SCC 2-Pump 12-Station Controllers
Part Number: 882.00249.00
Bulletin Number: CV3-650
Effective: 10/25/05
Write Down Your Serial Numbers Here For Future Reference:
_________________________
_________________________
_________________________
_________________________
_________________________
_________________________
We are committed to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change without notice.
DCN No. ____________
© Copyright 2005
All rights reserved.
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Shipping Information
Unpacking and Inspection
You should inspect your equipment for possible shipping damage. Thoroughly check the
equipment for any damage that might have occurred in transit, such as broken or loose wiring
and components, loose hardware and mounting screws, etc.
In the Event of Shipping Damage
According to the contract terms and conditions of the Carrier, the responsibility of the
Shipper ends at the time and place of shipment.
Notify the transportation company’s local agent if you discover damage
Hold the damaged goods and packing material for the examining agent’s inspection. Do not
return any goods before the transportation company’s inspection and authorization.
File a claim with the transportation company. Substantiate the claim by referring to the
agent’s report. A certified copy of our invoice is available upon request. The original Bill of
Lading is attached to our original invoice. If the shipment was prepaid, write us for a
receipted transportation bill.
Advise customer service regarding your wish for assistance and to obtain an RMA (return
material authorization) number.
If the Shipment is Not Complete
Check the packing list as back-ordered items are noted on the packing list. In addition to the
equipment itself, you should have:
; Bill of lading
; Packing list
; Operating and Installation packet
; Electrical schematic and panel layout drawings
; Component instruction manuals (if applicable)
Re-inspect the container and packing material to see if you missed any smaller items during
unpacking.
If the Shipment is Not Correct
If the shipment is not what you ordered, contact the shipping department immediately. For
shipments in the United States and Canada, call 1 (630) 595-1060; for all other countries, call
our international desk at (630) 595-1060. Have the order number and item number available.
Hold the items until you receive shipping instructions.
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Chapter 1: Safety
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Returns
Do not return any damaged or incorrect items until you receive shipping instructions from the
shipping department.
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.
No credit will be issued for material that is not within the manufacturer’s warranty period
and/or in new and unused condition, suitable for resale.
Warranty 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 returns are to be shipped prepaid.
The invoice number and date or purchase order number and date must be supplied.
After inspecting the material, a replacement or credit will be given, at the manufacturer’s
discretion, if the item is found to be defective in materials or workmanship. Purchased
components are covered under their specific warranty terms.
2–Pump 12-Station Controllers
Chapter 1: Safety
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Table of Contents
CHAPTER 1: SAFETY ................................................................6
1-1
How to Use This Manual .............................................................................................6
Safety Symbols Used in this Manual.....................................................................6
Warnings and Precautions ..........................................................................................7
Responsibility ..............................................................................................................8
General Responsibility...........................................................................................8
Operator Responsibility.........................................................................................9
Maintenance Responsibility...................................................................................9
Reporting a Safety Defect .....................................................................................9
1-2
1-3
CHAPTER 2: FUNCTIONAL DESCRIPTION............................10
2-1
2-2
2-3
Models Covered in This Manual................................................................................10
General Description...................................................................................................10
Standard Features.....................................................................................................11
Mechanical Features...........................................................................................11
Electrical Features...............................................................................................11
Controller Features..............................................................................................11
Optional Features......................................................................................................11
Safety Devices and Interlocks...................................................................................12
Safety Circuit Standards......................................................................................12
Fail Safe Operation .............................................................................................12
Safety Device Lock-Outs.....................................................................................12
2-4
2-5
CHAPTER 3: INSTALLATION ..................................................14
3-1
3-2
3-3
Uncrating...................................................................................................................14
Mounting the Control Panel.......................................................................................14
Electrical Connections...............................................................................................14
Making Control Panel Power Drop Wiring Connections......................................14
Connecting the Control Panel to Vacuum Hoppers.............................................15
Connecting the Control Panel to the Pump Package ..........................................15
Main Power .........................................................................................................17
Setup.........................................................................................................................17
Gaining Access to the Menu System...................................................................18
Station Settings Menu .........................................................................................19
Pump Settings Menu...........................................................................................27
System Settings Menu ........................................................................................32
Service Settings Menu ........................................................................................33
Saving Controller Settings to Flash Memory .......................................................33
Initial Startup .............................................................................................................33
3-4
3-5
CHAPTER 4: OPERATION ........................................................34
4-1
Startup.......................................................................................................................34
Setting Load Times .............................................................................................34
Enabling and Disabling Individual Stations..........................................................35
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4-2
Controller Description and Operation........................................................................35
Text Area.............................................................................................................35
Station Icons........................................................................................................37
Status Indicators..................................................................................................38
Controller Keypad................................................................................................39
4-3 Operation.....................................................................................................................40
Operation States .................................................................................................40
4-4
Shut-Down.................................................................................................................42
CHAPTER 5: MAINTENANCE...................................................43
Updating BIOS Software .....................................................................................43
CHAPTER 6: TROUBLESHOOTING.........................................46
6-1
General Troubleshooting...........................................................................................46
Controller Recovery using Flash Memory Technology........................................48
CHAPTER 7: APPENDIX ..........................................................49
7-1
Warranty....................................................................................................................49
Warranty Specifications.......................................................................................49
Warranty Restrictions..........................................................................................49
Warranty Liabilities..............................................................................................50
Customer Responsibilities...................................................................................50
Drawings and Diagrams............................................................................................51
Spare Parts List.........................................................................................................52
Controller Identification (Serial Number) Tag............................................................56
Technical Assistance (Contact Information)..............................................................56
Parts Department ................................................................................................56
Service Department.............................................................................................56
Sales Department................................................................................................56
Contract Department...........................................................................................56
7-2
7-3
7-4
7-5
CHAPTER 8: SERVICE ONLY INFORMATION ........................57
8-1
Service Settings Menu ..............................................................................................57
Setting the Ramp Up Time ..................................................................................57
Setting the Ramp Down Time..............................................................................58
Setting the Pump Stage Time..............................................................................59
Setting the LCD Blink Delay................................................................................60
Setting the Hi Vacuum Sensor Delay ..................................................................61
Setting the Hi Vacuum Vent Delay ......................................................................62
Setting the Hi Vacuum Load Count .....................................................................63
Using the Installation Aids Menus .......................................................................64
Other Controller Restricted Areas .............................................................................67
Using the OEM Service Menu .............................................................................67
Recovering Passwords........................................................................................68
Restoring the Controller to Factory Defaults .......................................................69
8-2
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Chapter 1: Safety
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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. Additional sections within the manual provide instructions for installation, pre-
operational procedures, operation, preventive maintenance, and corrective maintenance.
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup
of the equipment. We can also provide the assistance of a factory-trained technician to help
train your operator(s) for a nominal charge. This section includes instructions, checks, and
adjustments that should be followed before commencing with operation of the equipment.
These instructions are intended to supplement standard shop procedures performed at shift,
daily, and weekly intervals.
The Operation chapter includes a description of electrical and mechanical controls, in
addition to information for operating the equipment safely and efficiently.
The Maintenance chapter is intended to serve as a source of detailed assembly and
disassembly instructions for those areas of the equipment requiring service. Preventive
maintenance sections are included to ensure that your equipment provides excellent, long
service.
The Troubleshooting chapter serves as a guide for identification of most common problems.
Potential problems are listed, along with possible causes and related solutions.
The Appendix contains technical specifications, drawings, schematics, and parts lists. A
spare parts list with part numbers specific to your machine is provided with your shipping
paperwork package. Refer to this section for a listing of spare parts for purchase. Have your
serial number and model number ready when ordering.
Safety Symbols Used in this Manual
The following safety alert symbols are used to alert you to potential personal injury hazards.
Obey all safety messages that follow these symbols to avoid possible injury or death.
Danger!
Warning!
Caution!
DANGER indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation or practice which,
if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation or practice which, if
not avoided, may result in minor or moderate injury or in property
damage.
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Chapter 1: Safety
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Controller Safety Tags
Read Operation and Installation
Manual
High Voltage Inside
Enclosure
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.
To avoid possible personal injury or equipment damage when installing, operating, or
maintaining this equipment, use good judgment and follow these safe practices:
; Read and follow these operation and installation instructions when installing,
operating, and maintaining this equipment. If these instructions become
damaged or unreadable, additional copies are available from the manufacturer.
; Follow all SAFETY CODES.
; Wear SAFETY GLASSES and WORK GLOVES.
; Work only with approved tools and devices.
; Disconnect and/or lock out power before servicing or maintaining the equipment.
; Use care when LOADING, UNLOADING, RIGGING, or MOVING this
equipment.
; Operate this equipment within design specifications.
; OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.
You should remove the fuses and carry them with you.
; Make sure the equipment and components are properly GROUNDED before you
switch on power.
