Sterling Plumbing SCC4-38 manual

SCC4-38 Conveying Systems 4-Pump 38-Station Controllers Operation, Installation, and Service Manual Sterling 5200 W. Clinton Ave. Milwaukee, WI 53223 Tel. (414) 354-0970 Fax (414) 354-6421 www.sterlco.com Part No. A0565547 Bulletin No. SM2-615 12/12/03[...]

Page 2 of 60 Write down your unit serial number(s) Model # Serial # here for future reference ___ _____________ ________________ ________________ ________________ ________________ ________________ ________________ ________________ Performance figures stated in this manual are based on a standard atmosphere of 59°F (15°C) at 29.92” Hg (1,014 mil[...]

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Page 3 of 60 Table of Contents 1 General Information .......................................................................... 9 1-1 Equipment Function...................................................................................... 9 1-2 Necessary Documents ................................................................................. 9 1[...]

Page 4 of 60 5-2-2 Setting Up Stations ......................................................................... 24 5-2-2-1 Setting Up a Single Station ....................................................... 25 5-2-3 Setting Up Pumps .......................................................................... 27 5-2-3-1 Setting Up a Single Pump .....[...]

Page 5 of 60 11-3 Warranty ..................................................................................................... 56 12 Safety Tag Information ................................................................... 57 12-1 Controller Safety Tags ................................................................................ 57 12-2 Cont[...]

Page 6 of 60 Charts and Figures 1 SCC4/38 Controller with 6" Display ................................................................... 11 2 6” Default “Station Status” Screen Before Setup ............................................. 22 3 6” “System Setup” Screen Before Setup ......................................................[...]

Page 7 of 60 Safety Considerations Sterling SCC conveying systems are designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes. To avoid possible personnel injury or equipment damage when installing or operating this equipment, always use good judgment and fo[...]

Page 8 of 60 Sterling “SCC4-38” Conveying Systems 4-Pump 38-Station Controller This controller is manufactured by Sterling, Inc. at the ACS-Wood Dale facility: ACS, Inc. 800 N. Wood Dale Rd. Wood Dale, IL 60191 Phone: 414.354.0970 Fax: 414.354.6421 The equipment is distributed in Europe by our European Facility: ACS-EUROPE Daniels Industrial Es[...]

Page 9 of 60 1 General Information 1-1 Equipment Function Sterling conveying systems create vacuum for conveying pelletized or granular material in a central material handling system. A typical use is an in-plant distribution system for plastic processing plants. 1-2 Necessary Document s The documents below are necessary for proper installation, op[...]

Page 10 of 60 Use the minimum effective amount of vinyl flex hose to maximize material line efficiency. Keep material lines as straight as possible. Refer to the Sterling SPD/SPC Product Manual (Sterling Part No. A0571050) for installation recommendations. Important! Vacuum leaks occurring anywhere in your system reduce capacity. 1-4 Equipment Cycl[...]

Page 11 of 60 Figure 1: SCC4/38 Controller with 6" Display 24 ” 30 ” 6 ” * De p th dimension is 10”[...]

Page 12 of 60 2 Safety 2-1 W ork Rules The installation, operation, and maintenance of this equipment must be conducted in accordance with all appli- cable work and safety codes for the installation location. This may include, but is not limited to OSHA, NEC, CSA, SPI, and any other local, national, and international regulations. ; Read and follow [...]

Page 13 of 60 DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This word will be limited to the most serious situations. The term IMPORTANT emphasizes areas where equipment damage could result, or provi des additional information to make a step or procedure easier to understand. Disre[...]

Page 14 of 60 Hold daily equipment inspections in addition to regular maintenance checks. You will keep your equipment safe for production and exhibit your commitment to safety. Please read and use this ma nual as a guide to equipment safety. This manual contains safety warnings throughout, specific to each function and point of operation. 2-5 Oper[...]

Page 15 of 60 2-7 Safety Devices This section includes information on safety devices and procedures that are inherent to the SCC4/38 Controller. This manual is not intended to supersede or alter safety standards established by the us er of this equipment. Instead, the material contained in this section is recommended to supplement these procedures [...]

Page 16 of 60 guarding a motor, and the safety switch fails, the motor should not be able to run. 2-7-3 Safety Device Lock-Outs Some safety devices disconnect electrical energy from a circuit. The safety devices that are used in the SCC4-38 Controller are primarily concerned with electrical power disconnection. WARNING! Always disconnect and lockou[...]

