Sterling 882.00255.00 CV3-655 Bedienungsanleitung

SCC 24-Pump 128-Station Controller Part Number: 882.00255.0 0 Bulletin Number: CV3-655 Effective: 12/1/05 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continui[...]

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24-Pump, 128-Station Controller 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 [...]

24-Pump, 128-Station Controller Chapter 1: Safety 3 Table of Contents CHAPTER 1: SAFETY ................................................................ 5 1-1 How to Use This Manual ............................................................................................. 5 Safety Symbols Used in this Manual .....................................[...]

24-Pump, 128-Station Controller Chapter 1: Safety 4 4-1 Overview ................................................................................................................... 51 4-2 Starting and Stopping the System ............................................................................. 51 4-3 Basic Tasks ................................[...]

24-Pump, 128-Station Controller Chapter 1: Safety 5 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[...]

24-Pump, 128-Station Controller Chapter 1: Safety 6 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 local, national and interna[...]

24-Pump, 128-Station Controller Chapter 1: Safety 7 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 [...]

24-Pump, 128-Station Controller Chapter 1: Safety 8 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 acces[...]

24-Pump, 128-Station Controller Chap ter 2: Functional Description 9 Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, and m aintenance instructions for 24-Pump, 128- Station Conveying Controllers. Model numbers are listed on the serial tag. Make sure you know the model and serial numb[...]

24-Pump, 128-Station Controller Chap ter 2: Functional Description 10 Implosion Filter Cleaning. When this feature is enabled, the controller periodically pulls a vacuum on the filter chamber and then release s it to dislodge accumulated dust and debris. Grinder Empty. This feature allows a station to receive material from a grinder bin. The level [...]

24-Pump, 128-Station Controller Chap ter 2: Functional Description 11 • 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 o p erator and maintenance personnel from[...]

24-Pump, 128-Station Controller Chapter 3: Installation 12 Chapter 3: Inst allation 3-1 Uncrating 24-Pump, 128-Station Controllers are shipped m ounted 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; [...]

24-Pump, 128-Station Controller Chapter 3: Installation 13 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[...]

24-Pump, 128-Station Controller Chapter 3: Installation 14 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 t[...]

24-Pump, 128-Station Controller Chapter 3: Installation 15 Figure 3: Side View of a Typical Mounti ng 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 clip ping the tubi ng clamps onto the vacuum tube, just before[...]

24-Pump, 128-Station Controller Chapter 3: Installation 16 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 [...]

24-Pump, 128-Station Controller Chapter 3: Installation 17 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 a bout halfway down; f[...]

24-Pump, 128-Station Controller Chapter 3: Installation 18 • 61 to 63 — Alarm stations Setting ArmorBlock Addresses Locate the rotary switches underneath th e 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 t[...]

24-Pump, 128-Station Controller Chapter 3: Installation 19 Figure 5: ArmorBlock Address Node Rotary Switches Installing ArmorBlocks The ArmorBlock cable base should already be att ached 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 ArmorBlo[...]

24-Pump, 128-Station Controller Chapter 3: Installation 20 To secure the seal block: 1. Start the threads of each of the four cap tive 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 scr ew. Doing so insures that the cables are [...]

24-Pump, 128-Station Controller Chapter 3: Installation 21 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 co mpletely straight before continuing! The latch has two catches; the first loosely holds[...]

24-Pump, 128-Station Controller Chapter 3: Installation 22 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 e nd following the connector manufacturers in[...]

24-Pump, 128-Station Controller Chapter 3: Installation 23 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 loc[...]

24-Pump, 128-Station Controller Chapter 3: Installation 24 1. Attach a KwikLink connector included in the bag with power cables to the flat cables. One connector is used for the network gre y 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 con[...]

24-Pump, 128-Station Controller Chapter 3: Installation 25 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 junc tion box (s[...]

