgin and regrind materials, during a convey cycle. Touching RPV repeatedly at the Station n Setup screen steps through the three choices. Enable this option with PLC control if you will be adjusting the mix from the controller’s touch screen.
6-3 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, “Operation.” Name Idle Time Options Auto Shutdown Delay Alarm Options Local alarm Pump fault #1 Pump fault #2 Filter Cleaning Options Blow back Every n loads Description Options Default Length of time the pump continues to run unloaded without demand from any station.
Name # pulses On time Off time Implosion with Seal Valve Implosion without Seal Valve Every n Loads # Pulse(s) Vacuum Time Release Time Description Number of pulses of compressed air sent through the pump’s filter during cleaning. If blowback is not working as desired, the service department may ask you to change this setting. Number of seconds that the air compressor remains on for each pulse during filter cleaning.
Chapter 7: Troubleshooting 7-1 General Troubleshooting Problem The controller panel doesn’t light up at all. A pump package doesn’t run, even though it is on line and its indicator is lit. Possible cause The controller panel is not connected to a power source. Fuse/circuit breaker in the power drop is blown/tripped. Broken controller power switch. The motor circuit breaker/ overload has tripped. Main fuse in power drop circuit breaker has blown. Motor contact is faulty.
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. 2. You can also see a list of alarms and their causes in the controller’s online help.
Alarm message Pump X Option Output Conflict Purge Valve X Failure Purge Valve X Not Present Purge Valve X Power Failure Receiver Level RPV Failure Sequence Valve Failure Slide Gate Failure 10-Pump, 80-Station Controller Possible cause An assigned station has closed loop enabled and the pump has either implosion with sealing valve or Local Alarm enabled. Patch cord is cut or disconnected Solenoid has failed. ArmorBlock is not installed properly. ArmorBlock is not addressed correctly.
Pump Alarms Alarm message Blowback Solenoid Failure (Critical) Clearing Valve Failure Failure General Fault 1 General Fault 2 High Vacuum Switch Failure Not Present (Critical) Output Failure Output Power Failure (Critical) Contactor Fault Sealing Valve Failure Too Many Stations Assigned Vent Solenoid Failure Possible cause Patch cord is cut or disconnected. Solenoid has failed. Patch cord is cut or disconnected. Solenoid has failed. Pump disconnect is off. Patch cord is cut or disconnected.
Chapter 8: Appendix 8-1 Optional Components The following is a list of options that your controller may be equipped with: 230/1/60 Operation. Required to operate with a 230/1/60 supply voltage. Additional audible/visual alarm with silence button. Alarm light and horn assembly that can be remote mounted and wired into the controller to indicate an alarm condition. Remote Interface.
8-2 Drawings and Diagrams Figure 20: 10-Pump, 80-Station Controller with 10" Display Also, review electrical drawings supplied in the packet with this manual. Note: Allow 12” of clearance on each side of the controller for ventilation and cables.
Figure 21: Typical System Installation Layout 8-3 Main Control Panel Spare Parts List Quantity Part Number 1 1 1 1 1 1 1 A0569859 739.00017.00 A0542203 A0568903 A0542205 A0542209 10-Pump, 80-Station Controller Description Filter only- Clean as needed Fan grill with filter 4A Power supply 2A MDL fuse 10A FNQ fuse 2.
8-4 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.
8-5 Safety Tag Information Controller Safety Tags High Voltage Inside Enclosure 8-6 Read Operation and Installation Manual 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. XXX10-80 115 Volt Serial No.
8-7 Technical Assistance (Contact Information) Parts Department Call toll-free 7am–5pm CST [800] 423-3183 or call [262] 641-8610, Fax [262] 641-8653 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.
10 Pump / 80 Station Convey Control Hardware Setup and Upgrade Instructions 10-Pump, 80-Station Controller Chapter 8: Appendix 80
Table of Contents CompactLogix L35E Setup (Brand New Processor)…………………………… CompactLogix L35E Upgrade ….........................................................................
CompactLogix L35E Setup Use this procedure to setup a new CompactLogix PLC for use on a 10 Pump – 80 Station Convey Control. 1. Verify that the control is powered down and the PLC CPU key switch is in the RUN position. 2. Insert the configuration compact flash card containing the new version of the software labeled PLC Configure 744.00130.00 into the PLC CPU (Fig 1). Fig 1 3. Turn on power.
4. Wait for the Run LED on the top front of the CPU to turn solid green and for the I/O LED to stop blinking (Fig 2) for 30 seconds. Since a new CPU requires a firmware upgrade this will take about 2-3 minutes. Do not turn off power until the upgrade completes. Fig 2 5. Turn off power to the control enclosure. Wait 5 seconds. Turn on power. 6. Wait for the I/O LED to stop blinking (Fig 2). 7. Remove the card labeled PLC Configure 744.00130.