; Use extreme caution when working with your conveying system. HIGH VACUUM
can be dangerous. Keep body parts, tools, clothing, and debris away from vacuum
inlets.
; When welding or brazing in or around this equipment, make sure VENTILATION is
ADEQUATE. PROTECT adjacent materials from flame or sparks by shielding with
sheet metal. An approved FIRE EXTINGUISHER should be close at hand and
ready for use if needed.
; Do not restore power until you remove all tools, test equipment, etc., and the
equipment and related components are fully reassembled.
; Only PROPERLY TRAINED personnel familiar with the information in this
manual should work on this equipment.
We have long recognized the importance of safety and have designed and manufactured our
equipment with operator safety as a prime consideration. We expect you, as a user, to abide
by the foregoing recommendations in order to make operator safety a reality.
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Chapter 1: Safety
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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.
Each individual must take responsibility for observing the prescribed safety rules as outlined.
All warning and danger signs must be observed and obeyed. All actual or potential danger
areas must be reported to your immediate supervisor.
General Responsibility
No mater who you are, safety is important. Owners, operators and maintenance personnel
must realize that every day, safety is a vital part of their jobs.
If your main concern is loss of productivity, remember that production is always affected in a
negative way following an accident. The following are some of the ways that accidents can
affect your production:
• Loss of a skilled operator (temporarily or permanently)
• Breakdown of shop morale
• Costly damage to equipment
• Downtime
An effective safety program is responsible and economically sound.
Organize a safety committee or group, and hold regular meetings. Promote this group from
the management level. Through this group, the safety program can be continually reviewed,
maintained, and improved. Keep minutes or a record of the meetings.
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 manual as a guide to equipment safety. This manual contains safety
warnings throughout, specific to each function and point of operation.
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Chapter 1: Safety
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Operator Responsibility
The operator’s responsibility does not end with efficient 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 incentive rates, or
through a casual attitude toward machinery formed over a period of months or years. Your
employer probably has established a set of safety rules in your workplace. Those rules, this
manual, or any other safety information will not keep you from being injured while operating
your equipment.
Learn and always use safe operation. Cooperate with co-workers to promote safe practices.
Immediately report any potentially dangerous situation to your supervisor or appropriate
person.
Maintenance Responsibility
Proper maintenance is essential to safety. If you are a maintenance worker, you must make
safety a priority to effectively repair and maintain equipment.
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.
Be sure that all non-current carrying parts are correctly connected to earth ground with an
electrical conductor that complies with current codes. Install in accordance with national and
local codes.
When you have completed the repair or maintenance procedure, check your work, remove
your tools. Rigging, and handling equipment.
Reporting a Safety Defect
If you believe that your equipment has a defect that could cause injury, you should
immediately discontinue its use and inform the manufacturer.
The principle factors that can result in injury are failure to follow proper operating procedures
(i.e. lockout/tagout), or failure to maintain a clean and safe working environment.
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Chapter 1: Safety
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Chapter 2: Functional Description
2-1 Models Covered in This Manual
This manual provides operation, installation, and maintenance instructions for 2-Pump, 12-
Station 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.
The 2-Pump, 12-Station Conveying Controller is a programmable logic controller, with 24
VDC or 115 VAC control circuit, easy-to-use 16-key operator interface keypad and optional
audible/visual alarm.
2-2 General Description
Our systems create vacuum for the automatic pneumatic conveying of most free-flowing, dry,
pelletized, or granular materials in a central material handling system. Material
characteristics determine the type of equipment needed to convey the material.
A typical use for our equipment is an in-plant distribution system for plastic processing
plants.
Our central vacuum systems are as varied as the applications they service. The tubing and
equipment furnished in our system is designed to convey the material(s) specified at the time
of purchase at specific rates and distances.
We can advise you on your system capabilities based on system makeup, distance, material,
and conveying rates you want.
System capacity is directly affected by the pressure drop in the overall system, such as
number of material line bends, pipe length, Y-tubes, T-tubes, etc.
Note: Vacuum leaks occuring anywhere in your system reduce capacity.
Use the minimum effective amount of vinyl flex hose to maximize material line efficiency.
Keep material lines as straight as possible. Refer to the Mechanical Components Product
manual (Part No. A0536580) for installation recommendations.
2–Pump 12-Station Controllers
Chapter 2: Functional Description
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2-3 Standard Features
Mechanical Features
Time-fill Capability. The length of time a station’s vacuum 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 drawn in. The vacuum valve will close when material covers the station’s
volume-fill proximity sensor or this time elapses, whichever comes first.
Pump Blowback Filter Cleaning Outputs. When this feature is enabled, the controller
periodically sends compressed air backward through the pump’s air filter to dislodge
accumulated dust and debris.
Electrical Features
• 115/1/60 supply voltage
• 24 VDC control voltage
• Single-point power and ground connection
• Non-fused disconnect switch, lockable
• Branch circuit fusing
• Fully accessible NEMA 12-style electrical control enclosure
Controller Features
• Monitors Station status and Pump status
• Allows operator to transfer stations to a standby pump when a pump fails
• Electronic time delay between pump startups to prevent an excessive power demand at
your facility
2-4 Optional Features
Options marked with “*” indicate options that can be factory installed or retrofitted in the
field.
230/1/60 Operation. Required to operate with a 230/1/60 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.
CE Package for 220/1/50 Operation. Required in Europe and other areas that need
220/1/50 supply voltage.
2–Pump 12-Station Controllers
Chapter 2: Functional Description
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2-5 Safety Devices and Interlocks
This section includes information on safety devices and procedures that are inherent to the
Controller. This manual is not intended to supersede or alter safety standards established by
the user of this equipment. Instead, the material contained in this section is recommended to
supplement these procedures in order to provide a safer working environment.
At the completion of this section, the operator and maintenance personnel will be able to do
the following:
•
•
•
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.
Various agencies have contributed to the establishment of safety standards that apply to the
design and manufacture of automated equipment. The Occupational Safety and Health
Administration (OSHA) and the Joint Industrial council (JIC) are just a few of the
organizations that have joined with the plastics industry to develop safety standards.
Every effort has been made to incorporate these standards into the design of the conveying
system; however, it is the responsibility of the personnel operating and maintaining the
equipment to familiarize themselves with the safety procedures and the proper use of any
safety devices.
Fail Safe Operation
If a safety device or circuit should fail, the design must be such that the failure causes a
“Safe” condition. As an example, a safety switch must be a normally open switch. The switch
must be held closed with the device it is to protect. If the switch fails, it will go to the open
condition, tripping out the safety circuit.
At no time should the safety device fail and allow the operation to continue for example, if a
safety switch is guarding a motor, and the safety switch fails, the motor should not be able to
run.
Safety Device Lock-Outs
Some safety devices disconnect electrical energy from a circuit. The safety devices that are
used in this Controller are primarily concerned with electrical power disconnection.
WARNING! Always disconnect and lockout all electrical power and pneumatic (i.e. compressed air)
sources prior to servicing the 2-Pump, 12-Station Controller. Failure to do so may
result in serious injury. No one but the person who installed the lockout may remove
it.
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Chapter 2: Functional Description
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Chapter 3: Installation
3-1 Uncrating
2-Pump, 12-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. Lift slowly and only high enough to clear the skid. Use a pry bar
if necessary to carefully remove the skid from the unit.
4. Lower slowly.
3-2 Mounting the 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 that gives your operator
access to the control. The panel requires a low voltage power drop as listed on the serial tag.
3-3 Electrical Connections
Refer to local electrical codes, the schematic and connection diagrams supplied with this unit
and the serial tag for wiring considerations. Run all wiring in conduit if codes require it.
Making Control Panel Power Drop Wiring Connections
Plug the power cord supplied with your unit into a properly grounded, 3-slot, 115/1/50-60 VAC
or 230/1/50-60 VAC receptacle specified on the control panel serial tag. The control enclosure
draws less than five (5) amps during normal operation at 115/1/50-60 VAC.
Caution!
We recommend that you protect PLC memory by providing the control
panel with a dedicated circuit, a true earth ground, and a spike/surge
protector.
2–Pump 12-Station Controllers
Chapter 3: Installation
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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 voltage, distance, number of vacuum
hoppers, and the number of wires in each raceway. Consult a qualified
electrician.
1. On 24 VDC control voltage systems, run a common +24 VDC wire and a common 0
(zero) VDC wire from the controller to each vacuum hopper in the system.
Note: For safety, make sure that the +24 volt line is fused. The size of the
fuse depends on the number of stations installed.
A 4 amp fuse is sufficient for a 12-station installation.
2. On all systems, run two wires to each vacuum hopper: one each from the controller
to the Bin-Full switch (LS) and to the Atmospheric/Sequence-T solenoid (SOL)
valve.
3. Make sure that the solenoid and the proximity switch (if supplied) on vacuum
hoppers are the same voltage (24 VDC) as the 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 raceway. Consult a qualified electrician.