24-Pump, 128-Station Controller Chapter 3: Installation 26 Figure 10: 24/128 8-Connector ArmorBlock Connections Note 1: The block shown is addressed 01 for the fi rst (4) four hoppers. The block addressed 02 would have the connections for 5-8, etc. Note 2: If a hopper does not have an optional input or optional output, the T-connector is not requir[...]

24-Pump, 128-Station Controller Chapter 3: Installation 27 Figure 11: Proper Vacuum Receiver Connections[...]

24-Pump, 128-Station Controller Chapter 3: Installation 28 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 junc tion boxes to the appropriat[...]

24-Pump, 128-Station Controller Chapter 3: Installation 29 Figure 13: Proper Vacuum Pump Connections, Standard XPD/XPC Pumps[...]

24-Pump, 128-Station Controller Chapter 3: Installation 30 Figure 14: Proper Vacuum Pump Connections, XPDB Pump[...]

24-Pump, 128-Station Controller Chapter 3: Installation 31 Connecting Filter Chambers Make sure that all previous installation steps ha ve been done first before starting this task. To connect a filter chamber to the network: 1. Attach patch cords from vacuum pump filter cham ber to the appropriate connector(s). See Figures 9, 12, 15, and 16 (conne[...]

24-Pump, 128-Station Controller Chapter 3: Installation 32 Figure 15: Proper Filter Chamber Connections, Blowback[...]

24-Pump, 128-Station Controller Chapter 3: Installation 33 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 cab le ties so they do not interfere with operation and to give a pleasing appearance.[...]

24-Pump, 128-Station Controller Chapter 3: Installation 34 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 conne[...]

24-Pump, 128-Station Controller Chapter 3: Installation 35 Figure 17: Proper Central Alarm Connections 3. Attach one connector of a yellow patch co rd 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[...]

24-Pump, 128-Station Controller Chapter 3: Installation 36 Figure 18: 4-Connector ArmorBlock Connections for Central Alarms Alarm Silence Pushbutton (A-I0) Alarm Silence Pushbutton (A-I1) 4 Input / 4 Output ArmorBlock for Central Alarms Alarm Strobe Light (C- O0) Alarm Horn (C-O1) Alarm Silence Pushbutton (B-I2) Alarm Silence Pushbutton (B-I3) Alar[...]

24-Pump, 128-Station Controller Chapter 3: Installation 37 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 sc[...]

24-Pump, 128-Station Controller Chapter 3: Installation 38 8. The new setting appears under System Parameters on the System Setup screen. Setting the Date/Time You can set the current date and time by going to the System Setup screen and pressing Set Time & Date . 1. To set the time, touch Hour . A keypad will pop up and you will be able to ent[...]

24-Pump, 128-Station Controller Chapter 3: Installation 39 2. Check that the expected components ar e 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 128 should be grey. For central purge valv es, y[...]

24-Pump, 128-Station Controller Chapter 3: Installation 40 The current settings are displayed under Alarm Strobe Suppression and Alarm Horn Silence . 2. Touch Alarm Strobe Suppression or Alarm Horn Silence, as appropriate. A keypad pops up, with the current setting. 3. Enter the number of minutes you want the horn or light to be t u rne d off once [...]

24-Pump, 128-Station Controller Chapter 3: Installation 41 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 p[...]

24-Pump, 128-Station Controller Chapter 3: Installation 42 3. Touching Help in the lower right of t his 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 m ore than one embedded stat[...]

24-Pump, 128-Station Controller Chapter 3: Installation 43 2. You can enter a name of up to four (4) a lpha-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, [...]

24-Pump, 128-Station Controller Chapter 3: Installation 44 4. As appropriate, either continue co pying to other stations, or touch S tation 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[...]

24-Pump, 128-Station Controller Chapter 3: Installation 45 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 t his screen gives you a menu of online help for the choices in this screen. 4. Adjust settings as required. Touching any box that appe[...]

24-Pump, 128-Station Controller Chapter 3: Installation 46 c. Touch Next ► to go to the Pump n +1 Setup screen —or— 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 t[...]

