Sterling Plumbing Heat Pump 8820025400 User Manual

SCC 7-Pump 50D & D Plus-Station Controllers  
Part Number: 882.00254.00  
Bulletin Number: CV3-645  
Effective: 11/27/05  
Write Down Your Serial Numbers Here For Future Reference:  
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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.  
Returns  
Do not return any damaged or incorrect items until you receive shipping instructions from the  
shipping department.  
7/50D Plus or 7/50D Controller  
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......................................................................................................12  
Safety Devices and Interlocks...................................................................................12  
Safety Circuit Standards......................................................................................12  
Fail Safe Operation .............................................................................................12  
Safety Device Lock-Outs.....................................................................................13  
2-4  
2-5  
CHAPTER 3: INSTALLATION ..................................................14  
3-1  
3-2  
3-3  
3-4  
Uncrating...................................................................................................................14  
Mounting the Control Panel.......................................................................................14  
System Installation Overview ....................................................................................14  
Electrical Connections...............................................................................................15  
Making Control Panel Power Drop Wiring Connections......................................15  
Running KwikLink™ Cables................................................................................15  
Setting Up and Installing Mounting Plates...........................................................17  
Terminating Cable Runs......................................................................................18  
Addressing and Installing ArmorBlocks™ ...........................................................20  
Installing KwikLink™ Connectors........................................................................23  
Connecting the Controller to the Network............................................................24  
Connecting the Power Supply Enclosure to the Network....................................26  
Connecting Vacuum Receivers to the Network...................................................28  
Connecting Vacuum Pumps and Filter Chambers to the Network ......................30  
Connecting Central Alarms to the Network .........................................................33  
Setup.........................................................................................................................35  
Setting Up the System.........................................................................................36  
Setting Up Stations..............................................................................................43  
Setting Up Pumps ...............................................................................................47  
Finishing Setup: Setting Up Passwords ..............................................................51  
3-5  
3-6 Initial Startup...............................................................................................................53  
7/50D Plus or 7/50D Controller  
Chapter 1: Safety  
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CHAPTER 4: OPERATION ........................................................54  
4-1  
4-2  
4-3  
Overview ...................................................................................................................54  
Starting and Stopping the System.............................................................................54  
Basic Tasks...............................................................................................................55  
Reviewing Station Status ....................................................................................55  
Reviewing Pump Status ......................................................................................57  
Logging On and Logging Off ...............................................................................59  
Enabling and Disabling Stations and Pumps.......................................................60  
Reviewing and Adjusting Basic Station Settings .................................................61  
Advanced Tasks........................................................................................................64  
Reviewing and Resetting a Pump Hour Meter ....................................................65  
Transferring Stations to a Standby Pump............................................................66  
Alarms .......................................................................................................................69  
Reviewing Alarms................................................................................................69  
Clearing the Alarm Log........................................................................................70  
Silencing Alarms..................................................................................................71  
4-4  
3-5  
CHAPTER 5: MAINTENANCE..................................................72  
5-1  
5-2  
Preventative Maintenance.........................................................................................72  
Corrective Maintenance ............................................................................................72  
Network Scanner Module Considerations ...........................................................72  
CHAPTER 6: CONFIGURABLE SETTINGS.............................73  
6-1  
6-2  
6-3  
Memory Module Considerations................................................................................73  
Options for Station Setup ..........................................................................................73  
Options for Pump Setup............................................................................................78  
CHAPTER 7: TROUBLESHOOTING........................................80  
7-1  
General Troubleshooting...........................................................................................80  
7-2 Alarms..........................................................................................................................81  
Station Alarms.....................................................................................................81  
Pump Alarms.......................................................................................................82  
System Alarms ....................................................................................................83  
CHAPTER 8: APPENDIX ..........................................................84  
8-1  
Warranty....................................................................................................................84  
Warranty Specifications.........................................Error! Bookmark not defined.  
Warranty Restrictions............................................Error! Bookmark not defined.  
Warranty Liabilities................................................Error! Bookmark not defined.  
Customer Responsibilities.....................................Error! Bookmark not defined.  
Optional Components................................................................................................84  
Drawings and Diagrams............................................................................................85  
Spare Parts List.........................................................................................................88  
AC Voltage ..........................................................................................................88  
DC Voltage..........................................................................................................88  
Returned Material Policy ...........................................................................................88  
Credit Returns .....................................................................................................88  
Warranty Returns ................................................................................................89  
8-2  
8-3  
8-4  
8-5  
7/50D Plus or 7/50D Controller  
Chapter 1: Safety  
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8-6  
Safety Tag Information..............................................................................................89  
Controller Safety Tags.........................................................................................89  
Controller Identification (Serial Number) Tag............................................................89  
Technical Assistance (Contact Information)..............................................................90  
Parts Department ................................................................................................90  
Service Department.............................................................................................90  
Sales Department................................................................................................90  
Contract Department...........................................................................................90  
8-7  
8-8  
7/50D Plus or 7/50D Controller  
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.  
7/50D Plus or 7/50D Controller  
Chapter 1: Safety  
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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.  
7/50D Plus or 7/50D Controller  
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.  
7/50D Plus or 7/50D Controller  
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.  
7/50D Plus or 7/50D Controller  
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 7-Pump, 50D  
& D Plus-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 7-Pump, 50D & D Plus-Station Conveying Controller is a programmable logic  
controller, with 24 VDC or 115 VAC control circuit, easy-to-use touchscreen operator  
interface terminal and optional audible/visual alarm.  
2-2 General Description  
Our material conveying systems create vacuum for the automatic conveying of most free-  
flowing, dry, pelletized, or granular materials. 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.  
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.  
Note: Vacuum leaks occurring anywhere in your system reduce capacity.  
7/50D Plus or 7/50D Controller  
Chapter 2: Functional Description  
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2-3 Standard Features  
Mechanical Features  
Time-fill Capability. The length of time allowed for material to drain from the station to its  
receiver. During this time, the controller does not attempt to deliver any more material to the  
station.  
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.  
Vent Valve Output. The vent valve protects the pump motor from damage during high  
vacuum conditions if an undetected failure of the vacuum switch should occur. The vent  
valve limits system vacuum by allowing a plunger in the valve to shift and vent the pump.  
Closed-Loop Conveying. This feature allows material to be conveyed and processed  
without being contaminated by outside influences (such as dust, other materials, etc.).  
Common Purge Valve Output Control for Each Pump. This feature allows any remaining  
material to be cleaned out of the vacuum pump or station.  
Local 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 or 230/1/50/60 supply voltage  
24 VDC control voltage  
Single-point power and ground connection  
Non-fused disconnect switch, lockable  
Branch circuit fusing  
Fully accessible NEMA 4-style electrical control enclosure  
Controller Features  
Allen-Bradley SLC 5/04 programmable controller with 10” color touch screen operator  
interface  
Diagnostics, operating instructions and parts information are built into the interface  
Controls up to fifty (50) stations and up to seven (7) Vacuum Power Units.  
Controls up to three central alarms  
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  
7/50D Plus or 7/50D Controller  
Chapter 2: Functional Description  
11  
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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.  
Additional audible/visual alarm with silence button. Alarm light and horn assembly that  
can be remote mounted and wired into the controller to indicate an alarm condition.  
