Sterling Marine Battery SSC1 5Q User Manual

$3000  
SSC1-5Q  
Conveying Systems  
1-Pump 5-Station Controller  
Operation, Installation, and Service Manual  
Sterling  
5200 W. Clinton Ave  
Milwaukee, WI 53223  
Tel. (414) 354-0970  
Fax (414) 354-6421  
Part No. A0  
Bulletin No. SM2-615  
11/7/03  
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Write down your unit serial number(s)  
here for future reference  
Model #  
Serial #  
________________  
________________  
________________  
________________  
________________  
________________  
________________  
________________  
Performance figures stated in this manual are based on a standard atmosphere of 59°F  
(15°C) at 29.92” Hg (1,014 millibars) at sea level, using 60 Hz power. Altitude is an  
important consideration when specifying vacuum conveying components. Sterling can  
advise you on proper selection and sizing of systems for your operating environment.  
Sterling is committed to a continuing program of product improvement. Specifications,  
appearance, and dimensions described in this manual are subject to change without  
notice.  
© Copyright Sterling 2003  
All rights reserved.  
Part No. A0  
Effective 11/7/2003  
Bulletin No. SM2-615  
Page ii of 38  
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Table of Contents  
1
General Information.........................................................................8  
1-1 Equipment Function......................................................................................8  
1-2 Necessary Documents .................................................................................8  
1-3 System Capabilities......................................................................................8  
1-4 Equipment Cycle ..........................................................................................9  
1-5 Models Covered by this Manual ...................................................................9  
2
Safety...............................................................................................11  
2-1 Work Rules.................................................................................................11  
2-2 Tools and Equipment Needed....................................................................11  
2-3 Safety Considerations ................................................................................11  
2-3-1 Reporting a Safety Defect ..............................................................12  
2-4 General Responsibility................................................................................12  
2-5 Operator Responsibility ..............................................................................13  
2-6 Maintenance Responsibility........................................................................13  
2-7 Safety Devices............................................................................................14  
2-7-1 Safety Circuit Standards.................................................................14  
2-7-2 Fail Safe Operation ........................................................................14  
2-7-3 Safety Device Lock-Outs................................................................15  
3
4
Shipping Information......................................................................17  
3-1 Unpacking and Inspection ..........................................................................17  
3-2 In the Event of Shipping Damages.............................................................17  
3-3 Parcel Post Shipment.................................................................................17  
3-4 United Parcel Service Shipment.................................................................18  
3-5 If the Shipment is Not Complete.................................................................18  
3-6 If the Shipment is Not Correct ....................................................................18  
3-7 Returns.......................................................................................................18  
Installation.......................................................................................19  
4-1 Installing the VacTrac Control Panel ..........................................................19  
4-2 Making Electrical Connections ...................................................................19  
4-3 Making SSC1-5Q Control Panel Power Drop Wiring Connections ............19  
4-4 Connecting the Control Panel to Vacuum Receivers .................................19  
4-5 Connecting the Control Panel to the Pump Package.................................20  
Page iii of 38  
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Table of Contents  
5
6
Using the Controller .......................................................................21  
5-1 Introduction.................................................................................................21  
5-2 Setup ..........................................................................................................21  
5-2-1 Setting Up the System....................................................................21  
5-2-1-1-1 Setting Pump Parameters......................................................22  
5-2-1-1-2 Setting Blowback Parameters................................................22  
5-2-1-1-3 Input and Output Screen Features.........................................23  
5-2-1-1-4 Changing Parameters............................................................23  
5-2-2 Starting the System........................................................................23  
Configurable Settings.....................................................................25  
6-1 Options for Station Setup ...........................................................................25  
6-2 Options for Pump Setup .............................................................................26  
7
8
Maintenance...................................................................................27  
Troubleshooting ............................................................................28  
8-1 General Troubleshooting............................................................................28  
8-2 Alarms ........................................................................................................29  
8-2-1 Station Alarms................................................................................29  
8-2-2 Pump Alarms..................................................................................29  
9
Options ............................................................................................30  
10 Spare Parts List ..............................................................................31  
10-1 Recommended Spare Parts List.................................................................31  
11 Technical Assistance .....................................................................32  
11-1 Contact Information for Technical Assistance ............................................32  
11-2 Returned Material Policy ............................................................................33  
11-2-1Credit Returns ................................................................................33  
11-2-2Warranty Returns ...........................................................................33  
11-3 Warranty.....................................................................................................34  
12 Safety Tag Information...................................................................35  
12-1 Controller Safety Tags................................................................................35  
12-2 Controller Identification (Serial Number) Tag .............................................35  
13 Appendix .........................................................................................36  
Page iv of 38  
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Charts and Figures  
1 SSC1-5Q Controller ............................................................................................. 10  
Page v of 38  
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Safety Considerations  
Sterling conveying systems are designed to provide safe and  
reliable operation when installed and operated within design  
specifications, following national and local safety codes.  
