Sterling 882.00249.00 Bedienungsanleitung

SCC 2-Pump 12-Station Controllers Part Number: 882.00249.0 0 Bulletin Number: CV3-650 Effective: 10/25/05 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continui[...]

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2–Pump 12-Station Controllers Chapter 1: Safety 2 Shipping Information Unpacking and Inspection You should inspect your equipm ent for possible shipping damage. Thoroughl y check the equipment for any damage that m ight have occu rred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc. In the Event [...]

2–Pump 12-Station Controllers Chapter 1: Safety 3 Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping departme nt. 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 fo[...]

2–Pump 12-Station Controllers Chapter 1: Safety 4 Table of Contents CHAPTER 1: SAFETY ................................................................ 6 1-1 How to Use This Manual ............................................................................................. 6 Safety Symbols Used in this Manual .....................................[...]

2–Pump 12-Station Controllers Chapter 1: Safety 5 4-2 Controller Description and Operation ........................................................................ 35 Text Area ............................................................................................................. 35 Station Icons ............................................[...]

2–Pump 12-Station Controllers Chapter 1: Safety 6 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 a pplying efficient, proven techniques that enhance equipment productivity. This manual covers only light corrective main[...]

2–Pump 12-Station Controllers Chapter 1: Safety 7 Controller Safety Tags 1-2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national a nd local safety codes. This may include, but is not limited to OSHA, NEC, CSA, SPI, and any other loca[...]

2–Pump 12-Station Controllers Chapter 1: Safety 8 1-3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended inst ructions are followed in the maintenance and operation of the machine. All personnel engaged in the use of the machin e should become familiar with [...]

2–Pump 12-Station Controllers Chapter 1: Safety 9 Operator Responsibility The operator’s responsibility does not end with e fficient 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 incenti[...]

2–Pump 12-Station Controllers Chap ter 2: Functional Description 10 Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, and m aintenance instructions for 2-Pump, 12- Station Conveying Controllers. Model numbers are listed on the serial tag. Make sure you know the model and serial numbe[...]

2–Pump 12-Station Controllers Chap ter 2: Functional Description 11 2-3 Standard Features Mechanical Features Time-fill Capability. The length of time a station’s v acuum valve remains open to allow material to be drawn into its receiver. Volume-fill Capability. The length of time a station’s vacuum valve remains open to allow material to be [...]

2–Pump 12-Station Controllers Chap ter 2: Functional Description 12 2-5 Safety Device s and Interlocks This section includes information on safety devices and procedures that are inherent to the Controller. This manual is not intended to s upersede or alter safety standards established by the user of this equipment. Instead, the materi al contain[...]

2–Pump 12-Station Controllers Chap ter 2: Functional Description 13[...]

2–Pump 12-Station Controllers Chapter 3: Installation 14 Chapter 3: Inst allation 3-1 Uncrating 2-Pump, 12-Station Controllers are shipped mounted on a skid, enclosed in a pla stic 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; av[...]

2–Pump 12-Station Controllers Chapter 3: Installation 15 Connecting the Control Panel to Vacuum Hoppers Refer to the wiring connection diagram in Figure 1 on the next page that applies to your application. Note: Wire size depends on control volt age, distance, number of vacuum hoppers, and the number of wires in each raceway. Consult a qualified [...]

2–Pump 12-Station Controllers Chapter 3: Installation 16 Figure 1: Typical 24-Volt Junction Box Wiring Diagram A0544675 (115VAC)/(0V DC) TO CONTROLLER INPUT FOR PUMP HIGH -VACUUM 6 4 3 T 2 T 1 T 2 RESET TRIPPED TEST 98 97 96 95 A2 14 6 T3 4 T2 A2 A09 A1 13 L3 5 L2 3 L1 1 T1 2 L1 L2 L3 M OL T1 T2 T3 VS (NEUTRAL)/( +24VDC ) (115V AC) TO CONTROLL ER[...]