Remote Interface.  
Central Purge Capability.  
Material Line Proofing – includes an additional PLC located near the quick change  
manifold.  
CE Package for 220/1/50 Operation. Required in Europe and other areas that need  
220/1/50 supply voltage.  
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 controller;  
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.  
7/50D Plus or 7/50D Controller  
Chapter 2: Functional Description  
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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 7-Pump, 50D & D Plus-Station Controller. Failure to  
do so may result in serious injury. No one but the person who installed the lockout  
may remove it.  
7/50D Plus or 7/50D Controller  
Chapter 2: Functional Description  
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Chapter 3: Installation  
3-1 Uncrating  
7-Pump, 50D & D Plus-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, inserting forklift under the base. The forks must be equidistant  
from the centerline of the unit and the unit must be balanced on the forks. 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  
KwikLink connectors, ArmorBlocks, vacuum hoppers, the filter cham-  
ber atmospheric valve (if so equipped) and the pump motor starter(s),  
vacuum switch(es), and vent valve(s).  
Mount the control 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 System Installation Overview  
Installing the 7-pump 50-station controller is easy and straightforward. Because the system  
uses networked distributed I/O modules, you’ll only need to run two cables for the entire  
system.  
The following is a typical installation sequence:  
1. Run the black power and the grey data KwikLink™ flat cables from the start of the  
system to the end, attaching them to vacuum tubing with nylon cable ties.  
2. Set up mounting plates with tubing clamps; install KwikLink™ connectors and  
ArmorBlocks onto mounting plates as required.  
3. Install KwikLink connectors and ArmorBlock™ cable plates to mounting plates, and  
install on vacuum tubing at each node location, just before a T-fitting or valve.  
4. Install cable terminations.  
5. Determine location of network system nodes, and set addresses for ArmorBlocks as  
required.  
6. Set up and connect to the controller and, if purchased, remote display. Connect grey  
patch cords from controller terminals to KwikLink connectors installed in Step 3.  
7/50D Plus or 7/50D Controller  
Chapter 3: Installation  
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7. After determining quantity and location(s) of where to install system power  
supply(ies) (consult factory); set up and connect to KwikLink connectors installed in  
Step 3.  
8. Set up and connect vacuum receiver stations to ArmorBlocks installed in Step 3,  
using yellow patch cords.  
9. Set up and connect vacuum pump stations and filter chambers to ArmorBlocks  
installed in Step 3, using yellow patch cords.  
10. Determine location(s) of central alarm(s); set up and connect alarms using yellow  
patch cords.  
The following sections provide detailed information on these installation steps.  
3-4 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  
Hardwire the input power at 115/1/50-60 VAC or 230/1/50-60 VAC, depending on the  
specifications, which are located on the Control Panel Serial Tag. The control enclosure  
draws less than five (5) amps during normal operation at 115/1/50-60 VAC. The main power  
switch is located on the right side of the enclosure.  
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.  
Running KwikLink™ Cables  
About KwikLink Flat Cables  
KwikLink flat cable is physically keyed to prevent wiring mishaps. This type of cable is  
unshielded and contains four conductors. Use a long-jawed straight-bladed cable cutter at  
least 1½” long to cut KwikLink flat cable.  
You’ll install two (2) colors of flat cable: black and grey. The black cable transmits output  
power, and the grey cable transmits input power and data transmission.  
Figure 1: KwikLink Cable Cross-Section, Edge Identification  
Cross Section  
Edge Identification  
7/50D Plus or 7/50D Controller  
Chapter 3: Installation  
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Installing KwikLink Cable  
Before you install flat cable, determine how much length you need to install black power  
cable and grey data cable. Typical installations have equal lengths of each. This is a good  
time to plan for the future, and run these cables to each possible location in the plant. Use a  
straight-blade cable cutter to make the cut at each end.  
To install KwikLink cables:  
1. Cut both black and grey cables to the proper length.  
2. Use cable ties to attach KwikLink cables, black cable above grey cable, on the  
vacuum tubing. Attach cable to the tubing with cable ties at about three-foot (3 ft./  
1 m) invervals. Make sure that cable ties are snug, but not tightened enough to bend  
the flat cable.  
Caution!  
Install KwikLink cable on vacuum tubing only. DO NOT install KwikLink  
cable on material conveying tubing, as static electricity formed at material  
lines could disrupt system operation.  
Figure 2: Side View of a Typical Power Cable and Data Cable Installation  
Cable tie, buckle  
Black power cable  
Vacuum tube  
Grey data cable  
Note: When approaching a node location, stop the attachment process. Run  
the cables over the node area (such as a T-valve) and make sure you  
create a slight amount of slack when continuing the attachment with  
cable ties. Doing so lets you install KwikLink connectors or  
ArmorBlocks with greater ease, with less stress on the cable.  
7/50D Plus or 7/50D Controller  
Chapter 3: Installation  
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Setting Up and Installing Mounting Plates  
Setting Up Mounting Plates  
It’s a good idea to get all your mounting plates set up with KwikLink connector bases or  
ArmorBlock cable bases before installation, as your system layout determines.  
Note: ArmorBlock cable bases are installed on mounting plates  
perpendicular in orientation to the flat cable runs.  
Vacuum hoppers/receiver stations require 8-connector ArmorBlocks; vacuum  
pumps and central alarm stations require 4-connector ArmorBlocks.  
Make sure that each mounting plate has properly attached tube clamps as required. Each  
mounting plate requires two (2) tube clamps. Always use locking washers, especially in  
high-vibration environments.  
Figure 3: Side View of a Typical Mounting Plate Assembly with ArmorBlock Base  
Rotate 30º to 45º downward  
Installing Assembled Mounting Plates  
After you’ve set up the mounting plates:  
1. Install them at each node location by clipping the tubing clamps onto the vacuum  
tube, just before the node area (such as a T-valve).  
2. Orient the mounting plate parallel with the flat cables and at a 30º to 45º angle so the  
KwikLink connector or ArmorBlock faces the operator on the floor; torque the tubing  
clamp fasteners until tight.  
The flat cable will be installed inside KwikLink connectors and ArmorBlocks as described in  
the following sections of this chapter.  
7/50D Plus or 7/50D Controller  
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Terminating Cable Runs  
After you’ve run the black and grey network cables, you need to properly terminate the ends  
of the cables. By doing so, you’ll insure that the network runs properly. You will also have  
the benefit of being able to measure voltage in the system without disrupting operation.  
This section lists procedures for terminating these cables. To properly terminate a cable run:  
1. Mount three standard KwikLink connectors to a mounting plate in a triangle  
configuration. See Figure 4 on Page 19 for an illustration.  
Make sure that each connector is installed with the hinge side down.  
2. Mount the tubing clamps to the mounting plates. Each mounting plate requires two  
(2) tubing clamps.  
3. Mount the standard resistor cap from the KwikLink connector kit on the top center  
KwikLink connector for the black power flat cable. The standard resistor cap has  
metal prongs in the center.  
Repeat for the outside end KwikLink connector on the grey data flat cable.  
4. For the inside KwikLink connector (next to the outside end on the grey cable), mount  
a separately-packaged blank cap on it instead of the standard resistor cap in the  
KwikLink connector kit.  