24-Pump, 128-Station Controller Chapter 3: Installation 47 To copy the selected pump’s settings to one other pump 1. Touch the gray Copy to Pump button next to the gr een Copy To Single Pump button. The keypad pops up. 2. Enter the pump number for the pump you are copy ing to. Use ← to erase any mistakes. Use ↵ to enter the value. The keypad [...]

24-Pump, 128-Station Controller Chapter 3: Installation 48 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 ne ither password set. This allows every user access to all functions. Setup Password. If you define a password for se[...]

24-Pump, 128-Station Controller Chapter 3: Installation 49 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 an[...]

24-Pump, 128-Station Controller Chapter 3: Installation 50 3-6 Initial Startup Once you have finished all the setup described a bove, 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.[...]

24-Pump, 128-Station Controller Chapter 4: Operation 51 Chapter 4: Operation 4-1 Overview Your 24/128 controller electrically controls valves and solenoids to convey material from a central location to individual stations as n eeded. The controller senses demands for material at the stations and responds to the demands in a timely fashion. This sec[...]

24-Pump, 128-Station Controller Chapter 4: Operation 52 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 Sta tion Status screen. To reach this screen from any other screen: 1. Touch Stations . The Station Status [...]

24-Pump, 128-Station Controller Chapter 4: Operation 53 The following table explains the status represen ted by each color at the Station Status screen. Color Label Description Silver Offline Station is not enabled. The controller ign ores any demands or alarms. Blue Ready Station is enabled and idle (full). Dark Yellow Demand Station requires mate[...]

24-Pump, 128-Station Controller Chapter 4: Operation 54 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 repre[...]

24-Pump, 128-Station Controller Chapter 4: Operation 55 • 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 rema ins active until you log off or the password expires. (Setup p[...]

24-Pump, 128-Station Controller Chapter 4: Operation 56 Reviewing and Adjusting Basic Station Settings Reaching and Reading the Station Operator Screens The 24/128 Controller has a Station Operator Settings screen for each station, as shown below. This screen enables you to review a nd adjust all basic settings for the station. To reach the Station[...]

24-Pump, 128-Station Controller Chapter 4: Operation 57 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 come[...]

24-Pump, 128-Station Controller Chapter 4: Operation 58 Touch Priority Convey Activate. 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 fi nishing any convey already in progress). To stop a priority [...]

24-Pump, 128-Station Controller Chapter 4: Operation 59 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 l[...]

24-Pump, 128-Station Controller Chapter 4: Operation 60 shutdown delay, alarms, or blowback to the st andby pump. Mechanical connections must be changed manually. To transfer stations from a pump to a standby pum p: 1. At any screen, touch Pumps . The Pump Status screen appears. 2. Both the source pump and the standby pump must be offline. If eithe[...]

24-Pump, 128-Station Controller Chapter 4: Operation 61 10. When you enter the second pump num ber, 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 a[...]

24-Pump, 128-Station Controller Chapter 4: Operation 62 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, yo[...]

24-Pump, 128-Station Controller Chapter 5: Maintenance 63 Chapter 5: Maintenance 5-1 Preventative Maintenance No preventative maintenance is required on this unit. 5-2 Corrective Maintenance Network Scanner Module Considerations The manufacturer includes a network scanner softwa re diskette with your controller; this diskette and instructions are l[...]

24-Pump, 128-Station Controller Chapter 6: Configurable Settings 64 Chapter 6: Configurable Settings This section describes the proper setup of the 24-pump 128-station control system parameters. These parameters are operat or cha ngeable; however, these items should require setup only during the initial installation. Only authorized personnel shoul[...]

24-Pump, 128-Station Controller Chapter 6: Configurable Settings 65 Name Description Options Default Conveying Options Assigned to pump n Name of the pump to which this station’s vacuum line is connected. Special convey When this option is enable d, the station’s vacuum valve remains open for the co nvey time, even if the station is not demandi[...]