To avoid possible personnel injury or equipment damage  
when installing or operating this equipment, always use good  
judgment and follow these safe practices:  
; Follow all SAFETY CODES.  
; Wear SAFETY GLASSES and WORK GLOVES.  
; Use care when LOADING, UNLOADING, RIGGING, or  
MOVING this equipment.  
; OPEN, TAG, and LOCK ALL DISCONNECTS before  
working on equipment. It is a good idea to remove the  
fuses and carry them with you.  
; GROUND your conveying system properly before  
applying power.  
; Use extreme caution when working with your Sterling  
conveying system. HIGH VACUUM can be dangerous.  
Keep body parts, tools, clothing, and debris away from  
vacuum inlets.  
; Do not jump or bypass any electrical safety control.  
; Do not restore power until you remove all tools, test  
equipment, etc.  
; Only PROPERLY TRAINED personnel familiar with the  
information in this manual should work on this equipment.  
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Sterling  
“SSC1-5Q” Conveying Systems  
1-Pump 5-Station Controller  
This controller is manufactured by ACS, Inc. at the ACS-Wood Dale facility:  
ACS, Inc.  
801 Wood Dale Rd.  
Wood Dale, IL 60191  
Phone: 630.595.1060  
Fax: 630.595.6641  
The equipment is distributed in Europe by our European Facility:  
ACS-EUROPE  
Daniels Industrial Estate  
BATH ROAD  
Stroud, Gloucestershire, England  
GL5 3TJ  
Phone: (44) 1453 768980  
Fax: (44) 1453 768990  
Page 7 of 38  
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1
General Information  
1-1  
1-2  
Equipment Function  
Sterling systems create vacuum for conveying pelletized or  
granular material in a central material handling system.  
A typical use is an in-plant distribution system for plastic  
processing plants.  
Necessary Documents  
The documents below are necessary for proper installation,  
operation and maintenance of conveying systems. You can  
obtain additional copies from the Service Department at  
Sterling. Make sure that the appropriate personnel are  
familiar with these documents:  
This product manual.  
The Sterling SPD/SPC Series product manual.  
Electrical schematic and connection diagrams.  
Blower and electric motor information sheets.  
Operation and Installation manuals for all electrical  
components.  
1-3 System Capabilities  
Sterling central vacuum systems are as varied as the  
applications they service. The tubing and equipment  
furnished in a Sterling system are designed to convey the  
material(s) specified at the time of purchase at specific rates  
and distances.  
Sterling 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.  
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Use the minimum effective amount of vinyl flex hose to  
maximize material line efficiency. Keep material lines as  
straight as possible. Refer to the Sterling SPD/SPC Series  
Product Manual (Sterling Part No. A0571050) for installation  
recommendations.  
Important! Vacuum leaks occurring anywhere in your system reduce capacity.  
1-4 Equipment Cycle  
Sterling material conveying systems are used for automatic  
pneumatic handling of most free-flowing, dry, pelletized, or  
granular materials. Material characteristics determine the  
type of equipment needed to convey the material.  
1-5 Models Covered by this Manual  
SSC1-5Q 5-Station Controller  
Programmable Logic Controller.  
24 VDC control circuits.  
Easy-to-use operator interface.  
Audible/visual alarm.  