Discard the standard resistor cap to eliminate confusion.  
5. Mount the mounting plate assembly on the vacuum line at the end of the cable run.  
See Page 17 for more information.  
6. Using the straight-blade cable cutter, carefully trim each flat cable so it sticks out past  
the final KwikLink connector by 1/4” to 3/8”.  
Place a dust cap over the end of the trimmed cable.  
7. Lay the dust cap and cable into the KwikLink connector so the dust cap tabs engage  
in the connector slots. The dust cap tabs should fit into the connector slots perfectly.  
Left  
Right  
8. Lay the cable in the hinged base, noting the correct keyed profile; flat edge toward  
the hinge, keyed edge toward the latch. Make sure that the cable and dust cap are  
properly seated inside.  
9. Making sure that the cable is completely straight, carefully close the hinged  
assembly, and apply firm, even pressure until the first latch locks into place.  
Note: Make sure that the flat cable is completely staight before continuing!!  
The latch has two catches; the first loosely holds the connector on the cable, the  
second requires more pressure to close the connector tightly. The cable must be in the  
correct position for the connector to close properly.  
7/50D Plus or 7/50D Controller  
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10. Drive the two screws at the center points about halfway down; first on the latch side,  
then the hinge side.  
11. Continue to tighten the screws a little at a time until fully tightened; no more than 15  
inch-pounds (5.6 Nm) of torque.  
Note: You can only pierce the cable once. Once pierced, the KwikLock  
connector must not be removed. This insures that the inner conductors  
are not exposed to the elements.  
Installing Inside KwikLink Connectors with Blank Caps  
Once installed on the grey data cables, these connectors permit you to measure voltage in the  
system so you can analyze how it is working. The system cannot work properly unless these  
inside-mounted connectors have the blank (non-conductor) caps installed.  
1. Lay the cable in the hinged base, noting the correct keyed profile; flat edge toward  
the hinge, keyed edge toward the latch. Make sure that the cable is properly seated  
inside.  
2. Making sure that the cable is completely straight, carefully close the hinged  
assembly, and apply firm, even pressure until the first latch locks into place.  
Note: Make sure that the flat cable is completely straight before continuing!!  
The latch has two catches; the first loosely holds the connector on the cable, the  
second requires more pressure to close the connector tightly. The cable must be in the  
correct position for the connector to close properly.  
3. Drive the two screws at the center points about halfway down; first on the latch side,  
then the hinge side.  
4. Continue to tighten the screws a little at a time until fully tightened; no more than 15  
inch-pounds (5.6 Nm) of torque.  
Note: You can only pierce the cable once. Once pierced, the KwikLock  
connector must not be removed. This insures that the inner conductors  
are not exposed to the elements.  
The system should now be properly terminated. You can now continue to install components  
on the system.  
Figure 4: Proper Termination Connections  
Standard KwikLink  
Connectors  
Dust Caps  
Inside KwikLinkConnector
with Blank Cap  
Inside KwikLink Connector  
with Blank Cap  
ArmorBlockMountingPlateKit
Part No. A0556696  
7/50D Plus or 7/50D Controller  
Chapter 3: Installation  
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Addressing and Installing ArmorBlocks™  
Addressing Armorblocks  
An ArmorBlock permits you to give it a number “address” so that the controller network  
system can recognize its location and function. ArmorBlocks are used at vacuum  
hopper/receiver, pump, and alarm node locations.  
ArmorBlock Address Ranges  
The number range of ArmorBlock addresses are as follows:  
01 to 50 — Vacuum hopper/receiver stations; use a leading zero for  
numbers 01 to 09.  
51 to 57 — Pump stations  
58 to 60 — Alarm stations  
Setting Armorblock Addresses  
Locate the rotary switches underneath the ArmorBlock. The two switches are:  
MSD (most significant digit) for tens  
LSD (least significant digit) for units/ones  
For example, if you wanted to set an address at 36, you set the MSD rotary switch at 3 and  
the LSD rotary switch at 6. To set an address of 8, set the MSD rotary switch at 0 (leading  
zero), then set the LSD rotary switch at 8.  
Using a permanent black marker, write the number of the address  
on the white label located on the bottom front of the ArmorBlock.  
We suggest that you place numbered tags at node locations to ease  
installation and reduce any confusion of locations.  
To set the node address:  
Use a small straight-bladed screwdriver to rotate the switches.  
Line up the small arrowhead on the switch with the number you want  
to select.  
The following figure shows that the address is set at 01; the MSD rotary switch is set at 0 and  
the LSD rotary switch is set at 1.  
Figure 5: ArmorBlock Address Node Rotary Switches  
7/50D Plus or 7/50D Controller  
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Installing ArmorBlocks  
The ArmorBlock cable base should already be attached to the mounting plate, aligned so it is  
perpendicular to the flat cables. If not, reinstall it with its proper alignment.  
To install the flat cables in the ArmorBlock cable base:  
1. Lay the flat cable into the ArmorBlock cable base, grey data cable on the bottom and  
the black power cable on the top, making sure that the keyed edge is properly seated  
toward the top.  
Caution!  
EXERCISE CARE when handling the seal block.  
Cable contacts are SHARP!  
Only ONE attempt to pierce the cable is allowed for proper contact.  
Figure 6: Using seal block to pierce cable  
2. Align the seal block so the L-shaped tabs are towards the top, and the arrows are  
matched on the bottom of the cable base and seal block. Make sure that the arrows  
and the four captive screws on the seal block are properly aligned. Gently press it  
into place.  
Make sure that you align the seal block properly when you attach it to the base.  
Doing so maintains the integrity of the sealed base.  
Note: You can only pierce the cable once. Once pierced, the seal block must  
not be removed. This insures that the inner conductors are not exposed  
to the elements.  
7/50D Plus or 7/50D Controller  
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Figure 7: Securing the Seal Block to the Cable Base  
To secure the seal block:  
1. Start the threads of each of the four captive screws into the cable base receptacle  
holes.  
2. Drive each of the screws about halfway down, using the proper torque sequence:  
Bottom screw, top screw, left screw, right screw. Doing so insures that the cables are  
pierced evenly.  
3. Using the proper torque sequence, tighten each screw, a little at a time, until the  
seal block is fully seated into the cable base. Tighten to no more than 8 to 10 inch-  
pounds (3.0 to 3.7 Nm) of torque.  
The three seat lines on the seal block should meet the cable base, indicating that the  
seal block is fully seated. The seal block clips should also click into place onto the  
corresponding cable base slots.  
7/50D Plus or 7/50D Controller  
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Installing KwikLink™ Connectors  
KwikLink connectors let you connect the controller and the power supply to the system. They  
are also used to electronically terminate power cable and data cable runs.  
Just like ArmorBlocks, KwikLink connectors are insulation displacement connectors (IDCs).  
Caution!  
Exercise care when installing Kwiklink connectors.  
IDC blades on KwikLink connectors are SHARP!  
Gently push back any protruding IDC blades before installing flat cables  
inside.  
The KwikLink connector should already be attached to the mounting plate, so the hinge side  
is down. If not, reinstall it with its proper alignment, along the correct flat cable. See the  
installation drawing located in your Customer Information Packet for further details.  