9. Go to the System Setup Screen (Fig 3) by pressing the System Setup button on any screen. Fig 3 10. Go to the Save / Restore Screen (Fig 4) by pressing the Save / Restore button on the right side of the screen. Fig 4 11. Restore Settings by pressing the yellow Restore Settings button. 12. Wait for the “Restore Complete” message. (This message is only displayed for 10 seconds). 13.
15. 16. 17. 18. Save Settings by pressing the yellow Save Settings button. Wait for the “Save Complete” message. (This message is only displayed for 10 seconds). Go to the System Setup screen by pressing the System Setup button. Verify that the clock has the correct time. If not, set the correct time by pressing the Set Time & Date button.
CompactLogix L35E Upgrade Use this procedure to upgrade the software on a CompactLogix PLC for use on a 10 Pump – 80 Station Convey Control. 1. If the control is off, turn it on and wait for the control to power up. 2. Verify that the key switch on the front of the PLC CPU is in the RUN position. 3. Remove existing compact flash card from the PLC CPU by pressing the retaining clip to the right and pulling the compact flash card straight out (Fig 5). Fig 5 4.
5. Go to the System Setup Screen (Fig 6) by pressing the System Setup button on any screen. Fig 6 6. Go to the Save / Restore Screen (Fig 7) by pressing the Save / Restore button on the right side of the screen. 7. 8. 9. 10. Fig 7 Save Settings by pressing the yellow Save Settings button. Wait for the “Save Complete” message. (This message is only displayed for 10 seconds). Turn off power to the control enclosure. Wait 5 seconds. Turn on power.
about 10 seconds. If a firmware upgrade is required, this will take about 2-3 minutes. Do not turn off power until the upgrade completes. Fig 8 11. Turn off power to the control enclosure. Wait 5 seconds. Turn on power. 12. Go to the System Setup Screen by pressing the System Setup button on any screen. 13. Go to the Save / Restore Screen by pressing the Save / Restore button on the right side of the screen. 14. Restore Settings by pressing the yellow Restore Settings button. 15.
VersaView CE 1000H Setup Use this procedure to setup a new VersaView display or to upgrade a VersaView display for use on a Sterling 10 Pump – 80 Station Convey Control. 1. Remove the compact flash card from the VersaView if one is installed by pressing the Eject Button (Fig 9). Fig 9 2. If you are setting up a Remote Display, disconnect the Ethernet cable connecting the VersaView to the network. If you are setting up the Primary Display, leave the Ethernet cable connected. 3. Cycle power on the VersaView.
4. If you are upgrading a VersaView that has been configured to work with 10 Pump – 80 Station control an Error screen (Fig 10) will appear. Press the “OK [F7]” button to close the screen.
5. If VersaView boots to the Windows CE desktop (Fig 11) skip to step 26.
6. If the VersaView boots to the RSView ME Station screen with an “Exit [F8]” button (Fig 12), press the “Exit [F8]” button to bring up the Windows CE desktop (Fig 11). Skip to step 26.
7. If the VersaView boots to the RSView ME Station screen without an “Exit [F8]” button (Fig 13), insert the VersaView Program Compact Flash Card labeled 744.00134.00 10P80S Disp Program. Fig 13 8. Press the “Load Application [F1]” button.
9. The Load Application Screen (Fig 14) will appear. Fig 14 10. Press the “Source [F1]” button so the circle next to “External Storage 1” is filled. 11. Use the up and down arrows to select the “VersaViewCE_LockDown.mer” application. 12. Press the “Load [F2]” button.
13. The Replace Communications Confirmation Screen (Fig 15) will appear. Fig 15 14. Press the “Yes [F7]” button. 15. The RSView ME Station Screen without an “Exit [F8]” button (Fig 13) will appear. 16. Press the “Run Application [F2]” button when it is no longer grayed out.
17. The application will start after a short time (Fig 16). Fig 16 18. 19. 20. 21. 22. 23. 24. 25. 26. Press the “VersaView Enable” button. “VersaView Mode Enable” message will be displayed. Remove the VersaView Program Compact Flash Card from the display. Press the “Reboot” button. The display will reboot. If an Error Screen (Fig 10) appears, Press the “OK [F7]” button to close the screen. The RSView ME Station Screen with an “Exit [F8]” button (Fig 12) will appear.
27. The Firmware Upgrade Card Window (Fig 17) will appear. Fig 17 28. When prompted to upgrade firmware, press the “Upgrade [F7]” button 29. The firmware upgrade process will begin and after a short time the display will reboot.