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Figure 1: SSC1-5Q Controller  
16”  
6.35”  
6” Display  
2.0”  
16”  
* Depth dimension is 12”  
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2
Safety  
2-1  
Work Rules  
The installation, operation, and maintenance of this  
equipment must be conducted in accordance with all appli-  
cable work and safety codes for the installation location. This  
may include, but is not limited to OSHA, NEC, CSA, SPI,  
and any other local, national, and international regulations.  
; Read and follow these operating instructions when  
installing, operating, and maintaining this equipment. If  
the instructions become damaged or unreadable,  
additional copies are available from Sterling.  
; Only qualified personnel familiar with this equipment  
should work with this system.  
; Work only with approved tools and devices.  
; Disconnect and lock out power while working on this  
equipment.  
2-2 Tools and Equipment Needed  
These tools and equipment are necessary for installation:  
; Hand tools.  
; Wire, conduit, and fittings for wiring runs.  
; Anchor bolts with nuts and washers or red head-type  
anchors.  
2-3 Safety Considerations  
The terms NOTICE, CAUTION, WARNING, and DANGER  
have specific meanings in this manual.  
NOTICE is used to indicate a statement of company policy  
directly or indirectly related to the safety of personnel or  
protection of property.  
CAUTION indicates a potentially hazardous situation which,  
if not avoided, may result in minor injury.  
WARNING indicates a potentially hazardous situation which,  
if not avoided, could result in death or serious injury.  
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DANGER indicates an imminently hazardous situation  
which, if not avoided, will result in death or serious injury.  
This word will be limited to the most serious situations.  
The term IMPORTANT emphasizes areas where equipment  
damage could result, or provides additional information to  
make a step or procedure easier to understand. Disregarding  
information marked IMPORTANT would not be likely to  
cause personal injury.  
2-3-1 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 Sterling.  
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.  
2-4 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.  
Page 12 of 38  
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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.  
2-5 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.  
2-6 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.  
Page 13 of 38  
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2-7 Safety Devices  
This section includes information on safety devices and  
procedures that are inherent to the SSC1-5Q 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.  
2-7-1 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 SPD/SPC 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.  
2-7-2 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  
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guarding a motor, and the safety switch fails, the motor  
should not be able to run.  
2-7-3 Safety Device Lock-Outs  
Some safety devices disconnect electrical energy from a  
circuit. The safety devices that are used in the SSC1-5Q  
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 SSC1-5Q  
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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-Notes-  
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3
Shipping Information  
3-1  
Unpacking and Inspection  
You should inspect your Sterling SSC1-5Q 5-station  
controller for any possible shipping damage. If the container  
and packing materials are in re-usable condition, save them  
for reshipment if necessary.  
Thoroughly check the equipment for any damage that might  
have occurred in transit, such as broken or loose wiring and  
components, loose hardware and mounting screws, etc. In  
case of breakage, damage, shortage, or incorrect shipment,  
refer to the following sections.  
3-2 In the Event of Shipping Damages  
Important! 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 to  
Sterling before the transportation company inspection  
and authorization.  
; File a claim against 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 Sterling regarding your wish for assistance and to  
obtain an RMA (return material authorization) number.  
3-3 Parcel Post Shipment  
Notify Sterling at once in writing, giving details of the loss or  
damage. This information is required for filing a claim with  
our insurance company.  
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Hold the damaged goods with the container and packing  
materials for possible inspection by postal authorities.  
3-4 United Parcel Service Shipment  
; Contact your local UPS office regarding damage and  
insurance claims.  
; Retain the container and packing.  
; Notify Sterling at once.  
3-5 If the Shipment is Not Complete  
Check the packing list. The apparent shortage may be inten-  
tional. Back-ordered items are noted on the packing list. You  
should have:  
; Sterling SSC1-5Q 5-station controller  
; Bill of Lading  
; Packing list  
; Operating and Installation packet  
; Electrical schematic and panel layout drawings  
; Component instruction manuals  
Re-inspect the container and packing material to see if you  
missed any smaller items during unpacking. Determine that  
the item was not inadvertently taken from the area before  
you checked in the shipment. Notify Sterling immediately of  
the shortage.  