To install flat cable inside KwikLink connectors:  
1. Lay the cable in the hinged base, noting the correct keyed profile; flat edge toward  
the hinge, keyed edge toward the latch. Make sure that the cable is properly seated  
inside.  
2. Making sure that the cable is completely straight, carefully close the hinged  
assembly, and apply firm, even pressure until the first latch locks into place.  
Note: Make sure that the flat cable is completely straight before continuing!  
The latch has two catches; the first loosely holds the connector on the cable, the  
second requires more pressure to close the connector tightly. The cable must be in the  
correct position for the connector to close properly.  
3. Drive the two screws at the center points about halfway down; first on the latch side,  
then the hinge side.  
4. Continue to tighten the screws a little at a time until fully tightened; no more than 15  
inch-pounds (5.6 Nm) of torque.  
Note: You can only pierce the cable once. Once pierced, the KwikLink  
connector must not be removed. This insures that the inner conductors  
are not exposed to the elements.  
7/50D Plus or 7/50D Controller  
Chapter 3: Installation  
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Connecting the Controller to the Network  
To connect the controller to the network, make sure that the KwikLink connector is properly  
installed on the flat grey data cable. To connect:  
1. Attach the keyed round connector to the terminal of the controller marked  
NETWORK NO. 1. Tighten the cord grip ring until snug.  
2. Align the square connector of the grey drop cable so the cable leads down from the  
connector. Evenly press the square connector onto the top of the KwikLink  
connector. It should make two audible snaps when properly seated.  
3. Dress the excess cable with cable ties so it does not interfere with operation and gives  
a pleasing appearance.  
Connecting the Remote Interface to the Main Controller  
After selecting a location and installing the remote interface, connect it to the main controller:  
1. Determine the length of blue remote cable you need, and cut it to length.  
2. Run the cable from the remote interface to the main controller, neatly dressing the  
cable with cable ties so it does not interfere with system operation and to give it a  
neat appearance.  
3. Attach connectors at each end, following the connector manufacturer’s instructions.  
4. Attach one connector to the remote interface terminal marked REMOTE DISPLAY.  
Tighten the cord grip ring until snug.  
5. Attach the other connector to the terminal of the controller marked REMOTE  
DISPLAY. Tighten the cord grip ring until snug.  
7/50D Plus or 7/50D Controller  
Chapter 3: Installation  
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Figure 8: Proper Controller and Remote Interface Connections  
ArmorBlock Mounting Plate Kit  
Part No. A0556696  
Black Power Flat Cable  
Vacuum Tube  
Grey Network Flat Cable  
Power or Network Tap/Cable Drop  
Part No. A0555195  
One (1) Cord Required & is Connected,  
as Shown, to the Grey Network Flat Cable  
Main Touch-Screen  
Control Display  
Blue Cable, 20 ft. (6 m)  
One (1) Cord is Needed per Display, as Shown  
Connected to the Marked Terminals  
of the Main & Remote Control Boxes  
Remote Touch-Screen  
Control Display  
7/50D Plus or 7/50D Controller  
Chapter 3: Installation  
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Connecting the Power Supply Enclosure to the Network  
The power supply provides electrical power to make the system work. Some network layouts  
require more than one power supply.  
Location is also an important consideration when locating power supply enclosures on your  
network. Contact the factory for determining how many power supply enclosures your system  
needs, as well as where they need to be installed.  
After you’ve mounted the power supply enclosure(s), you can connect them to your network.  
To connect a power supply to the network:  
1. Attach a KwikLink connector included in the bag with power cables to the flat  
cables. One connector is used for the network grey cable and one connector is used  
for the auxiliary power black cable.  
2. Align the square connector of the grey drop cable so the cable leads down from the  
connector. Evenly press the square connector onto the top of the bottom KwikLink  
connector. It should make two audible snaps when properly seated.  
3. Align the square connector of the black drop cable so the cable leads down from the  
connector. Evenly press the square connector onto the top of the upper KwikLink  
connector. It should make two separate, audible snaps when properly seated.  
4. Attach the keyed round connectors to the receptacles on the side of the power supply  
enclosure marked 24 VDC POWER SUPPLY. Tighten the cord grip ring until  
snug.  
5. Dress the excess cables with cable ties so they do not interfere with operation and to  
give a pleasing appearance.  
If more than one power supply is required to properly energize the grey network flat cable:  
1. Remove the terminal block jumpers on all but the most centrally-located network  
power supply enclosures.  
For locations of jumpers, refer to the drawing shipped inside the power supply  
enclosure  
Note: Only one power supply should be connected to each section of the  
black auxiliary power flat cable. Do not remove any jumpers on power  
supplies that transmit energy to the black flat power cable.  
7/50D Plus or 7/50D Controller  
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Figure 9: Proper Power Supply Enclosure Connections  
Black Power Flat Cable  
Vacuum Tube  
Grey Network Flat Cable  
ArmorBlock Mounting Plate Kit  
Part No. A0556696  
Power Cable  
Part No. A0555195  
Two (2) Cords Required  
Power Supply Enclosure  
7/50D Plus or 7/50D Controller  
Chapter 3: Installation  
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Connecting Vacuum Receivers to the Network  
Make sure that all previous installation steps have been done first before starting this task.  
To connect a vacuum receiver to the network:  
1. Attach one connector of the yellow patch cord to the terminal on the vacuum receiver  
terminal box. Tighten the cord grip ring until snug.  
2. Attach the other connector to the upper left terminal of the ArmorBlock. Tighten the  
cord grip ring until snug.  
Note: Retain the terminal caps from the ArmorBlock. They may be used  
later.  
*** The installation steps listed above also apply to the 7/50D 4-connector  
ArmorBlock.  
Note the following illustrations for 4 and 8-connector ArmorBlocks:  
Figure 10: 7/50D 4-Connector ArmorBlock Connections  
Pump Verify (A-I0)  
High Vacuum (A-I1)  
Pump Starter (C-O0)  
Vent Solenoid (C-O1)  
Pump Fault #1 (B-I2)  
Pump Fault #2 (B-I3)  
Blowback Solenoid (D-O2)  
Local Alarm Light (D-O3)  
4 Input / 4 Output  
ArmorBlock  
T-Connector  
AB#1485P-P1R4-DR4  
Part No. A0555169  
3. Dress the excess patch cord cable with cable ties so it does not interfere with  
operation and gives a pleasing appearance.  
Figure 11: 7/50D Plus 8-Connector ArmorBlock Connections  
T-Connector  
AB#1485P-P1R4-DR4  
Part No. A0555169  
Sequence Valve (E-O0)  
Demand Switch (A-I0)  
Volume Fill Prox. (A-I1)  
Local Alarm Light (E-O1)  
RPV Material 'A' Solenoid (F-O2)  
RPV Material 'B' Solenoid (F-O3)  
Bypass Switch (B-I2)  
Slide Gate (G-O4)  
Blowback (G-O5)  
Receiver Level  
Sensor (C-I4)  
Not used  
Purge Solenoid (H-O6)  
8 Input / 8 Output  
ArmorBlock  
7/50D Plus or 7/50D Controller  
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3. Dress the excess patch cord cable with cable ties so it does not interfere with  
operation and to give a pleasing appearance.  