2–Pump 12-Station Controllers Chapter 3: Installation 17 Main Power Your 12-station controller system can operate from a 115 VAC or 220 VAC source at 50 Hz or 60 Hz. The main power switch on the controller is located on the right side of the housing. Built into the power switch are the controller fu ses. Also, the configuration of the fuse holder[...]

2–Pump 12-Station Controllers Chapter 3: Installation 18 Gaining Access to the Menu System To enter the menu system, make sure that the controller is in the OFFLINE state. Press the MENU key to initiate the menu system. The menu has three (3) top level menus: 1. Station Settings 2. Pump Settings 3. System Settings Press the CLEAR key in the menu [...]

2–Pump 12-Station Controllers Chapter 3: Installation 19 STATION SETTINGS? NO/YES OPERATION MODE? NO/YES Station Settings Menu To access the Station Settings menu, place the controller in the OFFLINE state: 1. Press the ENTER/MENU key to enter the menu syste m . 2. Continue to press the ENTER/MENU key until the following screen displays: To enter[...]

2–Pump 12-Station Controllers Chapter 3: Installation 20 ALL NORMAL MODE? NO/YES ALL SIGHTGLASS MODE? NO/YES STATION: 1 NORMAL Y=NORMAL N=SIGHTGLS To set all the stations to Normal mode and return to the Station Settings menu: • Press the YES key at the following screen prompt. This function lets you use the fast setup feature of the controller[...]

2–Pump 12-Station Controllers Chapter 3: Installation 21 TO SELECT A STATION PRESS STATION <1-12> SET DUMP DELAY? NO/YES DUMP DELAY 11: 15.0s PRESS ENTER TO SAVE Set Dump Delay, Station Settings Menu The second submenu in Station Settings is the Set Dump Delay submenu. To set dump delay time: • Press the YES key. After a hopper finishes l[...]

2–Pump 12-Station Controllers Chapter 3: Installation 22 SET INPUT DELAY? NO/YES TO SELECT A STATION PRESS STATION <1-12> The screen displays the station you selected (11 in the above example), and the current dum p delay time setting. Using number keys 1 to 0, enter th e new dump delay time (in seconds) into controller memory. Keep in mind[...]

2–Pump 12-Station Controllers Chapter 3: Installation 23 INPUT DLY 11: 0.250s PRESS ENTER TO SAVE SET STATION ALARMS? NO/YES To alter station input delay time: • Select a station to alter, then press the related Station ST nn key. nn is the station number you selected. The screen displays the selected station (11 in the following example) and t[...]

2–Pump 12-Station Controllers Chapter 3: Installation 24 TO SELECT A STATION PRESS STATION <1-12> ALARM 11: ENABLED Y=ENABLE N=DISABLE Each station has its own No Convey alarm setti ngs. You can enable or disable alarm s as needed. If a station doesn’t receive (or dump) material after a user definable number of load attempts, the controll[...]

2–Pump 12-Station Controllers Chapter 3: Installation 25 ALARM AFTER 3 LOADS PRESS ENTER TO SAVE STATION SETTINGS? NO/YES ASSIGN PUMP>STATION? NO/YES TO SELECT A STATION PRESS HOPPER <1-12> To exit from the Alarm Setting time menu and return to the Station Settings menu: • Press the CLEAR key. Assigning a Pump to a Station This functio[...]

2–Pump 12-Station Controllers Chapter 3: Installation 26 STATION 10: PUMP 1 SELECT PUMP 1 OR 2 To assign a station to a pump: 1. Press the related station ST key. The following menu screen displays: To assign Pump 1 to the station you selected: • Press 1. Instead of assigning Pump 1 to the station you selected, you can assign Pump 2: • Press [...]

2–Pump 12-Station Controllers Chapter 3: Installation 27 PUMP SETTINGS? NO/YES PUMP MODE? NO/YES SET PUMP MODE? Y=SINGLE N=DUAL Pump Settings Menu The Pump Settings menu lets you set all pump parameters. These include: • Pump Mode • Blowback • Delay Time Setting the Pump Mode The first setting to be configured is the Pump mode . This functi[...]