3-6 If the Shipment is Not Correct  
If the shipment is not what you ordered, contact Sterling  
immediately. For shipments in the United States and  
Canada, call 1 (414) 354-0970; for all other countries, call  
001 (414) 354-0970. Include the order number and item.  
Hold the items until you receive shipping instructions.  
3-7 Returns  
Important! Do not return any damaged or incorrect items until you receive  
shipping instructions from Sterling.  
Page 18 of 38  
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4
Installation  
4-1 Installing the SCC1-5Q Control Panel  
Note: Before you mount the panel, consider how you run wiring to  
the vacuum receivers, 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.  
4-2 Making 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.  
4-3 Making SSC1-5Q Control Panel Power Drop Wiring  
Connections  
Hardwire the input power at 110/1/50-60 VAC or 230V/1/50-  
60 VAC, depending on the specifications, which are located  
on the SSC1-5Q Control Panel Serial Tag. The main power  
switch is located on the right side of the enclosure.  
Important! Sterling recommends that you protect PLC memory by providing  
the control panel with a dedicated circuit, a true earth ground, and  
a spike/surge protector.  
4-4 Connecting the Control Panel to Vacuum Receivers  
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 receiver in the SSC system.  
2. On all systems, run two wires to each vacuum receiver:  
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 receivers are the same voltage (24  
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VDC) as the SSC 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 receivers, and the number of wires in each  
raceway. Consult a qualified electrician.  
5. Properly ground each receiver to reduce static build up  
generated by material conveying.  
4-5 Connecting the Control Panel to the Pump Package  
1. Wire the pump package motor starter coil (M) to the  
terminal provided in the SSC control panel enclosure.  
2. Wire the pump package vacuum relief valve solenoid  
(SOL A) to the terminal provided in the SSC control  
panel enclosure.  
3. Wire the pump package vacuum switch (VS) to the  
terminal located in the SSC control panel enclosure (If  
provided).  
4. On SPDB pumps, wire the pump package blowback  
solenoid (SOL B) to the terminal located in the SSC  
control panel enclosure.  
Wire the pump package motor overload to the terminal  
provided in the SSC 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 conveying  
system.  
4-6 Special Timed Convey  
Connect +24 VDC to inputs 11-15, corresponding to Stations  
1-5, to enable the Special Timed Convey feature.  
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5
Using the Controller  
5-1 Introduction  
This chapter gives the procedures for configuring your  
SSC1-5Q controller.  
Configuration of your SSC1-50Q controller includes setting  
the number of stations, setting variables such as convey  
time and blow-back interval. Sterling recommends that you  
carry out these procedures in the order given here.  
5-2 Setup  
Important! Before carrying out these procedures, install all equipment as  
described in Chapter 4: “Installation”, and in the manual SPD/SPC  
Series Conveying Systems.  
5-2-1 Setting Up the System  
This section provides an overview of the controller screens used in  
configuring the system. Section 6 provides a detailed explanation of the  
features listed on each screen.  
5-2-1-1 Basic Menus and Setup of Controller  
Once power has been applied to a properly installed  
system, turn the disconnect switch to the ON position.  
The alpha controller will display the screen for receiver 1  
(Hopper 1).  
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This screen allows the operator to adjust the convey time  
(CONVEY), dump delay (DUMP), and the number of tries  
before the no convy alarm activates (NO CONVEY).  
To disable a station, set the convey time to 0 (zero).  
Important!  
DO NOT set the Dump delay or No Convey to 0 (zero).  
To set the parameters for each receiver, use the left ()  
or right () arrow keys to scroll through the settings for  
the next () or previous () receiver.  
5-2-1-1-1 Setting Pump Parameters  
To access the pump screen, press the right  
arrow key () when in the station 5 screen or  
press the left arrow key () when in the  
blowback screen.  
This screen allows the operator to adjust the  
pump motor ramp up/ramp down time (RAMP)  
and the amount of time the pump runs unloaded  
before shutting off (IDLE).  
Important!  
DO NOT set the Idle Time or Ramp time to 0 (Zero).  
5-2-1-1-2 Setting Blowback Parameters  
Once the pump parameters have been set, the  
blowback parameters will need to be configured.  