Figure 12: Proper Vacuum Receiver Connections  
Black Power Flat Cable  
Vacuum Tube  
Grey Network Flat Cable  
ArmorBlock Mounting Plate Kit  
Part No. A0556696  
Yellow Patch Cord, 20 ft. (6 m)  
Part No. A0555190  
7/50 D Plus  
Connections  
8 Input / 8 Output ArmorBlock  
Part No. A0555192  
ArmorBlock Base  
Part No. A0555191  
Vacuum Receiver  
OR  
Make the same connections using a 4 input/ 4 output ARMORBLOCK  
7/50D  
Connections  
7/50D Plus or 7/50D Controller  
Chapter 3: Installation  
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Connecting Vacuum Pumps and Filter Chambers to the Network  
Connecting Vacuum Pumps  
Make sure that all previous installation steps have been done first before starting this task.  
You’ll use two yellow patch cords to connect.  
To connect a vacuum pump to the network:  
1. Attach one connector of the first yellow patch cord to the lower terminal on the  
vacuum pump terminal box. Tighten the cord grip ring until snug.  
2. Attach the other connector to the upper left terminal of the ArmorBlock. Tighten the  
cord grip ring until snug.  
3. Attach one connector of a yellow patch cord to the upper terminal on the vacuum  
pump terminal box. Tighten the cord grip ring until snug.  
4. Attach the other connector to the upper right terminal of the ArmorBlock. Tighten  
the cord grip ring until snug.  
Note: Retain the terminal caps from the ArmorBlock. They may be used  
later.  
Note the following illustration for 4-connector ArmorBlocks:  
Figure 13: 4-Connector ArmorBlock Connections  
Pump Verify (A-I0)  
High Vacuum (A-I1)  
Pump Starter (C-O0)  
Vent Solenoid (C-O1)  
Pump Fault #1 (B-I2)  
Pump Fault #2 (B-I3)  
Blowback Solenoid (D-O2)  
Local Alarm Light (D-O3)  
4 Input / 4 Output  
ArmorBlock  
T-Connector  
AB#1485P-P1R4-DR4  
Part No. A0555169  
5. Dress the excess patch cord cables with cable ties so they do not interfere with  
operation and to give a pleasing appearance.  
7/50D Plus or 7/50D Controller  
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Figure 14: Proper Vacuum Pump Connections  
Black Power Flat Cable  
Vacuum Tube  
Grey Network Flat Cable  
ArmorBlock Mounting Plate Kit  
Part No. A0556696  
Yellow Patch Cord, 20 ft. (6 m)  
Part No. A0555190  
Two (2) Cords Required  
4 Input / 4 Output ArmorBlock  
Part No. A0558296  
ArmorBlock Base  
Part No. A0555191  
Vacuum Pump  
7/50D Plus or 7/50D Controller  
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Connecting Filter Chambers  
Make sure that all previous installation steps have been done first before starting this task.  
You’ll use one yellow patch cord to connect.  
To connect a filter chamber to the network:  
1. Attach one connector of the yellow patch cord to the terminal on the filter chamber  
terminal box. Tighten the cord grip ring until snug.  
Figure 15: Proper Filter Chamber Connections  
Black Power Flat Cable  
Vacuum Tube  
Grey Network Flat Cable  
ArmorBlock Mounting Plate Kit  
Part No. A0556696  
8 Input / 8 Output ArmorBlock  
Part No. A0555192  
ArmorBlock Base  
Part No. A0555191  
Yellow Patch Cord, 20 ft. (6 m)  
Part No. A0555190  
VFC Filter Chamber  
2. Attach the other connector to the lower right terminal of the ArmorBlock you used  
to connect the vacuum pump. Tighten the cord grip ring until snug.  
Note: Retain the terminal caps from the ArmorBlock. They may be used  
later.  
3. Dress the excess patch cord cables with cable ties so they do not interfere with  
operation and to give a pleasing appearance.  
7/50D Plus or 7/50D Controller  
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Connecting Central Alarms to the Network  
Make sure that all previous installation steps have been done first before starting this task.  
First, determine where the best location for central alarms should be, and install the  
alarm module(s) there. You’ll use two yellow patch cords to connect.  
To connect an alarm module to the network:  
1. Attach one connector of the first yellow patch cord to the terminal on the alarm  
module. Tighten the cord grip ring until snug.  
2. Attach the other connector to the upper right terminal of the ArmorBlock. Tighten  
the cord grip ring until snug.  
Figure 16: Proper Central Alarm Connections  
Yellow Patch Cord, 20 ft. (6 m)  
Part No. A0555190  
Vacuum Tube  
Black Power Flat Cable  
Grey Network Flat Cable  
ArmorBlock Mounting  
Plate Kit - Part  
No. A0556696  
4 Input / 4 Output ArmorBlock  
Part No. A0558296  
ArmorBlock Base  
Part No. A0555191  
Yellow Patch Cord, 20 ft. (6 m)  
Part No. A0555190  
Push to Silence Button  
Remote Alarm  
3. Attach one connector of a yellow patch cord to the terminal on the alarm silence  
switch module. Tighten the cord grip ring until snug.  
7/50D Plus or 7/50D Controller  
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4. Attach the other connector to the upper left terminal of the ArmorBlock. Tighten the  
cord grip ring until snug.  
Note: Retain the terminal caps from the ArmorBlock. They may be used  
later.  
Note the following illustration for 4-connector central alarm ArmorBlocks:  
Figure 17: 4-Connector ArmorBlock Connections for Central Alarms  
Alarm Strobe Light (C-O0)  
Alarm Horn (C-O1)  
Alarm Silence Pushbutton (A-I0)  
Alarm Silence Pushbutton (A-I1)  
Alarm Strobe Light (D-O2)  
Alarm Horn (D-O3)  
Alarm Silence Pushbutton (B-I2)  
Alarm Silence Pushbutton (B-I3)  
4 Input / 4 Output  
ArmorBlock for  
Central Alarms  
5. Dress the excess patch cord cables with cable ties so they do not interfere with  
operation and to give a pleasing appearance.  
7/50D Plus or 7/50D Controller  
Chapter 3: Installation  
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3-5 Setup  
This section provides the procedures for configuring your 7/50D Plus or 7/50D  
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.  
Figure 18 below gives an overview of the basic flow between the menus used in setting  
up the system.  
Figure 18: Basic Menu Flow for Setup  
Pumps  
Station  
Pump  
Summary  
Summary  
Stations  
hold icon  
hold icon  
Station n  
Operator  
Pump n  
Setup  
System  
Setup  
System  
Station n  
Setup  
System  
Setup  
System  
DeviceNet  
Node Status  
DeviceNet  
Input Status  
7/50D Plus or 7/50D Controller  
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Setting Up the System  
Setting the Number of Stations and the Number of Pumps  
At the Station Summary screen (shown above), or at the Pump Summary screen:  
1. Touch the icon for any station (or pump) and hold it for several seconds. (When the  
controller arrives from the factory, only one icon appears.)  
A Station n Operator screen similar to the following appears. (If you started at the  
Pump Summary screen, the Pump n Setup screen appears instead.)  
7/50D Plus or 7/50D Controller  
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2. Touch Systemat the Station n Operator (or Pump n Setup) screen.  