2–Pump 12-Station Controllers Chapter 3: Installation 28 SET ACTIVE PUMP SELECT PUMP 1 OR 2 If you have a single pump system (default): 1. Press the YES key. Selecting Single Pump mode requires the assignment of the default pump; the screen then displays the following: Selecting Dual Pump mode requires ALL stations to be assigned to a pump. Do so[...]

2–Pump 12-Station Controllers Chapter 3: Installation 29 BLOWBACK SETTINGS? NO/YES SELECT PUMP 1 OR 2 USE KEYPAD TO ENTER ENABLE BLOWBACK? NO/YES Changing Blowback Settings, Pump Settings Menu As an option, you can equip the conveying s ystem filter chamber with a blowback feature to pulsate compressed air through the filter. This function cleans[...]

2–Pump 12-Station Controllers Chapter 3: Installation 30 BLOWBACK PULSES: 10 SETTING FOR PUMP 1 ON TIME: 0.500 s SETTING FOR PUMP 1 OFF TIME: 0.500 s SETTING FOR PUMP 1 The screen continues to the next prompt. The first setting for the blowback feature is the number of blowback pulses. This setting determines the number of pulses of air that will[...]

2–Pump 12-Station Controllers Chapter 3: Installation 31 BLBK AFTER 12 LOADS SETTING FOR PUMP 1 IDLE DELAY TIME? NO/YES Next, set the Pulse Off time value. This is th e duration that the blowback solenoid is turned OFF. • Using the number keys, enter the new Off Time setting, then press ENTER to save the new value. To save the current Off Time [...]

2–Pump 12-Station Controllers Chapter 3: Installation 32 SELECT PUMP 1 OR 2 USE KEYPAD TO ENTER IDLE TIME: 10.000 s SETTING FOR PUMP 1 The following screen displays. Each pump can have separate idle delay times. To alter idle delay, select a pump: • Using the keypad, enter the pump num ber (1 or 2). The following screen displays. • Using the [...]

2–Pump 12-Station Controllers Chapter 3: Installation 33 Service Settings Menu The settings in this menu are not meant to be m odified by floor personnel (operators). See the section at the end of this manual for these settings. Saving Controller Settings to Flash Memory Your 12 station controller uses a new technology called flash memory . This [...]

2–Pump 12-Station Controllers Chapter 4: Operation 34 TO SELECT A STATION PRESS STATION <1-12> LOAD TIME 10: 63sec PRESS ENTER TO SAVE Chapter 4: Operation 4-1 Startup ??????????????? Setting Load Times You can alter load times anytime while not in the menu system by pressing the SET key. The controller screen then prompts you to select the[...]

2–Pump 12-Station Controllers Chapter 4: Operation 35 SECTION 1 SECTION 2 SECTION 3 SECTION 4 2. Using number keys 1 to 0, enter the new time. 3. Press the ENTER key to save the new setting into controller memory. If several stations require altering: 1. Press the SET key instead of the ENTER key. The new settings are saved and the station number[...]

2–Pump 12-Station Controllers Chapter 4: Operation 36 STATION:-- OFFLINE TIME: --- LOGO P1:S--:--- OFFLINE P2:S—-:--- OFFLINE Pump Modes Single Pump Mode In Single Pump mode , the screen displays as shown below. The upper left corner displays the active station being loaded. If the system has no active station, two (2) hyphens -- in the station[...]

2–Pump 12-Station Controllers Chapter 4: Operation 37 Station Icons Below the text portion of the screen, 12 station ic ons display the status of each station in the system. Each station icon contains four segments. Figure 3: Station Icon Segments Label Description Segment 1 The top segment indicates the status of the valve above each station. Wh[...]

2–Pump 12-Station Controllers Chapter 4: Operation 38 Status Indicators Four (4) status indicators are located below th e station icons at the bottom of the display. These indicators include PUMP, BLOWBACK, HIGH VACUUM, and SYSTEM. Each icon word has a 1 and a 2 icon with it, indicating Pump 1 or Pum p 2. Figure 4: Status Indicator Icons Icon Lab[...]