Page 17 of 60 3 Shipping Information 3-1 Unp acking and Inspection You should inspect your Sterling SCC4-38 controller for any possible shipping damage. If the container and packing materials are in re-usable condition, save them for reshipment if necessary. Thoroughly check the equipment for any damage that might have occurred in transit, such as [...]

Page 18 of 60 Hold the damaged goods with the container and packing materials for possible inspection by postal authorities. 3-4 United Parcel Service Shipment ; Contact your local UPS office regarding damage and insurance claims. ; Retain the container and packing. ; Notify Sterling at once. 3-5 If the Shipment is Not Complete Check the packing li[...]

Page 19 of 60 4 Installation 4-1 Inst alling the Sterling Control Panel Note: Before you mount the panel, consider how you run wiring to the vacuum hoppers, the filter chamber atmospheric valve (if so equipped) and the pump motor starter(s), vacuum switch(es), and vent valve(s). Mount the panel on a flat, vertical area. It should be a visible area [...]

Page 20 of 60 3. Make sure that the solenoid and the proximity switch (if supplied) on vacuum hoppers are the same voltage (24 VDC) as the SCC control panel voltage. Consult the control panel serial tag and the solenoid valve nameplates. 4. Wire size depends on control voltage, distance, number of vacuum hoppers, and the number of wires in each rac[...]

Page 21 of 60 5 Using the Standard 6” Touch Screen 5-1 Introduction This chapter gives the procedures for configuring your SCC 4-38 controller. Configuration of your SCC4-38 controller includes setting the number of stations and pumps, setting variables such as convey time and blow-back interval, and setting up passwords. Sterling recommends that[...]

Page 22 of 60 Figure 2: 6” Default “Station Status” Screen Before Setup 1. At the “Station Status” screen (Figure 2) or at the “Pump Status” screen, touch the SYSTEM SETUP button. The “Menu” screen opens. Figure 3: 6” “System Setup” Screen Before Setup 2. At the “System Setup” screen, (Figure 3), touch STATIONS ACTIVE A [...]

Page 23 of 60 4. Touch PUMPS ACTIVE . A keypad pops up. 5. Enter the total number of pumps (1-4) to be controlled by the system. Use CLR to erase any mistakes. Use ENT to enter the value. The keypad disappears, and the new setting appears under PUMPS ACTIVE . 5-2-1-2 Setting Up Alarm Silences When an alarm occurs, a horn sounds and a strobe light f[...]

Page 24 of 60 mistakes. Use ENT to enter the value. The keypad disappears and the new setting appears under STROBE SUPPRESS . 4. On the “System Setup” screen (Figure 4), touch the HORN SILENCE button. A keypad pops up. 5. Enter the number of minutes (between 0 and 99) that you want the horn to stay off. If you want the horn to stay on as long a[...]

Page 25 of 60 5-2-2-1 Setting Up a Single Station 1. Go to the “Station Status” screen if needed. To reach this screen press station status button on any screen. Figure 5: 6” “Station Status” Screen 2. On the “Station Status” screen (Figure 5), touch the icon for the station you want to setup, and hold it for several seconds. The “S[...]

Page 26 of 60 Figure 6: 6” “Station Operator” Screen Before Setup 3. On the “Station Operator” screen (Figure 6), touch the STATION SETUP button. The “Station Setup” screen opens. Figure 7: 6” “Station Setup” Screen 4. On the “Station Setup” screen (Figure 7), adjust settings as required. Touching any box that appears in red[...]

Page 27 of 60 Touching RESET TO DEFAULTS in the lower right of the screen changes all the settings for this station back to their factory defaults. See pp. 46–49 for details on the options and their default settings. 5. As appropriate, setup the rest of the stations using either of the following methods: • Use the PREVIOUS or NEXT buttons to na[...]

Page 28 of 60 Figure 9: 6” Pump Setup Screen Before Setup 3. Adjust settings as required. Touching any box that appears in red (for “disabled”) toggles it to green (for “enabled”), and vice versa. Touching any box that appears in white gives you a keypad to enter a new value. Keypad entry works as with many ATM machines: the first digit y[...]