This screen can be accessed for each station,  
by pressing the right arrow key () when in the  
pump parameters screen (RAMP and IDLE  
times are displayed).  
This screen allows the operator to adjust all  
those settings related to cleaning the filter  
chamber: the number of conveys before  
blowback (CNV>BB), the duration between  
blowback pules (BB OFF), the duration of the  
pulse (BB ON), and the number of cleaning  
pulses (BB CYC).  
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Important!  
Setting either the CNV>BB or BB CYC parameters to “0” will disable  
the blowback feature. DO NOT set other blowback parameters to “0.”  
5-2-1-1-3 Input and Output Screen Features  
To access the I/O screen, press the right arrow  
key () when the Blowback Parameter screen  
is displayed or the left arrow key () when the  
Convey/Dump/No Convey screen is displayed.  
The I/O screen allows a service technician to  
view the status of the controller’s inputs and  
outputs during operation.  
5-2-1-1-4 Changing Parameters  
To change the settings in the Conveying, Pump  
Parameters, or Blowback screens {To access  
the required screen, press the right () or the  
left arrow key ()}, the following operations will  
need to be performed:  
1. When the controller is in the menu screen  
of the feature you wish to configure, press  
the up () and down () arrow keys to  
select the value you wish to change. (The  
parameter value will flash when selected.)  
2. Use the Plus (+) key to increase the value  
or the Minus (-) key to decrease the value.  
3. Press the OK key to update and accept the  
new value entered.  
4. Press the ESC key to cancel the  
parameters you entered and return the  
values to the previous settings.  
5-2-2  
Starting the System  
Once you have finished the setup procedues described on  
the previous pages, you are now ready to start the system.  
To start your system, complete the following steps.  
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1. Press the green START pushbutton in. The controller  
will display “✷✷✷” in the lower right corner of station and  
pump setup screens.  
Once the system has been started, each active station is  
polled in sequence for a demand signal. The convey  
sequence upon initiation, will continue until the set  
convey time has elapsed or the demand signal stops,  
whichever happens first. If the Special Timed Convey  
feature is enabled, conveying will continue until the  
convey time has elapsed. (Once station dump delay has  
been initiated during the convey sequence, a new  
demand signal will be ignored.) If the blowback  
sequence begins immediately following the convey  
sequence, the sequence valve will remain open  
throughout the blowback sequence.  
2. If during operation, a station conveys the specified  
number of consecutive times without clearing the  
demand signal, the NO CONVEY alarm will activate.  
Press the ALARM SILENCE pushbutton and hold it in to  
clear the alarm. The no convey alarm will sound in  
LONG TONES.  
3. Should the high vacuum pressure switch activate, the  
HIGH VACUUM alarm will sound. Press the ALARM  
SILENCE pushbutton and hold it in to clear the alarm.  
The high vaccum alarm will sound in SHORT TONES.  
4. If the pump motor contactor fails or the pump motor  
overload trips, the PUMP FAULT alarm will be activated.  
Press the ALARM SILENCE pushbutton and hold it in to  
clear the alarm. The pump fault alarm will sound in a  
CONTINUOUS TONE.  
5. To stop conveying, depress the green START  
pushbutton. The controller will no longer display “✷✷✷”  
on the station and pump setup screens.  
Page 24 of 38  
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6
Configurable Settings  
This section describes the proper setup of the SSC1-5Q  
control system parameters. These parameters are operator  
changeable; however, these items should require setup only  
during the initial installation. Only authorized personnel  
should change them.  
Many of the variables and setup parameters have been  
preset at the factory and do not need to be changed.  
However, this section of the manual will address all of the  
setup parameters that were available at the time of printing.  
The purpose of this is to familiarize the reader with all the  
setup parameters and their usage.  
6-1 Options for Station Setup  
Name  
Description  
Default  
Conveying Components  
Convey time  
(CONVEY)  
Length of time the station’s vacuum valve remains open to  
allow material to be drawn in. (For a volume-fill station, the  
valve closes when material covers the station’s volume-fill  
proximity sensor or this time elapses, whichever comes first.)  