2–Pump 12-Station Controllers Chapter 4: Operation 39 Controller Keypad Your 12-station controller has a 16-position ke ypad to let you operate and alter controller parameters. With the exception of the SET ke y, each key has at least two functions. The status of the controller determines what function is recognized. Figure 4: Controller Keypad S[...]

2–Pump 12-Station Controllers Chapter 4: Operation 40 4-3 Operation Your 12 station controller electrically controls valves and solenoids to convey material from a central location to individual stations as need ed. The controller works within this process by sensing a material demand and responds in a tim ely fashion to that demand. An active si[...]

2–Pump 12-Station Controllers Chapter 4: Operation 41 Label Description LOADING Following the IDLE (Startup) state, the vent valve is closed and the first station in demand loads when that station sequence valve opens. This is the LOADING state. You can define load ti mes for each station. The controller loads the station in demand until one of t[...]

2–Pump 12-Station Controllers Chapter 4: Operation 42 4-4 Shut-Down[...]

2–Pump 12-Station Controllers Chapter 5: Maintenance 43 Chapter 5: Maintenance Updating BIOS Software Occasionally, BIOS software updates are available to enhance the operation of the controller. These updates are available through the Service Deptartment or for download from the internet. To find out what the current BIOS so ftware version is, c[...]

2–Pump 12-Station Controllers Chapter 5: Maintenance 44 Figure 5: BIOS Connection, Electrical Diagram; Drawing 1 A 0 5 6 0 9 7 0 + 2 4 V D C 4 + 2 4 V D C 4 2 0 I / O C O N T R O L L E R A E C P / N : A 0 5 6 0 9 5 0 T B 1 - 3 U T B 1 - 4 U T B 1 - 5 U T B 1 - 6 U T B 1 - 2 U T B 1 - 6 L T B 1 - 5 L T B 1 - 1 U T B 1 - 2 L T B 1 - 1 L O P T I O N[...]

2–Pump 12-Station Controllers Chapter 5: Maintenance 45 Figure 6 : BIOS Connection, Electrical Diagram; Drawing 2 A0560970 LEGEND FIELD WIRING OPTION/SERVICE WIRING NOTE: ALL WIRES ARE #18 AWG UNLESS OTHERWI SE NOT ED +0 VDC 2 STATION 1 SENSORS STATION 2 SENSORS 2 2 STATION 3 S ENSORS 2 STATION 4 SENSORS 2 STATION 5 SENSORS 2 STATION 6 SENSORS 2 [...]

2–Pump 12-Station Controllers Chapter 6: Troubleshooting 46 Chapter 6: T roubleshooting 6-1 General Troubleshooting Problem Possible cause Solution The controller panel is not plugged in. Plug in the controller pan el. The external disconnect (recommend ed) in the dedicated circuit is open (off). Close the switch (on). Fuse/circuit breaker in the[...]

2–Pump 12-Station Controllers Chapter 6: Troubleshooting 47 Problem Possible cause Solution Defective wiring. Correct/replace wi ring. Defective terminal block. Replace defective terminal block. Defective PCB. Replace defective PCB. Output icon comes on, solenoid doesn’t. Defective solenoid. Replace defective solenoid. Power supply sho rting ou[...]

2–Pump 12-Station Controllers Chapter 6: Troubleshooting 48 WRITING PARAMETERS TO FLASH-PLEASE WAIT SAVING BACKUP TO FLASH-PLEASE WAIT Controller Recovery using Flash Memory Technology It is possible for a write error to occur while information is being saved in the controller’s memory. If this occurs, the system always saves a backup of the da[...]

2–Pump 12-Station Controllers Chapter 7: Appendix 49 Chapter 7: Appendix 7-1 Warranty Unless otherwise specified, this product includes a Standard ONE YE AR PARTS AND LABOR WARRANTY. Warranty Specifications The manufacturer hereby expressly warrants all equipment manufactured by it to be free fro m defects in workmanship and material when used un[...]