The System Setup screen appears:  
Note: Touching Helpin the lower right of this screen gives you a menu of  
online help for the choices in this screen.  
(7/50D Plus Screen shown)  
Touching Returnat the help menu brings you back to the System Setup screen.  
3. Touch Stations Presentin the upper left of the System Setup screen.  
A keypad pops up.  
4. Enter the total number of stations (1–50) to be controlled by this controller. Use to  
erase any mistakes. Use to enter the value.  
The keypad disappears and the new setting appears under Stations Present.  
5. Touch Pumps Presentin the upper part of the System Setup screen.  
A keypad pops up.  
6. Enter the total number of pumps (1–7) to be controlled by this controller. Use to  
erase any mistakes. Use to enter the value.  
7. The keypad disappears and the new setting appears under Pumps Present.  
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Checking Addressing and Wiring for System Components  
Once you have set the number of stations and pumps as described previously, you should  
verify that the controller is communicating with all stations, pumps, and central alarms, and  
with the ArmorBlocks for all central purge valves. To do so:  
1. At the System Setup screen, touch DeviceNet Node Statusnear the lower  
right of the screen.  
The DeviceNet Node Status screen appears:  
2. Check that the expected components are shown as present (green) and not present  
(black). (Disregard any error messages.)  
For example, if you have 18 stations, boxes 01through 18in the Stationssection  
should be green and boxes 19through 50should be black. For central purge valves,  
you should see a green box for each ArmorBlock installed.  
If the screen display is not as expected, either a component’s ArmorBlock has an incorrect  
address or the ArmorBlock is not correctly wired to the network.  
When you have verified that the controller is communicating with the other system  
components, you should verify that the inputs on all ArmorBlocks for stations and pumps are  
wired correctly and are working correctly. To do so:  
1. At the DeviceNet Node Status screen, touch DeviceNet Input Statusnear  
the lower right of the screen.  
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The DeviceNet Input Status screen appears:  
Station numbers are stacked vertically as column headings in this screen.  
2. Check that all inputs are on (green) or off (black) as expected and that they switch on  
and off as required:  
a. Station demand switch: In a new installation, the box labeled Demand  
Switchshould be green for every station (vacuum hopper) in the system.  
(All other boxes for demand switches will be black.) In a retrofit at an  
existing installation, each station’s Demand Switchbox should be green  
unless the receiver bin under the station is in fact full.  
b. Station volume-fill proximity switch: For each time-fill station, the box  
labeled Volume Fill Proxshould be black; no further check is needed  
for these stations. For each volume-fill station, you should calibrate the  
sensor now and, at the same time, check this input. To calibrate the sensor,  
remove the station’s cover, extract the volume-fill proximity switch, and  
place the switch in a container of the material that you will be using at this  
station. Adjust the sensor according to the procedure given in the  
manufacturer’s documentation for the switch. While you are doing this,  
check that:  
1.  
The box on this screen is green when the sensor indicates that no  
material is present, and  
2.  
The box is black when the sensor indicates that material is  
present.  
Then reinstall the switch in the station.  
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c. Station bypass switch: For every station, the box labeled Bypass Switch  
should match the state of the switch at the station. Flip the switches at the  
stations in order to check that:  
1.  
Each station’s box is black when its bypass switch is in the “0”  
position (station ready to convey), and  
2.  
Each station’s box is green when its bypass switch is in the “1”  
position (station bypassed).  
Leave each station with its bypass switch off (in the “0” position).  
d. Station receiver level: For each station whose receiver has no low-level  
switch, the box labeled Receiver Levelshould be black; no further  
check is needed for these stations. For each station whose receiver has a low-  
level switch, you should calibrate the sensor now and, at the same time,  
check this input. To calibrate the sensor, remove the receiver’s cover, extract  
the low-level switch, and place the switch in a container of the material that  
you will be using at this station. Adjust the sensor according to the procedure  
given in the manufacturer’s documentation for the switch. While you are  
doing this, check that:  
1.  
The box on this screen is green when the sensor indicates that no  
material is present, and  
2.  
The box is black when the sensor indicates that material is  
present.  
Note: You will not see any alarms for “receiver low level” during this  
procedure. In order to prevent nuisance alarms when the system starts,  
the controller’s software is designed to issue these alarms only after  
material has been detected in the receiver at least once.  
When you have finished calibration and checking, reinstall the switch in the  
receiver.  
e. Pump inputs (verify, high vacuum, fault #1, fault #2): All boxes for pump  
inputs should be black. Because these inputs can turn on only when the pump  
is running, it is not possible to check their operation further at this point.  
If any input does not operate as expected, check the wiring on the ArmorBlock. If this does  
not solve the problem, phone the Service Department for assistance.  
7/50D Plus or 7/50D Controller  
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Setting Up Alarm Silences  
When an alarm occurs, a horn sounds and a strobe light flashes at each installed central  
alarm. The lower right corner of the controller’s screen turns into a button labeled Alarm  
Silence. Touching this button silences the horn(s) and turns off the light(s) for  
configurable periods of time. You can set different lengths of time for keeping the horn silent  
and keeping the light turned off. If a new alarm occurs, the horn sounds and the light turns on  
again.  
To set the lengths of time for suppressing the alarm strobe and horn:  
1. Go to the System Setup screen.  
To reach this screen from the DeviceNet Input Status or DeviceNet Node Status  
screen, touch Returnuntil the System Setup screen appears.  
To reach this screen from the Station Summary or Pump Summary screen, touch and  
hold the icon for any station or pump, until the Station n Operator or Pump n Setup  
screen appears. Then touch System. The System Setup screen appears:  
The current setting are displayed under Alarm Strobe Suppressionand  
Alarm Horn Silence.  
2. Touch Alarm Strobe Suppression or Alarm Horn Silence, as appropriate.  
A keypad pops up, with an entry of 0.  
3. Enter the number of minutes (range: 0–99). If you want the light (or the horn) to stay  
on as long as the alarm persists, simply leave its entry at 0. If you want the horn (or  
the light) to stay off until a new alarm occurs, use 99 for its entry. Use to erase any  
mistakes. Use to enter the value.  
The keypad disappears and the new setting appears under Alarm Strobe  
Suppressionor AlarmHorn Silence.  
4. Repeat for the other device (strobe or horn) as appropriate.  
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Setting Up Pump Staging  
To avoid an excessive power demand at your facility when the conveying system starts up,  
you can stagger the times at which pumps start. Whenever a demand would cause two pumps  
to start simultaneously, your choice for pump staging sets the delay between the start of one  
pump and the start of the next. The factory default is a delay of three seconds. You need to  
change this setting only if this delay is too long or too short for your facility.  
To set the delay between the start of one pump and the next:  
1. Go to the System Setup screen if needed.  
To reach this screen from the Station Summary or Pump Summary screen, touch and  
hold the icon for any station or pump, until the Station n Operator or Pump n Setup  
screen appears. Then touch System. The System Setup screen appears.  
The current delay is displayed under Pump Staging.  
2. Touch Pump Staging.  
A keypad pops up, with an entry of 0.  
3. Enter the number of seconds (range: 1–99). Use to erase any mistakes. Use to  
enter the value.  
The keypad disappears and the new setting appears under Pump Staging.  