15 sec.  
Adjust this value to match the actual time needed to fill the  
station. To disable a station, set the convey time to Ø  
(zero).  
Dump delay  
(DUMP)  
Length of time allowed for material to drain from the station into  
the receiver. The controller will not attempt to deliver more  
material to the station until this time has elapsed.  
10 sec.  
Adjust this value to match the actual time needed to drain the  
station. If it is set too short, the controller may attempt to refill  
the station before it is empty, causing material to back up  
and/or underusing the station’s capacity. If it is set too long, the  
system may be unable to keep up with your equipment’s  
demand for material. DO NOT SET TO “Ø”.  
No convey  
(NO CONVEY)  
The controller issues a “no convey” alarm if it has repeatedly  
attempted to convey material to the station but the flapper  
never opened during the dump delay. (The number of attempts  
is controlled by this setting.)  
3
The setting for this option depends on (a) how much material  
your injection mold uses to make each part compared with the  
capacity of the receiver and (b) how important it is to keep your  
injection mold from running out of material and shutting down.  
A higher setting will give you fewer alarms, at the risk of  
emptying the receiver without warning. A lower setting will give  
more frequent alarms, at the risk of disrupting operations  
unnecessarily. DO NOT SET TO “Ø”.  
Page 25 of 38  
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6-2 Options for Pump Setup  
The ramp time represents the amount of time it takes for the  
vacuum blower to come up to full speed once it has been  
turned on. The ramp down time represents the amount of  
time it takes the blower to stop once it has been turned off.  
The ramp up time lets the blower reach full speed unloaded.  
When the ramp up time is reached, the vent valve will open  
and allow the pump to draw a vacuum on the main vacuum  
line. This in turn will open the receiver sequence valve  
connected to the main vacuum line and allow material to be  
drawn into the vacuum receiver.  
The ramp down time allows the vacuum blower to come to a  
full stop before it can be started again. This prevents the  
blower motor from becoming a generator and blowing fuses.  
Name  
Description  
Default  
Pump Settings  
Idle  
(IDLE)  
Length of time the pump continues to run unloaded without  
demand from any station. After this time has elapsed, the pump  
shuts down to save power and to prevent wear on the pump.  
Adjust this setting to fit the needs of your facility in trading off the  
savings against the costs associated with waiting for a pump to  
start up when there is a demand for material.  
45 sec.  
Ramp Up  
This feature specifies the time (in seconds) allowed for the pump  
motor to reach operating speed.  
This feature specifies the time (in seconds) allowed for the pump  
motor to come to a complete stop.  
When this option is enabled, the controller periodically sends  
compressed air backward through the pump’s air filter to dislodge  
accumulated dust and debris.  
5 sec.  
5 sec.  
Ramp Down  
(Ramp Dn)  
Conveys Before  
Blowback  
enabled  
(CNV>BB)  
Enable this option if and only if the pump has the equipment for  
compressed-air filter cleaning. Set to Ø to Disable Blowback.  
Number of conveying cycles to stations between filter cleanings.  
Adjust this setting based on experience. The more dust and  
debris in your material line, the smaller this number needs to be.  
5
Pulse On Time  
(BB ON)  
Tenths of seconds that the air pulse remains on for each cleaning  
pulse during filter cleaning.  
1.6 sec.  
If blow-back is not working as desired, the Sterling service may  
ask you to change this setting.  
Tenths of seconds between air pulses during filter cleaning.  
If blow-back is not working as desired, the Sterling service may ask you  
to change this setting.  
Pulse Off time  
(BB OFF)  
0.8 sec.  
1
Numbler of cleaning  
pulses (No. Pulses)  
(BB CYC)  
Number of pulses of compressed air sent through the pump’s  
filter during cleaning.  
If blow-back is not working as desired, the Sterling service may  
ask you to change this setting. Set to Ø to Disable Blowback.  
Page 26 of 38  
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7
Maintenance  
No Periodic maintenance is required on this unit.  
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8
Troubleshooting  
8-1  
General Troubleshooting  
Problem  
Possible Cause  
Solution  
The control panel doesn’t light up The control panel is not turned  
Turn on the control panel.  
at all  
on.  