5. Properly ground each hopper to reduce static build up generated by material
conveying.
Connecting the Control Panel to the Pump Package
1. Wire the pump package motor starter coil (M) to the terminal provided in the control
panel enclosure.
2. Wire the pump package vacuum relief valve solenoid (SOL A) to the terminal
provided in the control panel enclosure.
3. Wire the pump package vacuum switch (VS) to the terminal located in the control
panel enclosure.
4. On vacuum pumps with blowback, wire the pump package blowback solenoid (SOL
B) to the terminal located in the control panel enclosure.
5. On 24 VDC control voltage systems, run a common +24 VDC wire and a common 0
(zero) VDC wire from the controller to each pump package in the system.
2–Pump 12-Station Controllers
Chapter 3: Installation
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Figure 1: Typical 24-Volt Junction Box Wiring Diagram
SOL A/B
KAY VALVE
LOCATED ON
PUMP
GRD
FROM CONTROLLER OUTPUT
FOR VACUUM SOLENOID
VACUUM
(NEUTRAL)/(+24VDC)
TO TERMINAL A1 (NEUTRAL)/(+24 VDC)
ON MOTOR STARTER (M)
COMMON
L1
L2
TO
JUNCTION
BOX
L3
FROM CONTROLLER OUTPUT
FOR BLOWBACK SOLENOID
BLOWBACK
A1
3
5
L3
1
L1
L2
13
M
A09
T1
2
T2
4
T3
6
14
TO UPPER VALVE
PROCESS AIR
CONNECTION
A2
A2
J1
TEST
96
RESET
TRIPPED
97
95
98
OL
FROM CONTROLLER OUTPUT
FOR PUMP MOTOR STARTER
T
1
T
2
T
3
2
4
6
T1
T2
T3
TO MOTOR
(MTR)
(115VAC)/(0VDC)
VS
TO CONTROLLER INPUT FOR
PUMP HIGH-VACUUM
3 PHASE / 4 WIRE SERVICE AND
FUSED DISCONNECT SWITCH TO
BE PROVIDED BY CUSTOMER
SUBPANEL LAYOUT AND CONNECTION DIAGRAM
A0544675
LEGEND
(115V AC AND 24V DC)
FIELD WIRING
DISC
INTERNAL
WIRING
M
OL
FU
FU
FU
L1
L2
L3
L1
L2
L3
T1
T2
T3
WIRE LUG
MTR
5 HP PUMP
POWER WIRING
GRD
1PS
TO CONTROLLER INPUT FOR
PUMP HIGH VACUUM
(115V AC)
N. O.
(NEUTRAL)
1M
J1
VACUUM PUMP
FROM CONTROLLER OUTPUT
1M
MOTOR STARTER
FOR MOTOR STARTER
96
95
A2
A1
1SOL
VACUUM
FROM CONTROLLER OUTPUT
FOR VACUUM PUMP SOLENOID
SOLENOID ON PUMP
1SOL
BLOWBACK SOLENOID
ON PUMP
FROM CONTROLLER OUTPUT
FOR PUMP BLOWBACK SOLENOID
CONTROL WIRING
2–Pump 12-Station Controllers
Chapter 3: Installation
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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 fuses. Also, the configuration of the fuse holder
determines the voltage setting of the controller (115/220 VAC).
Marked on the faceplate of the fuse holder shows the configuration for the desired voltage.
Using a small screwdriver, remove the fuse holder. To select the operating voltage, align the
arrow marker on the holder and the switch as shown in the following section.
The 12 station controller has a standard IEC power cord. Plug the cord into any standard 115
VAC outlet. If you selected the 220 VAC option, remove the end connector and install a
standard 220 VAC plug. Doing so does NOT effect the controllers warranty.
DC Controller Power Sources
Although main controller power is 115/220 VAC, control power is actually unregulated 24
VDC. The 24 VDC control power supplies the power for all solenoids, sensors, and the
controller itself. The unregulated supply can deliver up to five (5) amps of continuous current
to drive a very large system.
Inputs
• Station connections
• High vacuum connections
• System error connections
Outputs
• Station connections
• Pump/blowback
• Spare
3-4 Setup
This section provides the procedures for configuring your 2-pump, 12-station controller.
Configuration of your controller includes setting the number of stations and pumps, setting
variables such as convey time and blow-back interval, and setting up passwords. We
recommend that you carry out these procedures in the order given here.
Note: Before carrying out these procedures, install all equipment as
described in this section and in the Mechanical Components manual.
To help you set up the controller quickly, this section walks you through the setup using the
menu system. This procedure will work for most applications, but you may need to perform
some minor adjustments afterwards to achieve the best conveying performance.
Note: The controller must be in Offline mode to permit access to the menu
system.
2–Pump 12-Station Controllers
Chapter 3: Installation
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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 system to bring you up one level.
Figure 2: Menu Tree Structure
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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 system.
2. Continue to press the ENTER/MENU key until the following screen displays:
STATION SETTINGS?
NO/YES
To enter the Station settings menu:
• Press the YES key.
To bring you up one level within any menu:
• Press the CLEAR key.
Operation Mode, Station Settings Menu
In most applications, each loading station can use different types of hoppers. The two
common types are standard hoppers and sight glass loaders. You’ll need to set up your
controller for the type of hopper you are using for each of the 12 loading stations.
The first submenu in the Station Settings menu is the Operation Mode.
To enter the Operation Mode submenu:
• Press the YES key at the following screen prompt.
OPERATION MODE?
NO/YES
Each station in the conveying system can be a standard configuration or a sight glass
configuration. Each hopper design operates in a slightly different manner.
In Standard mode, a flapper sensor detects a demand on the system. The volume fill sensor
senses when the hopper is filled with material. These two (2) sensors are wired in series and a
single input of the controller reads them. The controller determines the difference in the
signals, depending on load sequence timing.
In Sight Glass mode, only one single sensor detects demand. This mode has no volume fill
operation, and you’ll need to disable that function. Properly setting the operation mode lets
the controller correctly sequence station loading.
Upon entering the Operation Mode menu, the controller prompts you to set all 12 stations to
Normal (default) mode.
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To set all the stations to Normal mode and return to the Station Settings menu:
• Press the YES key at the following screen prompt.
ALL NORMAL MODE?
NO/YES
This function lets you use the fast setup feature of the controller. Normal mode is the factory
default, so if no sight glass loaders are on your system, you won’t need to alter this setting.
Pressing the NO key moves to the All Sight Glass Mode screen. Again, this function lets you
quickly change all stations to Sight Glass mode if all stations have sight glass loaders.
ALL SIGHTGLASS MODE?
NO/YES
To move on to the individual settings screen:
• Press the NO key.
The following screen displays.
STATION: 1 NORMAL
Y=NORMAL N=SIGHTGLS
Starting with Hopper 1, the controller now lets you individually set the operation mode of
each station.
1. Press the YES key to set the station to Normal mode.
2. Press the NO key to set the station to the Sight Glass mode.
3. Press the SET key to save the new setting into controller memory and increment to
the next station in sequence.
4. Press the CLEAR key to exit to the Station Settings menu.
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Set Dump Delay, Station Settings Menu
The second submenu in Station Settings is the Set Dump Delay submenu.
SET DUMP DELAY?
NO/YES
To set dump delay time:
• Press the YES key.
After a hopper finishes loading, the next hopper in the queue usually gets loaded. The time it
takes to load the new hopper(s) usually gives ample time for the first hopper to dump its
material. However, in a situation where a single hopper is being loaded, a demand may be
generated during the dump cycle from material catching on the flapper switch. This may
cause an inadvertent load while the hopper is still dumping material.
To prevent this from occurring, a dump delay timer starts after each hopper loads. The
controller then waits until the timer elapses before loading the station. Setting this timer is
critical to an efficiently operating conveying system. If you set the timer too short,
inadvertent loads result. If you set the timer too long, unneccessary sequence delays occur.
To determine the proper setting, fill the hopper with material and measure the time it takes to
dump the material. Add one second (1 sec.) for smaller hoppers and three seconds (3 sec.) for
larger hoppers to this time. Enter the setting into controller memory using the following
procedure. You may have to adjust the time setting for the best overall system efficiency.
TO SELECT A STATION
PRESS STATION <1-12>
To alter station dump delay time:
• Select the station requiring the dump delay time change, and press the related Station
STnn key. nn is the number of the station you want to alter.
The following screen displays.
DUMP DELAY 11: 15.0s
PRESS ENTER TO SAVE
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The screen displays the station you selected (11 in the above example), and the current dump
delay time setting. Using number keys 1 to 0, enter the new dump delay time (in seconds)
into controller memory. Keep in mind that the value shifts to the left as you enter. Use the 0
key to shift to the next multiple of ten.