Page 29 of 60 5-2-4 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. 5-2-4-1 Setup Password If you define a password for setup personnel, then all settings [...]

Page 30 of 60 Note: If you want to protect the operator’s functions with a password, you must also define a setup password. If you leave the setup password undefined, then all users will have access to all functions. If you want two different levels of password protection, you must make the passwords diffe rent from each other. If the two passwor[...]

Page 31 of 60 To change the duration of the password, complete the following steps: 1. On the “System Setup” screen (Figure 4), touch the Operator Password Duration button or the Setup Password Duration button, depending on which password duration you want to change. A keypad pops up. 2. Enter the number of minutes (between 1 and 99) that you w[...]

Page 32 of 60 5-3 General Operation 5-3-1 Overview Your SCC4-38 controller electrically controls valves and solenoids to convey material from a central location to individual stations as ne eded. 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 yo[...]

Page 33 of 60 Figure 10: 6” “Station Status” Screen During Operation The status of each station is color-coded. You can see an explanation of each status by using the online help. To do so from this screen, complete the following steps: 1. Touch HELP . The “HELP Menu” screen opens. 2. Touch Station States . The “Station Symbols Help” [...]

Page 34 of 60 Additional basic information about each station (convey time, dump delay, and pump assignment) is available at the “Station Operator” screen. See page 38 for details. Detailed configuration settings for each station are available at the “Station Setup” screen. See page 47 for details about each of these settings. 5-3-2-2 Revie[...]

Page 35 of 60 The following table explains the status represented by each color at the Station Status screen. Color Label Description Gray outline Offline Pump is not enabled. The controller ignores any alarms. Green Ready Pump is off, waiting for demand from a station. Light Blue Idle Pump is on, waiting for demand from a station. If there is no d[...]

Page 36 of 60 Figure 12: 6” “Password Entry” Screen Enter the four-digit password (including any leading zeros). For example, if the password is 1, enter 0001 . Each digit appears as an “ * ” as you touch it. When you touch the fourth digit, the controller carries out your request. For example, it enables or di sables the requested pump o[...]

Page 37 of 60 Note: For a station to be available for the system, it must be enabled at the controller’s screen and its bypass switch must be in the “Convey” position. To enable or disable a station (or pump), complete the following steps: 1. Go to the “Station Stat us” (or “Pump Status”) screen, if needed. To reach this screen from a[...]

Page 38 of 60 5-3-2-6 Reviewing and Adjusting Basic Station Settings The Sterling controller has a “Station Operator” 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 Operator” screen, complete the following steps: 1. Go to the “Station Status ?[...]

Page 39 of 60 5-3-2-7 Navigating among the “Station Operator” Screens The controls at the top of the screen enable you to move among the “Station Operator” screens: • To display the screen for the next lower-numbered station (for example, to move from the screen for Station 15 to the screen for Station 14), touch PREVIOUS . • To display[...]

Page 40 of 60 To adjust a station’s convey time (or the unload time), complete the following steps: 1. Go to the “Station Operator” screen by touching and holding a station icon, or go to the “Station Setup” screen. 2. Touch CONVEY TIME . A keypad pops up. 3. Enter the number of seconds desired for convey time or unload time. Use CLR to e[...]

Page 41 of 60 controller finishes the current convey, if any, and resumes normal operation. 5-3-3 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 and of[...]

Page 42 of 60 5-3-3-2 Transferring Stations to a Standby Pump If a pump fails, you can transfer all of the controller’s station assignments for that pump to a standby pump. To do this, you must disable (take offline) both the source pump and the standby pump, and the standby pump must have no stations already assigned to it. The transfer operatio[...]

Page 43 of 60 Figure 15: 6” “Transfer To Standby Pump” Screen 6. Use CLR to erase any mistakes. Use ENT to enter the value. Figure 16: 6” Transfer To Standby Pump Button Note: 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 the[...]

Page 44 of 60 system begins using the pump. In addition, all “Station Operator” and “Station Setup” screens show the new pump assignment. Standby Pump Errors If the error message tells you to disable the source pump and/or the standby pump, touch RETURN at this screen, then PUMP STATUS at the “Pump Setup” screen. Take the pumps offline [...]