Setting Up Touch Switch Delay  
During operation, the controller normally displays the Station Summary screen or the Pump  
Summary screen, showing the current status of all stations or pumps. Briefly touching the  
icon for a station or pump toggles between taking it offline (disabling it) and putting it online  
(enabling it). Touching the icon and holding it takes the user into the controller’s menu  
system. The setting for touch switch delay determines how long the user must keep an icon  
touched before a menu appears. The factory default is 1.5 seconds. You need to change this  
setting only if you find that users are having difficulty with the current setting.  
To change the touch switch delay:  
1. Go to the System Setup screen if needed.  
To reach this screen from the Station Summary or Pump Summary screen, touch and  
hold the icon for any station or pump, until the Station n Operator or Pump n Setup  
screen appears. Then touch System. The System Setup screen appears.  
The current delay is displayed under Touch Switch Delay.  
2. Touch Touch Switch Delay.  
A keypad pops up, with an entry of 0.  
3. Enter the number of seconds (range: 0.0–99.0). As with many ATM machines, the  
first digit you enter initially appears to the right of the decimal point and moves to the  
left as you enter more digits. You do not need to use the decimal point. Use to  
erase any mistakes. Use to enter the value.  
The keypad disappears and the new setting appears under Touch Switch Delay.  
7/50D Plus or 7/50D Controller  
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Setting Up Stations  
Before starting the system, you must define several settings for each station, such as which  
pump conveys material to it and whether the station has a slide gate. This section first  
discusses how to use the controller’s menu system to configure stations. The table on pp. 73–  
77 discusses the individual choices.  
Setting Up a Single Station  
1. Go to the Station Summary screen if needed.  
To reach this screen from any other screen, touch Stationson the right-hand side  
of the screen. The Station Summary screen appears:  
2. Touch the icon for the station you want to set up, and hold it for several seconds.  
The Station n Operator screen for the selected station appears:  
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3. Touch Setupat the Station n Operator screen.  
The Station n Setup screen appears:  
(7/50D Plus shown)  
Note: Touching Helpin the lower right of this screen gives you a menu of  
online help for the choices in this screen. Touching Returnat the  
help menu brings you back to the Station n Setup screen.  
4. Adjust settings as required. Touching any box that appears in red (for “disabled”)  
toggles it to green (for “enabled”), and vice versa (except that RPVhas three settings,  
as described below). Touching any box that appears in light gray gives you a keypad  
to enter a new value.  
Keypad entry works as with many ATM machines: the first digit you enter initially  
appears in the rightmost column and moves to the left as you enter more digits. You  
do not need to use the decimal point. Use to erase any mistakes. Use to enter the  
value. The keypad disappears and the Station n Setup screen shows the new value in  
the selected gray box.  
Touching RESET TO DEFAULTSin the lower right of the screen changes all  
settings for this station back to their factory defaults.  
See pp. 73–77 for details on the options and their default settings.  
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5. As appropriate:  
a. Copy this station’s settings to one or more other stations, as described below  
- or -  
b. Touch Backto go to the Station n-1 Setup screen  
- or -  
c. Touch Nextto go to the Station n+1 Setup screen  
- or -  
d. Touch Gotoand enter a station number to go to that station’s setup screen  
Copying Settings from One Station to Others  
If other stations at your facility will use the same settings as a station you have already set up,  
you can copy the settings from this station to the others. To do so:  
1. At the Station n Setup screen (for the station you want to copy from), touch Copyin  
the screen’s upper right.  
The Station Copy screen appears, showing the station number for the station you are  
copying from:  
2. Follow the directions on the following pages to copy settings to one other station, a  
range of stations, or all stations.  
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To copy the selected station’s settings to one other station  
1. Touch the gray Copy to Stationbutton next to the green button labeled Copy  
To Single Station.  
The keypad pops up.  
2. Enter the station number for the station you are copying to. Use to erase any  
mistakes. Use to enter the value.  
The keypad disappears and the Station Copy screen shows the station number you  
entered under Copy to Station.  
3. Touch the green Copy to Single Stationbutton.  
Complete” briefly appears at the top of the screen.  
4. As appropriate, either continue copying to other stations, or touch Returnto go  
back to the Station n Setup screen.  
To copy the selected station’s settings to a range of other stations  
1. Touch First Station button next to the green button labeled.  
The keypad pops up.  
2. Enter the station number for the hopper at the lower end of the range you are copying  
to. Use to erase any mistakes. Use to enter the value.  
The keypad disappears and the Station Copy screen shows the station number you  
entered under First Station.  
3. Touch Last Stationbutton next to the light grey button labeled First  
Station.  
The keypad pops up.  
4. Enter the station number for the hopper at the upper end of the range you are copying  
to. Use to erase any mistakes. Use to enter the value.  
The keypad disappears and the Station Copy screen shows the station number you  
entered under Last Station.  
5. Touch the green CopyTo Range of Stations button.  
Complete” briefly appears at the top of the screen.  
6. As appropriate, either continue copying to other stations, or touch Returnto go  
back to the Station n Setup screen.  
To copy the current station’s settings to all other stations  
1. Touch the green CopyTo All Stationsbutton.  
Complete” briefly appears at the top of the screen.  
2. Touch Returnto go back to the Station n Setup screen.  
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Setting Up Pumps  
Before starting the system, you must define several settings for each pump, such as how  
quickly to shut it down when it is not in use and whether the pump has a local alarm. This  
section first discusses how to use the controller’s menu system to configure pumps. The table  
on pp. 78–79 discusses the individual choices.  
Setting Up a Single Pump  
1. Go to the Pump Summary screen.  
To reach this screen from any other screen, touch Pumpson the right side of the  
screen. The Pump Summary screen appears:  
2. Touch the icon for the pump you want to set up, and hold it for several seconds.  
The Pump n Setup screen appears:  
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Note: Touching Helpin the lower right of this screen gives you a menu of  
online help for the choices in this screen. Touching Returnat the  
help menu brings you back to the Pump n Setup screen.  
3. Adjust settings as required. Touching any box that appears in red (for “disabled”)  
toggles it to green (for “enabled”), and vice versa. Touching any box that appears in  
light gray gives you a keypad to enter a new value.  
Keypad entry works as with many ATM machines: the first digit you enter initially  
appears in the rightmost column and moves to the left as you enter more digits. You  
do not need to use the decimal point. Use to erase any mistakes. Use to enter the  
value. The keypad disappears and the Pump n Setup screen shows the new value in  
the selected gray box.  
See pp. 73 –77 for details on the options and their default settings.  
4. As appropriate:  
a. Copy this pump’s settings to one or more other pumps, as described below  
—or—  
b. Touch Backto go to the Pump n-1 Setup screen  
—or—  
c. Touch Nextto go to the Pump n+1 Setup screen  
—or—  
d. Touch Gotoand enter a pump number to go to that pump’s setup screen  
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Copying Settings from One Pump to Others  
If other pumps at your facility will use the same settings as a pump you have already set up,  
you can copy the settings from this pump to the others. To do so:  
1. At the Pump n Setup screen (for the pump you want to copy from), touch Copyin  
the screen’s upper right.  
The Pump Copy screen appears, showing the pump number for the pump you are  
copying from:  
2. Follow the directions below to copy settings to one other pump, a range of pumps, or  
all pumps.  