To exit from the Dump Delay menu and return to the Station Settings menu:
• Press the CLEAR key.
To save the new value and escape from the Dump Delay menu:
• Press the ENTER key.
To save the new value to the controller memory and increment to the next station in the
sequence:
• Press the SET key.
If you press the SET key without entering a value, the original value is retained and the
controller moves to the next station in the sequence.
Set Input Delay, Station Settings Menu
The third submenu under Station Settings is the Set Input Delay submenu.
To set input delay time:
• Press the YES key.
The following screen displays.
SET INPUT DELAY?
NO/YES
The Input Delay function protects the system from erroneous inputs caused by noise or
mechanical vibration. The signal must be present for the input delay time setting duration for
the input to be recognized.
To alter input delay time:
• Press the YES key.
The following screen displays.
TO SELECT A STATION
PRESS STATION <1-12>
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To alter station input delay time:
• Select a station to alter, then press the related Station STnn key. nn is the station
number you selected.
The screen displays the selected station (11 in the following example) and the current input
delay time setting.
INPUT DLY 11: 0.250s
PRESS ENTER TO SAVE
• Using number keys 1 to 0, enter the new time in seconds into controller memory.
Keep in mind that the value shifts to the left as you enter it. Use the Zero 0 key to shift
to the next multiple of ten.
To exit from the Input Delay time menu and return to the Station Settings menu:
• Press the CLEAR key.
To save the new value and escape from the Input Delay menu:
• Press the ENTER key.
To save the new value to the controller memory and increment to the next station in the
sequence:
• Press the SET key.
If you press the SET key without entering a value, the original value is retained and the
controller moves to the next station in the sequence.
Set Station Alarms, Station Settings Menu
The fourth submenu under Station Settings is the Set Station Alarms submenu.
To set station alarms:
• Press the YES key.
The following screen displays.
SET STATION ALARMS?
NO/YES
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Each station has its own No Convey alarm settings. You can enable or disable alarms as
needed. If a station doesn’t receive (or dump) material after a user definable number of load
attempts, the controller activates an alarm condition. Perform the following procedure to set
alarm conditions.
To alter the Input Delay time:
• Press the YES key.
The following screen displays.
TO SELECT A STATION
PRESS STATION <1-12>
To alter stations alarm settings:
• Select a station to alter, then press the related Station STnn key. nn is the station
number you selected.
The screen displays the selected station (11 in the following example) and the current
station alarm setting.
ALARM 11: ENABLED
Y=ENABLE N=DISABLE
To enable the alarm:
• Press the YES key.
The alarm is enabled on the station you selected.
If you want to disable the alarm:
• Press the NO key.
The alarm is disabled on the station you selected.
The controller increments to the next station in sequence.
To retain the original setting:
• Press the SET key.
The next station in the sequence displays.
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To exit from the Alarm Setting time menu and return to the Station Settings menu:
• Press the CLEAR key.
ALARM AFTER 3 LOADS
PRESS ENTER TO SAVE
Assigning a Pump to a Station
This function lets you easily set all 12 stations.
From the main operating screen:
1. Press the MENU key until the following screen displays:
STATION SETTINGS?
NO/YES
To enter the Station Settings menu:
1. Press the YES key.
2. Press the MENU key again until the following screen displays:
ASSIGN PUMP>STATION?
NO/YES
To assign pumps to stations:
1. Press the YES key.
The following screen displays:
TO SELECT A STATION
PRESS HOPPER <1-12>
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To assign a station to a pump:
1. Press the related station ST key.
The following menu screen displays:
STATION 10: PUMP 1
SELECT PUMP 1 OR 2
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.
To save the new setting and display the Station Assignment screen:
• Press the ENTER key.
To save the new pump assignment and increment to the next station sequence:
• Press the SET key.
To exit the Station Settings menu:
1. Press the CLEAR key.
2. Press the CLEAR key repeatedly to exit to the next higher menu, or to exit the menu
system.
Caution!
You must assign the correct pump to a hopper before starting the
conveying process.
Failure to properly assign pumps can result in damage to the conveying
system!
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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 function tells the controller how
many pumps are connected to the system and how the pumps are to be controlled.
You can select two pump modes: Single Pump mode and Dual Pump mode. In Single Pump
mode (default), one (1) pump is used to convey material to all 12 stations. In Dual Pump
mode, two (2) pumps are used simultaneously, resulting in a more efficient conveying
process.
From the main operating display (OFFLINE):
1. Press the MENU key repeatedly until the screen displays the following:
PUMP SETTINGS?
NO/YES
To enter the Pump Settings menu:
1. Press the YES key.
2. Press the NO or MENU key repeatedly until the screen displays the following:
PUMP MODE?
NO/YES
To enter the Pump Mode setting menu:
1. Press the YES key.
The screen displays the following:
SET PUMP MODE?
Y=SINGLE N=DUAL
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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:
SET ACTIVE PUMP
SELECT PUMP 1 OR 2
Selecting Dual Pump mode requires ALL stations to be assigned to a pump. Do so in the
Station Settings Menu.
The pump mode is now set.
To exit from the Pump Settings Menu:
1. Press the CLEAR key.
Note: You can always press the CLEAR key repeatedly to bring you up one
level in the menu system.
Selecting the Dual Pump option immediately returns you to the Pump Settings menu.
Caution!
If you select Dual Pump mode, you MUST assign each station to a pump.
Each station defaults to Pump 1 if not assigned.
Caution!
Not assigning a station to its related pump can cause damage to the loading
system!
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Changing Blowback Settings, Pump Settings Menu
As an option, you can equip the conveying system filter chamber with a blowback feature to
pulsate compressed air through the filter. This function cleans the filter after a pre-set number
of load sequences.
To set up the controller blowback feature, enter the Pump Settings menu, then:
• Press the MENU key until the Blowback Settings prompt screen displays:
BLOWBACK SETTINGS?
NO/YES
• Press the YES key to alter the blowback settings.
The following screen displays.
SELECT PUMP 1 OR 2
USE KEYPAD TO ENTER
Each pump can have separate blowback settings. To alter pump settings, select a pump:
• Using the keypad, enter the pump number (1 or 2).
The following screen displays.
ENABLE BLOWBACK?
NO/YES
To disable the blowback feature:
• Press the NO key.
The screen returns to the Pump Settings menu.
If you want to enable the blowback feature:
• Press the YES key.
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The screen continues to the next prompt.
BLOWBACK PULSES: 10
SETTING FOR PUMP 1
The first setting for the blowback feature is the number of blowback pulses. This setting
determines the number of pulses of air that will be pushed through the filter during the
blowback cycle. It has a range of 1 to 99, with a factory default of ten (10) pulses.
• Using the number keys, enter the new blowback pulse setting, then press ENTER to
save the new value.
To save the current set value and move to the next menu item:
• Press ENTER without entering a value.
If a value is entered beyond the limits such as less than 1 or greater than 99, the screen
displays question marks ?? in the settings area. If this happens:
• Simply re-enter the new value or press CLEAR to restore the value to the original
setting.
If you’ve properly entered the value, the following screen displays.
ON TIME: 0.500 s
SETTING FOR PUMP 1
Next, set the Pulse On time value. This is the duration that the blowback solenoid is turned
ON.
• Using the number keys, enter the new On Time setting, then press ENTER to save the
new value.
To save the current On Time setting and move to the next menu item:
• Press ENTER without entering a value.
The following screen displays.
OFF TIME: 0.500 s
SETTING FOR PUMP 1
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Next, set the Pulse Off time value. This is the 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 setting and move to the next menu item:
• Press ENTER without entering a value.
The following screen displays.
BLBK AFTER 12 LOADS
SETTING FOR PUMP 1
The last blowback setting tells the controller how many loads on stations assigned to the
selected pump must be completed before starting a blowback cycle.
After you define this setting, the controller returns to the Pump Settings menu screen.
Idle Delay Time Settings, Pump Settings Menu
After a station load is complete, the controller looks for a new demand on the system. If all
stations are satisfied with material, the controller enters IDLE (No Activity) state. During this
state, the atmospheric vent valve is open and vacuum vents. During IDLE (No Activity) state
time, the controller monitors inputs looking for a demand on the system. Eventually, if no
demand is on the system, the controller shuts down the pump(s) and waits for a demand
signal. This process saves energy and prolongs the life of the vacuum pump.
The Idle time is the length of time in which the controller waits with no demand until the
pump is turned off.
To set up the controller Idle Delay time, enter the Pump Settings menu, then:
• Press the MENU key until the Idle Delay Time prompt screen displays as follows:
IDLE DELAY TIME?
NO/YES
• Press the YES key to alter the Idle Delay time.
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The following screen displays.
SELECT PUMP 1 OR 2
USE KEYPAD TO ENTER
Each pump can have separate idle delay times. To alter idle delay, select a pump:
• Using the keypad, enter the pump number (1 or 2).