2–Pump 12-Station Controllers Chapter 7: Appendix 50 Warranty Liabilities THE COMPANY EXPRESSLY DIS CLAIMS 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 incide ntal damages, so the ab[...]

2–Pump 12-Station Controllers Chapter 7: Appendix 51 7-2 Drawings and Diagrams Figure 7: 2 pump 12 station Controller Control Panel Depth dimension of subpanel: 8.0” D (20 .3 cm). Also, review electrical drawings supplied in the packet with this manual. SECTION 1 SECTION 2 SECTION 3 SECTION 4[...]

2–Pump 12-Station Controllers Chapter 7: Appendix 52 7-3 Spare Parts List Figure 8 : Typical 12-Station Controller Ext erior Components, Exploded View A0560974 Power cord A0560954 13 12 10 11 10 14 2 4 places 9 16 8 7 6 5 5 15 2 4 places 4 places 4 places 4 3 2 1 1[...]

2–Pump 12-Station Controllers Chapter 7: Appendix 53 Figure 9 : Exterior Components Parts List Refer to Figure 8 on Page 51 when identifying parts. Item Qty. Part no. Description 1. 1 A0560963 ENCL, CARL ON, MOUNT FLNG, MNK1 0L 2. 1 A056096 4 ENCL, CARLON, 12 X 10 BODY, NP1210B 3. 1 A0560955 SW, PWR, SH AFNR W/FLT R & FUSE 4. 2 W00015317 SCR,[...]

2–Pump 12-Station Controllers Chapter 7: Appendix 54 Figure 10 : Typical 12-Station Controller Inte rior Components, Exploded View A0560974 11 8 5 4 3 1 13 11 12 10 9 7 6 2[...]

2–Pump 12-Station Controllers Chapter 7: Appendix 55 Figure 11: Interior Components Parts List Refer to Figure 10 on Page 53 when identifying parts. Item Qty. Part no. Description 1. 4 W00001055 WASH, #6 SAE FLAT, PLD 2. 1 A0560961 PNL, SUB, C ARLON, JP1210, 10 X 8 3. 4 A0530780 STND, OFF ( M/F) #6-3 2 X 0.5” L G. HE 4. 1 A0560958 PCB, DNTL, 20[...]

2–Pump 12-Station Controllers Chapter 7: Appendix 56 7-4 Controller Identification (Serial Number) Tag (Located on the side of the controller box) 7-5 Technical Assistance (Contact Information) Parts Department Call toll-free 7am–5pm CST [ 800 ] 423- 3183 or call [ 630 ] 595-1060, Fax [630] 475-700 5 The ACS Customer Service Group w ill provide[...]

2–Pump 12-Station Controllers Chapter 8: Service Only Information 57 SET RAMP UP TIME? NO/YES SELECT PUMP 1 OR 2 USE KEYPAD TO ENTER RAMP UP DLY: 1.500s SETTING FOR PUMP n Chapter 8: Service Only Information Note: Hidden, programmable features and hidden menu pages should not be made available to floor operators. These pages include the Service I[...]

2–Pump 12-Station Controllers Chapter 8: Service Only Information 58 SET RAMP DOWN TIME? NO/YES RAMP DN DLY: 8.000s SETTING FOR PUMP n SELECT PUMP 1 OR 2 USE KEYPAD TO ENTER Setting the Ramp Down Time Ramp down time is a delay that allows the pump to come to a full stop when needed. The control cannot restart until this delay is completed. This i[...]

2–Pump 12-Station Controllers Chapter 8: Service Only Information 59 SET PUMP STAGE TIME? NO/YES STAGE DELAY: 3.000s PRESS ENTER TO SAVE Setting the Pump Stage Time Pump stage time is a delay that prevents both pumps from engaging at the same time. Although rare in a two-pump system, both pumps can sometimes start at the same time. This condition[...]