24-Pump, 128-Station Controller Chapter 6: Configurable Settings 66 Name Description Options Default Partial convey When this option is enabled, the controll er issues a “partial convey ” alarm if it has repeatedly attempted to convey material to the station, and material has moved from t he station into the receiver, but the volume-fill proxim[...]

24-Pump, 128-Station Controller Chapter 6: Configurable Settings 67 Name Description Options Default Every n loads Number of convey ing cycles between filter cleanings. Adjust this setting based on experi ence. The more dust and debris in your material lin e, the smaller this number needs to be. 1–99 5 # pulses Number of pulses of compressed ai r[...]

24-Pump, 128-Station Controller Chapter 6: Configurable Settings 68 Name Description Options Default RPV (Remote Proportioning Valve) This option allows the system to use a remote proportioning valve to mix two different materials, typically virgin and regrind m aterials, during a convey cycle. Touching RPV repeatedly at the Station n Setup screen [...]

24-Pump, 128-Station Controller Chapter 6: Configurable Settings 69 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 Description Options Default[...]

24-Pump, 128-Station Controller Chapter 6: Configurable Settings 70 Name Description Options Default # pulses Number of pulses of compressed ai r sent through the pump’s filter during cleanin g. If blowback is not working as de sired, the service department may ask you to chan ge this setting. 1–99 5 On time Number of seconds that the air comp [...]

24-Pump, 128-Station Controller Chapter 7: Troubleshooting 71 Chapter 7: T roubleshooting 7-1 General Troubleshooting Problem Possible cause Solution The controller panel is not connected to a power source. Plug in the controller panel. Fuse/circuit breaker in the power drop is blown/tripped. Replace/reset. The controller panel doesn’t light up a[...]

24-Pump, 128-Station Controller Chapter 7: Troubleshooting 72 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 tab[...]

24-Pump, 128-Station Controller Chapter 7: Troubleshooting 73 Alarm message Possible cause Pump X Option Output Conflict 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 Purge Valve X Failure Solenoid has f ailed. ArmorBlock is not installed pr[...]

24-Pump, 128-Station Controller Chapter 7: Troubleshooting 74 Pump Alarms Alarm message Possible cause Patch cord is cut or disconnected. Blowback Solenoid Failure (Critical) Solenoid has failed. Patch cord is cut or disconnected. Clearing Valve Failure Solenoid has failed. Pump disconnect is off. Patch cord is cut or disconnected. Failure Pump con[...]

24-Pump, 128-Station Controller Chapter 8: Appendix 75 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 un der recommended conditions. The company’s obligation is limited to repair or replace FOB th e factory any parts that are returned prepai[...]

24-Pump, 128-Station Controller Chapter 8: Appendix 76 8-3 Drawings and Diagrams Figure 20: 24-Pump, 128-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.[...]

24-Pump, 128-Station Controller Chapter 8: Appendix 77 Figure 21: Typical System Installation Layout 8-4 Spare Parts List Quantity Part Number Description 1 A0569859 Fan grill with filter 1 739.00017.00 4A Power supply 1 A0542203 2A MDL fuse 1 A0568903 10A FNQ fuse 1 A0542205 2.5A MDL fuse 1 A0542209 4A MDL fuse[...]

24-Pump, 128-Station Controller Chapter 8: Appendix 78 8-5 Returned Material Policy Credit Returns Prior to the return of any material, authoriz ation 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 manufacture[...]

24-Pump, 128-Station Controller Chapter 8: Appendix 79 8-6 Safety Tag Information Controller Safety Tags 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 PA NEL Model No. XXX 24-128 Serial No. 31K0182 115 Volt 60 Hz 1 Ph Control[...]

24-Pump, 128-Station Controller Chapter 8: Appendix 80 8-8 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 il l provide your company with genu ine OEM quality parts manufactured to engi neering design specific at[...]