The following screen displays.
IDLE TIME: 10.000 s
SETTING FOR PUMP 1
• Using the keypad, enter the idle delay time.
The controller is now properly set up and ready for operation.
System Settings Menu
Audio Alarm Time
Video Alarm Time
Password Enable/Disable
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Service Settings Menu
The settings in this menu are not meant to be modified 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 type of memory
writes and reads like normal memory, but the advantage is that the data is retained after
power is shut down. If you alter any parameter, the controller saves the new data to flash
memory. This procedure takes several seconds and takes all the processor time. For this
reason, the controller does not write to flash memory while running. Any changes to load
times are saved when you press the STOP key and the controller shuts down completely.
Note: Let the controller save parameter changes to flash memory completely
before you shut down the controller.
It is also possible for a write error to occur during this operation. If this occurs, the system
always saves a backup of the data. See the Maintenance Section for instructions on how to
restore the previous settings.
3-5 Initial Startup
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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 station you want to alter:
TO SELECT A STATION
PRESS STATION <1-12>
To select a station to alter:
1. Press the related station ST key of the station you want to alter.
The screen prompts you to enter a load time in seconds.
LOAD TIME 10: 63sec
PRESS ENTER TO SAVE
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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 increments to the next station in sequence.
Press the SET key without entering a value to retain the original value in controller memory.
The load time range of the station is from 1 to 360 seconds. Entering values beyond this
range result in the screen displaying three (3) question marks (???).
To abort this erroneous entry and return to normal operation mode:
1. Press the CLEAR key.
Enabling and Disabling Individual Stations
Except while you are in the menu system and when you are altering system parameters, you
can enable or disable any station in the system.
To enable or disable a loading station:
1. Press the STnn key (where nn is the station number you want) to toggle between
station enable or disable mode.
4-2 Controller Description and Operation
Your 12-station controller system has been designed for quick setup and easy, low
maintenance operation. Before you begin operation, make sure you become familiar with the
functions and features of your controller.
The controller screen displays the status of the controller at any given time. By a simple
glance, you can know exactly what the controller is doing. The screen has three areas:
• Text area, a 2-line, 20-character screen
• Station icons for displaying the status of each individual station
• Status indicators for displaying the operation of the pump.
Text Area
The text area is separated into four (4) sections. The appearance of the screen depends on the
setting of the Pump mode.
SECTION 1 SECTION 2
SECTION 3 SECTION 4
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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 area display. The lower left corner displays the load time in seconds. When a station is
loading, this area displays how much time elapses during the load cycle. If no station is
active, three (3) hyphens ---display.
The upper right area displays the status of the control. This section displays the condition of
the controller, and what action is occurring in the loading sequence. The different status
displays are described on Pages 24 and 25.
The lower right section of the display is not used in Single Pump mode. It simply displays the
manufacturer’s logo.
STATION:-- OFFLINE
TIME: --- LOGO
Dual Pump Mode
In Dual Pump mode, the screen displays as shown on the following page. The first line of the
screen displays information for Pump 1 and the second line of the screen displays information
for Pump 2.
Each line has twenty (20) characters divided into two (2) groups of ten (10). From the left
character position, P0 S:--:--- is read as “Pump 0 Station --:Load Time ---.” This screen
displays important information in an easy-to-read display. The right ten (10) character group
displays the status of the specific pump. Again, the different status displays are described on
Pages 24 and 25.
P1:S--:--- OFFLINE
P2:S—-:--- OFFLINE
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Station Icons
Below the text portion of the screen, 12 station icons display the status of each station in the
system. Each station icon contains four segments.
Figure 3: Station Icon Segments
Label
Description
The top segment indicates the status of the valve above each station. When
the valve is open (control output energized), this icon highlights. In Single
Pump mode, only one valve indicator is active at a time. In Dual Pump
mode, up to two valve indicators can be active at a time. When this
indicator flashes, it indicates the assignment of a priority convey.
Segment 1
The center square segment indicates the existence of a station specific alarm
condition. The alarm is typically related to a No Convey condition, but can
also indicate the station with a high vacuum condition.
Segment 2
Segment 3
Located on the bottom of the station icon, the lower segment indicates the
station demand input. This is a real time indicator, displaying when the
station demand input is active. This indicator may toggle on and off during
the load cycle, and should be considered normal.
Segment 4 is the indicator word ON, located below the station icon. When
ON displays, the related station loads when the system senses a demand
signal. When ON does not display, the station demand input signal is
ignored and the related station does not load. Segment 4 blinks with
Segment 2 in a high vacuum condition.
Segment 4
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Status Indicators
Four (4) status indicators are located below the 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 Pump 2.
Figure 4: Status Indicator Icons
Icon
Label
Description
The PUMP status indicator specifies an active pump.
PUMP displays when any pump is active, and the 1 or 2
icon indicates which (or both) pump is active.
Pump Status
Indicator
1
2
PUMP
When enabled during the Blowback sequence, the
BLOWBACK icon displays. The 1 or 2 icon indicates the
activity of the blowback solenoid.
Blowback
Indicator
1
2
BLOWBACK
The High Vacuum indicator displays when a high vacuum
condition is present. The 1 or 2 icon indicates the pump
that has the high vacuum condition. The Alarm icon
(Segment 2) and the ON icon (Segment 4) flash at the
hopper with the high vacuum condition.
High
Vacuum
Indicator
1
2
HIGH VACUUM
The Check System indicator displays any system errors.
Three input for each pump, when active, prompts the
CHECK SYSTEM icon to display. The 1 or 2 icon
indicates which pump has the System input(s) active.
System errors can include Dirty Filter, … are common
uses for these inputs.
Check
System
Indicator
1
2
CHECK SYSTEM
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Controller Keypad
Your 12-station controller has a 16-position keypad to let you operate and alter controller
parameters. With the exception of the SET key, each key has at least two functions. The
status of the controller determines what function is recognized.
Figure 4: Controller Keypad
1
2
3
START
STOP
ST 1
ST 2
ST 3
4
5
6
SET
ST 4
ST 5
ST 6
7
8
9
CLEAR
PRIOR
ENTER
MENU
ST 7
ST 8
ST 9
NO
0
YES
ST 10
ST 11
ST 12
Key Descriptions
Label
Description
Use the ten (10) numeric keys marked 1 to 0 to enter numerical information
on the controller.
Number
Keys
Press one of the 12 station keys marked ST1 to ST12 to select or activate the
specific station or hopper you want.
Station Keys
Press the START/STOP key once to start the loading sequence. Press the
START/STOP key again to stop the loading sequence.
Start/Stop
Key
Press the SET key to set hopper loading times. Using the SET key also
permits you to increment through each of the twelve (12) stations/hoppers
when setting loading times. Press the SET key to save the updated value of
the parameter you set, then increments to the next station.
Set Key
Press the CLEAR/PRIOR key to initiate the priority convey sequence; this
key also acts much like an escape key.
Clear/Prior
Key
Press the NO or YES keys to answer questions or prompts while you are
using the menu system.
No/Yes
Keys
Press the ENTER/MENU key to save any data you entered in the controller
memory. You can also press the key to let you enter the menu system.
Enter/Menu
Key
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4-3 Operation
Your 12 station controller electrically controls valves and solenoids to convey material from a
central location to individual stations as needed. The controller works within this process by
sensing a material demand and responds in a timely fashion to that demand.
An active signal sent from a demand sensor prompts the controller to place the station in a
demand queue. The controller responds to this condition by loading the stations in a first
come, first served basis. This is the most efficient manner of conveying material to different-
sized stations.
The basic sequence of a normal load operation is:
1. Sense the demand from a station.
2. Add that station demand into the queue.
3. When required, remove the station from the queue.
4. If required, start the vacuum pump.
5. Open the sequence valve.
6. Load the station until the volume sensor activates or load time expires.
7. Close the sequence valve.
8. Continue on to load the next station in the queue.
9. If no demand is present in system after a short delay, then shut down the system
vacuum pump.
Operation States
Label
Description
The OFFLINE operation state is the default state at the point when you apply
power to the controller. While in this state, all outputs in the system are
deactivated and access to the menu system is permitted. All station demands
are ignored.
OFFLINE
If you press the START/STOP key in the OFFLINE state, the controller
enters the IDLE (Startup) state. If no demand is on the system, the controller
immediately enters the READY state. With a valid demand, the IDLE
(Startup) state allows the pump to get up to speed before starting to load a
station.
IDLE (Startup)
While in the IDLE (Startup) state, all station sequence valves are closed and
the vent valve is open. The vent valve allows the vacuum pump to vent to
atmosphere, keeping the system from becoming depressurized.
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Label
Description
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 times for each station. The controller
loads the station in demand until one of the two events below occur:
LOADING
1. The volume fill sensor becomes active.
2. The load time is exhausted.
At the end of the LOADING cycle, the controller closes the sequence valve
and continues to the next station in the queue. If all stations are satisfied, the
controller enters the IDLE (No Activity) state.