The external disconnect  
(recommended) in the dedicated  
circuit is open (off).  
Close the switch (on).  
Fuse/circuit breaker in the power Replace/reset.  
drop is blown/tripped.  
Control power switch is broken.  
The motor overload has tripped.  
Replace.  
A pump package doesn’t run,  
even though it is on-line and its  
indicator is lit.  
Reset the overload and check  
the motor for the proper amp  
draw on tag.  
Main fuse in power drop or  
optional fused disconnect has  
blown.  
Replace the fuse.  
Motor contact is faulty.  
Repair or replace as required.  
A vacuum receiver is being by-  
passed in the loading cycle.  
The vacuum receiver is off-line.  
Use the controller to put the  
vacuum receiver on-line.  
The convey time for the vacuum  
receiver is set to zero.  
Use the controller to enter a  
longer convey time.  
The field-installed station bypass Normal operation. Set the switch  
switch is simulating a Bin Full  
condition.  
so the vacuum receiver is back in  
the loading sequence.  
The field-installed station bypass Repair, replace, or re-wire.  
switch is bad or mis-wired.  
The vacuum receiver was  
assigned to the wrong pump  
during setup.  
Repeat the setup procedure.  
Vacuum receivers are overfilling. Conveying times are too long  
(Time Fill Mode only).  
Time the vacuum receiver (s)  
during loading, and set the  
conveying times to a few  
seconds less.  
Maximum conveying times are  
too long, and the PLC does not  
recognize the Vacuum Receiver  
Full Proximity Switch(es).  
Check proximity sensors for  
proper operation and proper  
wiring to the PLC. Repair as  
needed. Reset the conveying  
times to a reasonable value, and  
adjust as needed.  
Page 28 of 38  
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8-2  
Alarms  
The format for all station alarms is “Station n [alarm text],” for  
example, “Station 12 receiver low level.” The format for all  
pump alarms is “Pump n [alarm text].” Any alarm that does  
not start with “Station” or “Pump” is a system alarm.  
The following tables list all alarms alphabetically, together  
with possible causes. A “critical” alarm is one that causes the  
affected device to stop.  
Note: You can also see a list of alarms and their causes in the  
controller’s online help. To display this information, touch the  
color key of statuses in the upper right-hand corner of either  
the “Station Status” or the “Pump Status” screen, or touch  
Help at any other screen. When you are finished reviewing  
the help, touch Return.  
8-2-1 Station Alarms  
Alarm message  
Possible cause  
Material line is blocked.  
Vacuum line is blocked.  
Convey time is too long (time-fill station only).  
Sequence valve has malfunctioned.  
Vacuum switch has malfunctioned.  
High vacuum  
Note: After you have corrected the cause of this alarm, the alarm will be  
cleared when the controller has conveyed a full load to this station.  
Material container is empty.  
Material line is disconnected from material source.  
Vacuum line is disconnected from station.  
Take-off compartment is not adjusted properly.  
Convey time is too short.  
No convey  
Note: As a stopgap measure, you can disable the “no convey” alarm for  
this station until the problem can be remedied.  
8-2-2 Pump Alarms  
Alarm message  
Pump failure  
(Critical)  
Possible cause  
Circuit breaker or overload protector has tripped.  
Contactor has malfunctioned.  
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9
Options  
The following is a list of options that your controller may be  
equipped with:  
230/1/60 Operation  
Required to operate with a 230/1/60 supply voltage.  
CE Package for 220/1/50 Operation  
Required in Europe and other areas that need 220/1/50  
supply voltage  
Remote Audible/visual alarm  
Alarm light and horn assembly that can be remote mounted  
and wired into the controller to indicate an alarm condition.  
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10  
Spare Parts List  
10-1 Recommended Spare Parts List  
Quantity  
Sterling Part Number  
A0538007  
Vendor Part Number  
FNM-6  
Description  
Fuse  
1
1
A0536896  
FNM-2  
Fuse  
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11  
Technical Assistance  
11-1 Contact Information for Technical Assistance  
Parts Department  
[
]
[414]  
Call toll-free 7am–5pm CST 800 423-3183 or call 354-0970, Fax [414] 354-6421  
The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to  
Sterling engineering design specifications, which 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 Sterling parts needs and is dedicated to providing excellent customer service.  