30. When the calibration screen (Fig 18) appears, follow the on-screen instructions (use a pencil eraser, pen cap or other dull pointing device). Fig 18 31. When the firmware upgrade complete window appears, remove the VersaView Firmware Upgrade Compact Flash Card from the display by pressing the Eject Button. 32. Press the “Exit [F8]” button. 33. If the VersaView boots to the RSView ME Station screen (Fig 12), press the “Exit [F8]” button to bring up the Windows CE desktop (Fig 11). 34.
39. A window will appear showing the contents of the “My Computer” folder (Fig 19). Fig 19 40. Double tap the “Storage Card2” folder.
41. A window will appear showing the contents of the “Storage Card2” folder (Fig 20). Fig 20 42. Double tap the “BRutil” icon.
43. The System Backup/Recover Window (Fig 21) will appear. Fig 21 44. Press the “Restore system” button. DO NOT PRESS THE “BACK UP SYSTEM” BUTTON.
45. A Warning Window (Fig 22) will appear. 46. 47. 48. 49. 50. Fig 22 Press the “OK” button in the upper right corner of the Warning Window (Fig 22). After a short delay the VersaView will reboot. If the calibration screen (Fig 18) appears, follow the on-screen instructions (use a pencil eraser, pen cap or other dull pointing device). The Windows CE desktop will appear for a short time. The VersaView will then launch the Primary Display program.
• Remote Display #4 – Select “745_00092_00.mer”. 11. Press the “Load [F2]” button. 12. The Replace Communications Confirmation Screen (Fig 15) will appear. 13. Press the “Yes [F7]” button. 14. The RSView ME Station Screen will appear (Fig 12). 15. The application will load. This will take several seconds. While it is loading several buttons will be grayed out. 16. When the application completes loading, press the “Terminal Settings [F4]” button. 17. The Terminal Settings Menu will appear (Fig 23).
20. The Startup Options Screen (Fig 24) will appear. 21. Press the enter “ Fig 24 ” button to select “RSView ME Station Startup” button.
22. The RSView ME Station Startup Screen (Fig 25) will appear. Fig 25 23. Verify that the circle next to “Run Current Application” is filled. If not, press the “On Startup [F1]” button until the “Run Current Application” is filled. 24. Press the “OK [F7]” button. 25. The Startup Options Screen (Fig 24) will appear. 26. Press the “Close [F8]” button. 27. The Terminal Settings Menu (Fig 23) will appear. 28. Press the up arrow “▲” button to highlight “Networks and Communications”. 29.
30. The Networks and Communications Menu (Fig 26) will appear. Fig 26 31. Press the down arrow “▼” button to highlight “Network Connections”. 32. Press the enter “ ” button to select “Networks Connections” .
33. The Network Connections Menu will appear (Fig 27). Fig 27 34. Press the down arrow “▼” button to highlight “Network Adaptors”. 35. Press the enter “ ” button to select “Networks Adaptors”.
36. The Network Adaptors Screen will appear (Fig 28). Fig 28 37. Press the “IP Address [F2]” button.
38. The IP Address screen will appear (Fig 29). Fig 29 39. Press the “IP Address [F1]” button.
40. A keyboard will appear (Fig 30). Fig 30 41. Enter the appropriate IP Address for the display you are setting up: • Remote Display #1 - Enter “192.168.10.2” via the keyboard. • Remote Display #2 - Enter “192.168.10.3” via the keyboard. • Remote Display #3 - Enter “192.168.10.4” via the keyboard. • Remote Display #4 - Enter “192.168.10.5” via the keyboard. 42. Press the “Enter” key to close the keyboard. 43. The IP Address Screen (Fig 29) will appear. 44. Press the “OK [F7]” button.
45. After a short delay the Adapters Screen (Fig 31) will appear. Fig 31 46. Press the “OK [F7]” button. 47. The Network Adaptors Screen will appear (Fig 28). 48. Press the “Close [F8]” button. 49. The Network Connections Menu will appear (Fig 27). 50. Press the “Close [F8]” button. 51. The Network and Communications Menu will appear (Fig 26). 52. Press the “Close [F8]” button. 53. The Terminal Settings Menu will appear (Fig 23). 54. Press the “Close [F8]” button. 55.
57. A Reset Confirmation screen will appear (Fig 32). Fig 32 58. Press the “Yes [F7]” button. 59. After a short delay the screen will reboot. 60. While the VersaView is rebooting, plug the Ethernet cable back in. 61. The Windows CE desktop will appear for a short time. The VersaView will then launch the Remote Display program.