The IDLE (No Activity) state acts as an energy saver and pump lifetime
extender. During this state, the atmospheric valve is open, allowing the
vacuum to be vented. All sequence valves are closed and all inputs are
monitored for demand activity. This feature reduces repeated starting and
stopping of pumps, extending pump operation life.
IDLE
(No Activity)
If the controller senses a demand during the IDLE (No Activity) state, the
controller re-enters the LOADING state by closing the vent valve and opening
the sequence valve of the station in demand.
If no demand exists in the system for the duration of the IDLE (No Activity)
time setting, the controller then enters the READY state.
Note: IDLE is any condition in the conveying system when the pump
runs but no station loads.
The READY state is a monitoring function. All outputs are off and the
controller waits for a demand signal to be fulfilled. If the controller senses a
demand condition, the controller then re-enters the STARTING state and
returns to load material into the hoppers.
READY
When enabled, the controller enters the BLOWBACK state following a user-
definable number of station loads. The blowback function is to pulse air
through the filter system to keep the filter from clogging. The number and
duration of the air pulses is also user-definable; see the Blowback menu on
Pages 54-58 for more information.
BLOWBACK
In Dual Pump mode, if you start the controller with demand from stations
assigned to both pumps, both pumps start at the same time. In many plants,
such a resulting power surge can momentarily exceed the electrical limits of
the plant. To prevent this condition, the pumps are staged in sequence
separated by a short duration. Pump 1 always starts first, followed by Pump 2.
LOADING/IDLE
(2 Pump Mode
Only)
This state also applies when both pumps are in the OFFLINE state and
demand occurs on both systems at the same time.
2–Pump 12-Station Controllers
Chapter 4: Operation
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4-4 Shut-Down
2–Pump 12-Station Controllers
Chapter 4: Operation
42
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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 software version is, call the Service Department
for details.
You can update the software with a laptop computer and an RS-232 serial connection through
the COM1 serial port. As shown in the electrical diagrams and the electrical diagram on the
following page, connect a serial cable as shown. Follow the installation program instructions
supplied with the software update. The installation program automatically updates the BIOS.
2–Pump 12-Station Controllers
Chapter 5: Maintenance
43
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Figure 5: BIOS Connection, Electrical Diagram; Drawing 1
LINE
2–Pump 12-Station Controllers
Chapter 5: Maintenance
44
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Figure 6: BIOS Connection, Electrical Diagram; Drawing 2
+0 VDC
+24 VDC
20 I/O CONTROLLER
AEC P/N: A0560950
2
4
4
1SOL
2SOL
3SOL
4SOL
5SOL
6SOL
7SOL
8SOL
9SOL
10SOL
1LS
2LS
2
STATION 1 SENSORS
STATION 2 SENSORS
STATION 3 SENSORS
STATION 4 SENSORS
STATION 5 SENSORS
STATION 6 SENSORS
STATION 7 SENSORS
STATION 8 SENSORS
STATION 9 SENSORS
2
2
2
2
2
2
Station 1 sequence valve
TB2-2L
TB2-2U
TB2-3U
TB2-4U
TB2-5U
TB2-6U
TB2-7U
TB2-8U
TB2-9U
TB2-10U
TB2-11U
TB2-14U
TB2-15U
N. C.
N. C.
N. C.
N. C.
N. C.
N. C.
4
N. O.
N. O.
N. O.
N. O.
N. O.
N. O.
N. O.
N. O.
N. O.
N. O.
N. O.
1PRS
3PRS
5PRS
7PRS
9PRS
11PRS
2
4
4
Station 2 sequence valve
Station 3 sequence valve
Station 4 sequence valve
Station 5 sequence valve
Station 6 sequence valve
Station 7 sequence valve
Station 8 sequence valve
Station 9 sequence valve
Station 10 sequence valve
Station 11 sequence valve
Station 12 sequence valve
TB2-3L
TB2-4L
TB2-5L
TB2-6L
TB2-7L
TB2-8L
TB2-9L
TB2-10L
TB2-11L
N. C.
N. C.
N. C.
4
4
4
4
4
N. O.
2PRS
4PRS
3LS
4LS
2
N. O.
2
4
4
N. O.
5LS
2
N. O.
6LS
2
4
4
N. O.
7LS
2
6PRS
8PRS
2
2
2
2
2
2
N. O.
4
4
8LS
2
4
4
4
4
4
N. C.
N. O.
9LS
2
N. O.
4
4
4
10LS
11LS
12LS
2
STATION 10 SENSORS
STATION 11 SENSORS
STATION 12 SENSORS
N. C.
N. O.
11SOL
N. O.
12SOL
N. O.
10PRS
12PRS
2
TB2-14L
TB2-15L
N. O.
2
N. C.
N. O.
4
13SOL
N. O.
14SOL
N. O.
13LS
4
4
2
HIGH VACUUM SENSOR 1
2
2
2
2
2
2
2
2
2
2
2
2
Pump 1 solenoid
Pump 2 solenoid
Vent solenoid 1
Vent solenoid 2
Blowback solenoid 1
Blowback solenoid 2
Audible alarm
TB2-16L
TB2-17L
TB2-18L
TB2-19L
TB2-20L
TB2-21L
TB2-22L
TB2-23L
TB2-12L
TB2-13L
TB2-12U
TB2-13U
TB2-16U
TB2-17U
TB2-18U
TB2-19U
TB2-20U
TB2-21U
TB2-22U
TB2-23U
TB2-1U
N. O.
4
4
4
14LS
2
HIGH VACUUM SENSOR 2
N. O.
15SOL
15LS
2
MACHINE ALARM SENSOR 1
4
4
4
4
4
4
4
4
4
4
N. O.
N. O.
N. O.
N. O.
16SOL
17SOL
18SOL
16LS
2
MACHINE ALARM SENSOR 2
MACHINE ALARM SENSOR 3
MACHINE ALARM SENSOR 4
SPARE 1
4
4
4
4
4
N. O.
17LS
2
N. O.
18LS
2
N. O.
N. O.
19SOL
N. O.
20SOL
N. O.
19LS
2
N. O.
20LS
2
SPARE 2
Visual alarm
N. O.
4
4
4
4
2
2
2
2
TB2-24U
TB2-1L
TB2-24L
LEGEND
A0560970
FIELD WIRING
OPTION/SERVICE WIRING
NOTE: ALL WIRES ARE #18 AWG
UNLESS OTHERWISE NOTED
2–Pump 12-Station Controllers
Chapter 5: Maintenance
45
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Chapter 6: Troubleshooting
6-1
Problem
General Troubleshooting
Possible cause
Solution
The controller panel is not
plugged in.
Plug in the controller panel.
The external disconnect
The controller panel doesn’t light (recommended) in the dedicated Close the switch (on).
up at all.
circuit is open (off).
Fuse/circuit breaker in the power
drop is blown/tripped.
Replace/reset.
Broken controller power switch.
Replace.
Reset the overload and check
The motor overload has tripped. the motor for the proper amp
draw on tag.
Main fuse in power drop or
A pump package doesn’t run,
even though it is on line and its
indicator is lit.
optional fused disconnect has
blown.
Replace the fuse.
Motor contact is faulty.
Repair or replace as required.
Normal operation. When the
level drops, material conveys to
the hopper.
The bin below it is full if its
amber indicator light is off.
Using the controller, place the
hopper on line.
The hopper is off line.
A vacuum hopper is being
bypassed in the loading cycle.
The convey time for the hopper
is set to zero.
Using the controller, enter a
reasonable convey time.
The field-installed station bypass Normal operation. Set the switch
switch is simulating a Bin Full
condition.
so the hopper is back in the
loading sequence.
The field-installed station bypass
switch is bad or mis-wired.
Repair, replace, or rewire.
Time the hopper(s) during
loading, and set conveying times
to a few seconds less.
Conveying times are too long
(Time Fill mode only).
Check proximity sensors for
proper operation and proper
wiring to the PCB. Repair as
needed. Reset the conveying
times to a reasonable value, and
adjust as needed.
Vacuum hoppers are over-filling.
Maximum conveying times are
too long and the PCB does not
recognize the Hopper Full
proximity switch(es).
2–Pump 12-Station Controllers
Chapter 6: Troubleshooting
46
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Problem
Possible cause
Defective wiring.
Solution
Correct/replace wiring.
Replace defective terminal
block.
Replace defective PCB.
Replace defective solenoid.
Output icon comes on,
solenoid doesn’t.
Defective terminal block.
Defective PCB.
Defective solenoid.
Power supply shorting out.
Repair shorting circuit.
Verify proper solenoid use. Call
Engineering for assistance.
Replace fuse with one that has a
proper rating.
Eliminate source of static.
Ground the controller properly.