Page 45 of 60 5-3-4 Alarms 5-3-4-1 Reviewing Alarms To review your system’s alarms, touch Alarms on any screen. The “Alarm Log” screen appears, with the newest alarm listed first. Figure 17: 6” Alarm Log Screen To scroll up and down through the list, touch DOWN or UP at the top of the screen. 5-3-4-2 Silencing Alarms Whenever a new alarm oc[...]

Page 46 of 60 6 Maintenance No Periodic maintenance is required on this unit.[...]

Page 47 of 60 7 Configurable Settings This section describes the proper setup of the SCC4-38 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[...]

Page 48 of 60 Name Description Options Default Assigned to pump n Number (address) of the pump to which this station’s vacuum line is connected. 0–4 (0 = not assigned) 0 Special convey When this option is enabled, the station’s vacuum valve remains open for the convey time, even if the station is not demanding material and is indicating that [...]

Page 49 of 60 7-2 Options for Pump Setup Several of the items in this screen are not setup options but are instead intended for use du ring operation. These items (hour meter and transferring stations to a standby pump) are described in Chapter 5, which cover operation procedures. Name Description Options Default Idle Time Options 1 Idle time Lengt[...]

Page 50 of 60 8 Troubleshooting 8-1 General T roubleshooting Problem Possible Cause Solution The control panel is not turned on. Turn on the control panel. Fuse/circuit breaker in the power drop is blown/tripped. Replace/reset. The control panel doesn’t light up at all Control power switch is broken. Replace. Fuse in display is blown. Replace. Lo[...]

Page 51 of 60 8-2 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 wit[...]

Page 52 of 60 9 Options The following is a list of options that your controller may be equipped with: 230/1/50 Operation Required to operate with a 230/1/50 supply voltage. Audible/visual alarm Alarm light and horn assembly that can be remote mounted and wired into the controller to indicate an alarm condition. Ethernet Capability Enables SCC contr[...]

Page 53 of 60 10 Spare Parts List 10-1 Recommended S p are Part s List Quantity Sterling Part Number Description 1 A0569874 AB 20A Power Supply, 24VDC, #1606-XL480EP 1 A0569870 Relay Magnecraft #781XAXML 1 A0569859 Filter/Grill 1 A0540997 Fuse, MDL –1 1 A0542210 Fuse, MDL – 5 1 A0544793 Fuse, MDL – 15 5 A0542205 Fuse, MDL – 2.5 1 A0542209 F[...]

Page 54 of 60 11 Technical Assistance 11-1 Cont act Information for T echnical Assist ance Parts Department Call toll-free 7am–5pm CST [ 800 ] 423-3183 or call [414] 354-0970, Fax [414] 354-6421 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to Sterling engineering design specifications, which[...]

Page 55 of 60 11-2 Returned Material Policy 11-2-1 Credit Returns 1. Prior to the return of any material, authorization must be given by Sterling. A RMS number will be assigned for the equipment to be returned. 2. Reason for requesting the return must be given. 3. All returned material purchased from Sterling is subject to 15% ($75.00 minimum) rest[...]

Page 56 of 60 11-3 W arranty Sterling. warrants all equipment m anufactured by it to be free from defects in workmanship and material when used under recommended conditions. The Company’s obligation is limited to repair or replace FOB the factory any parts that are returned prepaid within one year of equipment shipment to the original purchaser, [...]

Page 57 of 60 12 Safety Tag Information 12-1 Controller Safety T ags 12-2 Controller Identification (Serial Number) T ag (Located on the side of the controller box) 5200 W. Clinton Ave. Milwaukee, WI 53223 Tel. (414) 354-0970 Fax (414) 354-6421 SCC CONTROL PANEL Model No. SCC4-38 Serial No. 31K0182 115 Volt 60 Hz 1 Ph Control Voltage 24VDC High Vol[...]

Page 58 of 60 13 Appendix Review electrical drawings supplied in the packet with the manual.[...]

Sterling warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions. The Company’ s obligation is limited to repair or replace (FOB the factory) any parts for a period of 12 months from in itial start-up or 18 months from the date of start-up, whichever is less, which, in t[...]

Auxiliary Equipment for the Process Industries PO Box 245018 5200 West Clinton Avenue • Milwaukee, WI 53224-9518 (414) 354-0970 • Fax (414) 354-6421 Scrap Process Heating/ Automated Material Recovery Systems Cooling Parts Removal Processing[...]