2–Pump 12-Station Controllers Chapter 8: Service Only Information 60 SET LCD BLINK DELAY? NO/YES BLINK DELAY: .500s PRESS ENTER TO SAVE Setting the LCD Blink Delay LCD Blink Delay lets you alter the ON/OFF time that the LCD blinks during an alarm. This delay does not effect the Visual or Audible alarm outputs. The delay defaults to 0.5 seconds an[...]

2–Pump 12-Station Controllers Chapter 8: Service Only Information 61 HI VAC SENSOR DELAY? NO/YES SELECT PUMP 1 OR 2 USE KEYPAD TO ENTER HIVAC DELAY: 3.000s SETTING FOR PUMP n Setting the Hi Vacuum Sensor Delay Hi vac sensor delay is the time that a high vacuum condition must exist before it is sensed by the controller. This delay eliminates the a[...]

2–Pump 12-Station Controllers Chapter 8: Service Only Information 62 HI VAC VENT DELAY? NO/YES SELECT PUMP 1 OR 2 USE KEYPAD TO ENTER HV VENT DLY: 10.000s SETTING FOR PUMP n Setting the Hi Vacuum Vent Delay Hi vacuum vent delay is the vent time initiated by a high vacuum condition. This delay defaults to 10.0 seconds and should not be altered unl[...]

2–Pump 12-Station Controllers Chapter 8: Service Only Information 63 HI VAC LOAD COUNT? NO/YES SELECT PUMP 1 OR 2 USE KEYPAD TO ENTER HV LOAD CNT: 7 SETTING FOR PUMP n Setting the Hi Vacuum Load Count Hi vacuum load count sets the maximum number of loads on a station in a high vacuum condition. If a station repeatedly experien ces a high vacuum c[...]

2–Pump 12-Station Controllers Chapter 8: Service Only Information 64 INPUT MONITOR? NO/YES IN BNK0: 0000000000 IN BNK1: 0000000000 Using the Installation Aids Menus Input Monitor Screen To assist in the installation process or to aid in problem diagnoses, the controller uses two (2) OEM menu functions. The Input Monit or screen displays all 20 in[...]

2–Pump 12-Station Controllers Chapter 8: Service Only Information 65 OUTPUT CONTROL? NO/YES AUTOMATIC OR MANUAL? N=AUTO Y=MANUAL Output Control Menu The Output Control menu gives you direct access to all 20 outputs of the controller. The menu has two (2) modes: Manual and Automatic . Automatic mode cycles each output on and off. Manual mode gives[...]

2–Pump 12-Station Controllers Chapter 8: Service Only Information 66 OUTBNK0: 0000000000 OUTBNK1: 0000000000 To access the outputs manually, at the AUTOMATIC OR MANUAL? screen prom pt: 1. Press the YES key. The following screen displays. A cursor displays on the screen. To move the cursor left: • Press the 4 key. To move the cursor right: • P[...]

2–Pump 12-Station Controllers Chapter 8: Service Only Information 67 OEM MENU ACCESS IS NOW AVAILABLE! OEM SETTINGS? NO/YES 8-2 Other Controller Restricted Areas Using the OEM Service Menu The OEM service menu ( O riginal E quipment M anufacturer) lets you set parameters not commonly used. It also contains functions to aid in the installation of [...]

2–Pump 12-Station Controllers Chapter 8: Service Only Information 68 PWL1:1111 PWL2:2222 PWL3:3333 PWL4:4444 Recovering Passwords By following this procedure, passwords can be displayed should they be lost or forgotten. Note: In the interest of system security and integrity, make sure that only setup people and supervisors know this procedure. Fo[...]

2–Pump 12-Station Controllers Chapter 8: Service Only Information 69 ROM CHECKSUM: 0x0000 PRESS YES TO RESUME Restoring the Controller to Factory Defaults Although rare, you may experience a condition when you need to perform a total reset of the controller. To do so, perform the following procedure. Note: All parameters you set are lost when doi[...]