Cold-boot the controller. Restore
the controller to factory defaults;
see Section 8-5 on Page 75 for
more information.
Excessive loading on solenoids.
Improper fuse installed.
Excessive static.
Controller blows fuses.
Erratic operation.
Corrupt RAM data.
Ground the controller properly.
Replace PCB.
I/O logic failing.
False input signal.
No Convey alarm does not light. False input signal.
Increase input delay time.
Increase input delay time.
2–Pump 12-Station Controllers
Chapter 6: Troubleshooting
47
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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 data.
To recover from a write failure:
• Shut off the controller, wait 15 seconds, then restart the controller.
The boot sequence detects the write error and attempts to restore the
backup file.
It is also possible, although rare, that the backup and original file could both become corrupt.
If this occurs, then reset the controller to factory default parameters before proceeding.
However, all parameters you’ve previously stored are lost and you’ll need to set up the
controller from the beginning. You should record what settings you use in the controller
system if this occurs.
The following screens display while the controller writes to flash memory. Again, do not
cycle power while these two screens display.
WRITING PARAMETERS
TO FLASH-PLEASE WAIT
SAVING BACKUP
TO FLASH-PLEASE WAIT
Note: The controller needs about 30 seconds for saving to flash
memory. If the controller doesn’t clear this display within 60
seconds, you may need to cycle power. This rare type of problem
is caused by a write failure not detected by the controller. This
rare condition usually requires a complete factory default reset
for full recovery.
2–Pump 12-Station Controllers
Chapter 6: Troubleshooting
48
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Chapter 7: Appendix
7-1 Warranty
Unless otherwise specified, this product includes a Standard ONE YEAR PARTS AND
LABOR WARRANTY.
Warranty Specifications
The manufacturer hereby expressly warrants all equipment manufactured by it to be free from
defects in workmanship and material when used under recommended conditions, as set forth
in the operating manuals for such equipment. THE FOREGOING EXPRESS WARRANTY
IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, GUARANTIEES,
AGREEMENTS, AND SIMILAR OBLIGATIONS OF THE COMPANY AND/OR
MANUFACTURER (UNLESS OTHERWISE SPECIFIED IN THE SPECIFIC PRICE
PAGE OR LIMITED BY THE MANUFACTURERS’ WARRANTY FOR PARTS). The
Company’s obligation is limited to repair or replace FOB the factory any parts that are
returned, prepaid, within one year of equipment shipment to the original purchaser, and
which in the Company’s opinion, are defective. Any replacement part assumes the unused
portion of this warranty.
Warranty Restrictions
This parts warranty does not cover any labor charges for replacement of parts, adjustment
repairs, or any other work. This warranty does not apply to any equipment which, in the
Company’s opinion, has been subjected to misuse, negligence, or operation in excess of
recommended limits, including freezing or which has been repaired or altered without the
Company’s express authorization. If the serial number has been defaced or removed from the
component, the warranty on that component is void. Defective parts become the property of
the warrantor and are to be returned immediately, without any further use or handling.
2–Pump 12-Station Controllers
Chapter 7: Appendix
49
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Warranty Liabilities
THE COMPANY EXPRESSLY DISCLAIMS 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 incidental damages, so the above limitation may not
apply to you. The Company’s obligation for parts not furnished as components of its
manufactured equipment is limited to the warranty of the manufacturers of said parts. The
company neither assumes nor authorizes any other persons to assume for it any liability in
connection with the sale of its equipment not expressed in this warranty. No person, agent,
manufacturer, distributor, dealer, installer or company is authorized to change, modify or
extend the terms of this warranty in any manner whatsoever.
The time within which an action must be commenced to enforce any obligation of the
Company’s arising under this warranty, or under any statute or law of the United States or
any state thereof, is hereby limited to the duration of this warranty. Some states do not permit
this limitation, so the above may not apply to you. This warranty gives you specific legal
rights and you may also have other rights which vary from state to state. For transactions
involving the potential applicability of international law or that of a foreign country,
this warranty policy and the procedures hereunder shall be governed by
applicable federal and state law, but not by the United Nations Convention on Contracts for
the Sale of Goods.
Customer Responsibilities
Any sales, use, or other tax incident to the replacement of parts under this warranty is the
responsibility of the purchaser.
2–Pump 12-Station Controllers
Chapter 7: Appendix
50
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7-2 Drawings and Diagrams
Figure 7: 2 pump 12 station Controller Control Panel
SECTION 1 SECTION 2
SECTION 3 SECTION 4
Depth dimension of subpanel: 8.0” D (20.3 cm).
Also, review electrical drawings supplied in the packet with this manual.
2–Pump 12-Station Controllers
Chapter 7: Appendix
51
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7-3 Spare Parts List
Figure 8: Typical 12-Station Controller Exterior Components, Exploded View
8
7
13
6
5
12
10
4
places
11
10
15
14
2
4
2
4
places
places
5
4
3
2
9
1
1
4
places
16
A0560974
Power cord
A0560954
2–Pump 12-Station Controllers
Chapter 7: Appendix
52
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Figure 9: Exterior Components Parts List
Refer to Figure 8 on Page 51 when identifying parts.
Item Qty. Part no.
Description
ENCL, CARLON, MOUNT FLNG, MNK10L
ENCL, CARLON, 12 X 10 BODY, NP1210B
SW, PWR, SHAFNR W/FLTR & FUSE
1.
2.
1
1
1
2
1
1
1
1
2
4
1
1
1
A0560963
A0560964
A0560955
3.
4.
W00015317 SCR, RHM, 4-40 X 5/8
5.
6.
7.
8.
A0560962
A0560965
A0803341
A0560501
ENCL, CARLON, COLLAR, NH1210C
ENCL, CARLON, 12 X 10 LID, NH1210L
KYP, LONG TACTILE
GRPH, 12 STATION, VAC-TRAC
9.
W00000960 NUT, HEX HD, PLT, 4-40
10.
11.
12.
13.
A0560968
A0559156
A0560969
A0560967
NUT, HEX HD, PLT, 2-56
DSPLY, LCD, CRYSTALOID, CRUSM1056
SPCR, NYLON, 0.091 ID, 0.185 OD, 1/8”
SCR, PAN HD, SLTD, PLT, 2-56 X 3/4”
2–Pump 12-Station Controllers
Chapter 7: Appendix
53
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Figure 10: Typical 12-Station Controller Interior Components, Exploded View
13
11
12
10
9
11
8
7
6
5
4
3
2
1
A0560974
2–Pump 12-Station Controllers
Chapter 7: Appendix
54
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Figure 11: Interior Components Parts List
Refer to Figure 10 on Page 53 when identifying parts.
Item Qty. Part no. Description
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
4
1
4
1
4
1
1
1
2
1
5
1
1
W00001055 WASH, #6 SAE FLAT, PLD
A0560961
A0530780
A0560958
A0101507
A0539383
A0560956
A0539387
PNL, SUB, CARLON, JP1210, 10 X 8
STND, OFF (M/F) #6-32 X 0.5” LG. HE
PCB, DNTL, 201/O, 128 K RAM/ROM
SCR, RHM, PLD, 6-32 X 1/4
RECT, BRIDGE, 25 AMPS, GBPC2510
ELEK, RES, 50 OHM, 50 WATT, CLEROSTAT
XFMR, 16 VCT, 112 VA, MCI 4-07-8016
W00015057 SCR, PAN HD, SLTD, PLT, 4-40 X
A0069176
A0102356
A0539389
A0539382
SCR, RHM, PLD, 10-32 X 3/4
SCR, RHM, PLD, 8 X 32 X 3/8
CAP, BRKT, MT, VRIO, MALLORY
CAP, ELEC, 22000UFD, 30 VDC, ALUCAN
2–Pump 12-Station Controllers
Chapter 7: Appendix
55
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7-4 Controller Identification (Serial Number) Tag
(Located on the side of the controller box)
Street Address
Town, State, Zip Code
Telephone Number
Fax Number
XXX CONTROL PANEL
Model No. XXX2-12
Serial No. 31K0182
Ph
230 Volt
60 Hz
1
Control Voltage 24VDC
7-5 Technical Assistance (Contact Information)
Parts Department
[
]
[
]
Call toll-free 7am–5pm CST 800 423-3183 or call 630 595-1060, Fax [630] 475-7005
The ACS Customer Service Group will provide your company with genuine OEM quality parts
manufactured to engineering design specifications, which will maximize your equipment’s performance
and efficiency. To assist in expediting your phone or fax order, please have the model and serial
number of your unit when you contact us. A customer replacement parts list is included in this manual
for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to providing
excellent customer service.
Service Department
[
]
[
]
Call toll-free 8am–5pm CST 800 233-4819 or call 630 595-1060
[
]
Emergencies after 5pm CST, call 847 439-5655
We have a qualified service department ready to help. Service contracts are available for most
products.