Service Department  
[
]
[
] 3  
Call toll-free 8am–5pm CST 800 657-4679 or call 414 54-0970  
[
]
Emergencies after 5pm CST, call 847 439-5655  
Sterling has a qualified service department ready to help. Service contracts are available for most Sterling products.  
Sales Department  
[414]  
Call  
354-0970 Monday–Friday, 8am–5pm CST  
Sterling 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 414 354-0970 Monday–Friday, 8am–5pm CST  
Let Sterling 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.  
Sterling  
5200 W. Clinton Ave  
Milwaukee, WI 53223  
[
]
[414]  
354-6421  
414 354-0970 Fax  
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11-2 Returned Material Policy  
11-2-1Credit Returns  
1. Prior to the return of any material, authorization must be  
given by Sterling. A RMS number will be assigned for  
the equipment to be returned.  
2. Reason for requesting the return must be given.  
3. All returned material purchased from Sterling returned is  
subject to 15% ($75.00 minimum) restocking charge.  
4. All returns are to be shipped prepaid.  
5. The invoice number and date or purchase order number  
and date must be supplied.  
6. 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.  
11-2-2Warranty Returns  
1. Prior to the return of any material, authorization must be  
given by Sterling. A RMS number will be assigned for  
the equipment to be returned.  
2. Reason for requesting the return must be given.  
3. All returns are to be shipped prepaid.  
4. The invoice number and date or purchase order number  
and date must be supplied.  
5. After inspecting the material, a replacement or credit will  
be given, at Sterling’s discretion, if the item is found to  
be defective in materials or workmanship, and it was  
manufactured by Sterling. Purchased components are  
covered under their specific warranty terms.  
Page 33 of 38  
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11-3Warranty  
Sterling warrants all equipment manufactured by it to be  
free from defects in workmanship and material when used  
under recommended conditions. The Company’s obligation  
is limited to repair or replace FOB the factory any parts 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.  
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.  
The Company is not liable for any incidental, consequential,  
or special damages or expense. 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.  
Any sales, use, excise, or other tax incident to the  
replacement of parts under this warranty is the responsibility  
of the purchaser.  
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.  
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12  
Safety Tag Information  
12-1 Controller Safety Tags  
High Voltage  
Inside Enclosure  
Read Operation and  
Installation Manual  
12-2Controller Identification (Serial Number) Tag  
(Located on the side of the controller box)  
5200 W. Clinton Ave  
Milwaukee, WI 53223  
Tel. (414) 354-0970  
Fax (414) 354-6421  
SSC CONTROL PANEL  
Model No. SSC1-5Q  
Serial No. 31K0182  
Ph  
115 Volt  
60 Hz  
1
Control Voltage 24VDC  
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13  
Appendix  
Review electrical drawings supplied in the packet with the  
manual.  
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Sterling warrants all equipment manufactured by it to be free from defects in workmanship and  
material when used under recommended conditions. The Company’s obligation is limited to repair  
or replace FOB the factory any parts that are returned prepaid within one (1) 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.  
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 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.  
The Company is not liable for any incidental, consequential, or special damages or expenses. 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.  
Any sales, use, excise, or other tax incident to the replacement of parts under this warranty is the  
responsibility of the purchaser.  
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.  
Many types of Sterling equipment carry an additional one-year service policy. Consult your  
Sterling/Sterlco sales representative for specific details.  
PO Box 245018 5200 W. Clinton Avenue Milwaukee, WI 53224-9518 USA  
Phone (414) 354-0970 Fax (414) 354-6421  
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Service Department  
Call Toll Free  
(800) 783-7835  
Auxiliary Equipment for the Process Industries  
PO Box 245018  
5200 West Clinton Avenue Milwaukee, WI 53224-9518  
(414) 354-0970 Fax (414) 354-6421  
Scrap  
Recovery Systems  
Process Heating/  
Cooling  
Automated  
Parts Removal  
Material  
Processing  
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