Sales Department
[
]
Call 630 595-1060 Monday–Friday, 8am–5pm CST
Our products are sold by a world-wide network of independent sales representatives. Contact our Sales
Department for the name of the sales representative nearest you.
Contract Department
[
]
Call 630 595-1060 Monday–Friday, 8am–5pm CST
Let us install your system. The Contract Department offers any or all of these services: project planning;
system packages including drawings; equipment, labor, and construction materials; and union or non-
union installations.
2–Pump 12-Station Controllers
Chapter 7: Appendix
56
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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
Information located in this section. Unauthorized changes to these
factory settings by inexperienced operators may prevent the controller
from operating properly, and may void part or all of the warranty.
Note: If this manual is to be used on the floor by the operator, keep this
section separate from the rest.
8-1 Service Settings Menu
Setting the Ramp Up Time
Ramp up time is a delay that allows the pump to establish full speed before the valve opens.
This delay defaults to 1.5 seconds and should not be altered unless instructed to do so by
the Service Department.
SET RAMP UP TIME?
NO/YES
At the above message prompt:
• Press the YES key to enter the Ramp Up Time menu.
SELECT PUMP 1 OR 2
USE KEYPAD TO ENTER
Select the pump for altering ramp up time.
RAMP UP DLY: 1.500s
SETTING FOR PUMP n
Using the keypad:
• Enter the new time and press the ENTER key to save the new setting.
2–Pump 12-Station Controllers
Chapter 8: Service Only Information
57
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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 is also known as the Shutdown delay.
This delay defaults to 8.0 seconds and should not be altered unless instructed to do so by
the Service Department.
SET RAMP DOWN TIME?
NO/YES
At the above message prompt:
1. Press the YES key to enter the Ramp Down Time menu.
2. Select the pump for altering ramp down time.
SELECT PUMP 1 OR 2
USE KEYPAD TO ENTER
The following screen displays.
RAMP DN DLY: 8.000s
SETTING FOR PUMP n
Using the keypad:
3. Enter the new time and press the ENTER key to save the new setting.
2–Pump 12-Station Controllers
Chapter 8: Service Only Information
58
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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 causes an excess of current on the electrical system from such a surge.
The pump stage time delay defaults to 3.0 seconds and should not be altered unless you are
instructed to do so by the Service Dept.
SET PUMP STAGE TIME?
NO/YES
At the above message prompt:
1. Press the YES key to enter the Pump Stage Time menu.
STAGE DELAY: 3.000s
PRESS ENTER TO SAVE
Using the keypad:
2. Enter the new time and press the ENTER key to save the new setting.
2–Pump 12-Station Controllers
Chapter 8: Service Only Information
59
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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
and should not be altered unless you are instructed to do so by the Service Department.
SET LCD BLINK DELAY?
NO/YES
At the above message prompt:
1. Press the YES key to enter the LCD Blink Delay menu.
BLINK DELAY: .500s
PRESS ENTER TO SAVE
Using the keypad:
2. Enter the new time and press the ENTER key to save the new settings.
2–Pump 12-Station Controllers
Chapter 8: Service Only Information
60
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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 annoying Hi Vacuum errors which self-clear or are
erroneous. This delay defaults to 3.0 seconds and should not be altered unless you are
instructed to do so by the Service Department.
HI VAC SENSOR DELAY?
NO/YES
At the above message prompt:
1. Press the YES key to enter the Hi Vacuum Sensor Delay Time menu.
SELECT PUMP 1 OR 2
USE KEYPAD TO ENTER
At the above message prompt:
2. Select the pump for altering vacuum sensor delay.
The following screen displays:
HIVAC DELAY: 3.000s
SETTING FOR PUMP n
Using the keypad:
3. Enter the new time and press the ENTER key to save the new setting.
2–Pump 12-Station Controllers
Chapter 8: Service Only Information
61
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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 unless you are instructed to do so by the
Service Department.
HI VAC VENT DELAY?
NO/YES
At the above message prompt:
1. Press the YES key to enter the Hi Vacuum Vent Delay Time menu.
SELECT PUMP 1 OR 2
USE KEYPAD TO ENTER
At the above screen prompt:
2. Select the pump for altering vacuum vent delay.
The following screen displays.
HV VENT DLY: 10.000s
SETTING FOR PUMP n
Using the keypad:
3. Enter the new time and press the ENTER key to save the new setting.
2–Pump 12-Station Controllers
Chapter 8: Service Only Information
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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 experiences a high vacuum condition for the selected
number of loads without being cleared or attended to, it goes off line to prevent damage to
the conveying system. This parameter defaults to 7 loads and should not be altered unless
you are instructed to do so by the Service Department.
HI VAC LOAD COUNT?
NO/YES
At the above message prompt:
1. Press the YES key to enter the Hi Vacuum Load Count menu.
SELECT PUMP 1 OR 2
USE KEYPAD TO ENTER
At the above screen prompt:
2. Select the pump for altering the high vacuum load count.
The following screen displays.
HV LOAD CNT: 7
SETTING FOR PUMP n
Using the keypad:
3. Enter the new time and press the ENTER key to save the new setting.
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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 Monitor screen displays all 20 inputs in real time. 0
represents no input and 1 indicates an active input.
INPUT MONITOR?
NO/YES
At the above message prompt:
1. Press the YES key to enter the Input Monitor menu.
You now have access to the OEM menu system and Input Monitor menu.
The following screen displays:
IN BNK0: 0000000000
IN BNK1: 0000000000
The top row (Bank 0 [IN BNK0]) shows the input status of the first ten (10) inputs. The
bottom row shows the status of inputs 11-20 (Bank 1 [IN BNK0]).
To exit this menu:
2. Press the CLEAR key.
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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 you access to each individual output.
OUTPUT CONTROL?
NO/YES
At the above message prompt:
1. Press the YES key to enter the Output Control menu.
The following screen displays.
AUTOMATIC OR MANUAL?
N=AUTO Y=MANUAL
To start the automatic cycle:
• Press the NO key.
To increase speed:
• Press the START/STOP key.
To decrease speed:
• Press the SET key.
To exit the Output Control menu and turn all outputs OFF:
2. Press the CLEAR key.
Caution!
Automatically cycling outputs with the pump in Active mode can damage
the conveying system.
Caution!
Do not perform this action unless directed to do so by the Service
Department.
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To access the outputs manually, at the AUTOMATIC OR MANUAL? screen prompt:
1. Press the YES key.
The following screen displays.
OUTBNK0: 0000000000
OUTBNK1: 0000000000
A cursor displays on the screen.
To move the cursor left:
• Press the 4 key.
To move the cursor right:
• Press the 6 key.
To move the cursor up:
• Press the 2 key.
To move the cursor down:
• Press the 8 key.
To toggle output ON or OFF:
• Press the START/STOP key.
To exit this menu:
2. Press the CLEAR key.
Caution!
Enabling the Pump output without opening any sequence valves can cause
damage to the conveying system.
Caution!
Do not perform this action unless directed to do so by the Service
Department.
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8-2 Other Controller Restricted Areas
Using the OEM Service Menu
The OEM service menu (Original Equipment Manufacturer) lets you set parameters not
commonly used. It also contains functions to aid in the installation of the controller. Access
to this menu should be restricted to setup and maintenance personnel only.
To gain access to the OEM service menu:
1. Remove power from the controller.
2. Press and hold the Zero 0 key and re-apply power. While holding the Zero 0 key,
allow the controller to initialize.
The controller displays the message below and permits access to the OEM service
menu.
OEM MENU ACCESS
IS NOW AVAILABLE!
Gain access to the OEM service menu by entering the menu system. An additional menu
screen is shown below.
OEM SETTINGS?
NO/YES
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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.
Follow these steps to recover passwords.
1. Remove power from the controller.
2. Press and hold the 3 key.
3. Reapply power as you continue to hold down the 3 key.
4. The screen displays up to four (4) password settings during controller initialization.
Note the sample screen below.
5. Press the CLEAR key to contine with initialization.
PWL1:1111 PWL2:2222
PWL3:3333 PWL4:4444
Note: Passwords shown on this screen are illustration only.
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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 doing this procedure,
including passwords and OEM Service settings.
Follow these steps to restore the controller to factory defaults.
1. Remove power from the controller.
2. Press and hold the CLEAR key.
3. Re-apply power while holding down the CLEAR key.
During initialization, the screen displays a message indicating that factory default
settings are set.
Verifying Software Checksums
Follow these steps to verify software checksum values.
1. Remove power from the controller.
2. Press and hold the SET key.
3. Re-apply power while holding down the SET key.
During initialization, the screen displays a message while the controller calculates the
software check sum. This number is in hexadecimal format (Base 16) and displays in
numbers and letters.
Example: 0x1FC9 is a valid checksum format.
ROM CHECKSUM: 0x0000
PRESS YES TO RESUME
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