To copy the selected pump’s settings to one other pump  
1. Touch the gray Copy to Pumpbutton next to the green Copy To Single  
Pump button.  
The keypad pops up.  
2. Enter the pump number for the pump you are copying to. Use to erase any  
mistakes. Use to enter the value.  
The keypad disappears and the Pump Copy screen shows the pump number you  
entered under Copy to Pump.  
3. Touch the green CopyTo Single Pump button.  
Complete” briefly appears at the top of the screen.  
4. As appropriate, either continue copying to other pumps, or touch Returnto go back  
to the Pump n Setup screen.  
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To copy the selected pump’s settings to a range of other pumps  
1. Touch First Pumpnext to the green button labeled Copy To Range of  
Pumps button.  
The keypad pops up.  
2. Enter the number for the pump at the lower end of the range you are copying to. Use  
to erase any mistakes. Use to enter the value.  
The keypad disappears and the Pump Copy screen shows the pump number you  
entered under First Pump.  
3. Touch Last Pumpnext to the light grey button labeled First Pump.  
The keypad pops up.  
4. Enter the number for the pump at the upper end of the range you are copying to. Use  
to erase any mistakes. Use to enter the value.  
The keypad disappears and the Pump Copy screen shows the pump number you  
entered under Last Pump.  
5. Touch the green Copybutton labeled Copy To Range of Pumps.  
Complete” briefly appears at the top of the screen.  
6. As appropriate, either continue copying to other pumps, or touch Returnto go back  
to the Pump n Setup screen.  
To copy the current pump’s settings to all other pumps  
1. Touch the green CopyTo All Pumps button.  
Complete” briefly appears at the top of the screen.  
2. Touch Returnto go back to the Pump n Setup screen.  
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Finishing Setup: Setting Up Passwords  
You can set up passwords for two levels of security: for operators and for setup personnel.  
The controller comes from the factory with neither password set. This allows every user  
access to all functions.  
Setup Password. If you define a password for setup personnel, then most settings can be  
changed only after entering the password. The password will be required to display the  
following screens:  
System Setup (to review and change system-wide settings, clear the  
alarm log, and go to the network status screens)  
Station Setup (to review and change settings for all station options)  
Pump Setup (to review and change settings for all pump options)  
Operator Password. If you define a password for operators, then a password will be  
required to carry out any function (other than reviewing station and pump status, silencing  
alarms, reviewing the alarm log, and looking at help screens). Entering the operator’s  
password will give the user access to the functions at the following screens:  
Station Summary (to enable or disable a station, and start or stop  
system)  
Pump Summary (to enable or disable a pump, and start or stop system)  
Station n Operator (to adjust a station’s convey time and dump delay,  
activate priority convey, and review the station’s last convey time and  
pump assignment; depending on the options installed, the screen may  
also enable the operator to adjust the mixture percentage for a remote  
proportioning valve, review the last purge time and purge valve, and  
set the intended material line for material proofing)  
Entering the setup password will give the user access to all functions.  
Note: If you want to protect the operator’s functions with a password, you  
must also define a setup password. If you leave the setup password  
undefined, then all users will have access to all functions.  
If you want two different levels of password protection, you must make the  
passwords different from each other. If the two passwords are the same as each  
other, then any user who enters the password will have access to all functions.  
To set (or remove) password protections:  
1. Go to the System Setup screen if needed.  
To reach this screen from the Station Summary or Pump Summary screen, touch and  
hold the icon for any station or pump, until the Station n Operator or Pump n Setup  
screen appears. Then touch System.  
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The System Setup screen appears:  
The current passwords are displayed under Operator Passwordand Setup  
Password. A value of 0000means that no password is required.  
2. Touch Operator Password or Setup Password, as appropriate.  
A keypad pops up, with an entry of 0.  
3. Enter up to four digits. If you want to remove the password protection, simply leave  
the entry at 0. Use to erase any mistakes. Use to enter the value.  
The keypad disappears and the new setting appears under Operator (or Setup)  
Password. In addition, if you have added a password, a new button appears on the  
screen, labeled Log Off Operatorand/or …Setup, depending which  
passwords are now active.  
Note: When entering a password, all four digits must be supplied. For  
example, if you enter a password of 2here, you will need to enter  
0002when the controller prompts for the password.  
If desired, you can also change the duration for which a password remains effective. During  
operation, the password-protected screens are available either until the user logs off or until  
this time elapses, whichever comes first. This feature prevents the password from remaining  
active if a user forgets to log off.  
Note: The password timer starts when the user logs on. It expires even if the  
user is actively using the screens when the chosen time is up. If the  
timer expires, the system goes to the Station Summary screen. Your  
password duration should be long enough to allow authorized users to  
complete their tasks but short enough to provide adequate protection  
against tampering.  
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To change the duration of a password:  
1. At the System Setup screen, touch Operator Password Durationor Setup  
Password Duration, as appropriate.  
A keypad pops up, with an entry of 0.  
2. Enter the number of minutes (range: 5–99). Use to erase any mistakes. Use to  
enter the value.  
The keypad disappears and the new setting appears under Operator (or Setup)  
Password Duration.  
3-6 Initial Startup  
Once you have finished all the setup described above, you are ready to start the system. To do  
so:  
1. At any screen, touch Stationson the right-hand side of the screen.  
The Station Summary screen appears.  
2. For each station that you want to use, briefly touch its icon.  
The icon turns blue, indicating that the station is ready or yellow, indicating that the  
station needs material.  
3. Touch Pumps.  
The Pump Summary screen appears.  
4. For each pump that you want to use, briefly touch its icon.  
The icon turns blue, indicating that the pump is ready.  
5. Touch Push to Start Systemin the lower right-hand corner of the screen.  
The system starts. If any alarm messages appear on the top of the screen, see p. 71.  
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Chapter 4: Operation  
4-1 Overview  
Your 7/50D Plus or 7/50D controller electrically controls valves and solenoids to convey  
material from a central location to individual stations as needed. The controller senses  
demands for material at the stations and responds to the demands in a timely fashion.  
This section gives the procedures for using your controller, and it covers tasks that can be  
carried out with no password or with an operator’s password. The section is divided into four  
sub-sections:  
Starting and stopping the system  
Basic tasks: tasks normally carried out by a station operator  
Advanced tasks: tasks normally carried out by setup personnel  
Alarms: silencing and clearing alarms  
Note: Before you carry out any of the procedures in this chapter, the system  
must be set up as described in the previous chapter.  
4-2 Starting and Stopping the System  
Note: In an emergency, you can use the power switch on the upper right-  
hand side of the controller cabinet if a password is required to stop the  
system and you do not know the password.  
Normally, all the stations and pumps you want to use should be enabled before  
you start the system. When the system is stopped, icons for enabled stations are  
blue when full and yellow when they need material. Icons for enabled pumps  
are yellow. Enabling stations and pumps is described on p. 60.  
A button to start and stop the system is located in the lower right of the Station Summary,  
Pump Summary, and Alarm Log screens. When the system is off, the button is red and reads  
Push to Start System. When the system is on, the button is green and reads Push  
to Stop System. Depending on the setup at your facility, the system may prompt for a  
password when you touch this button.  
Note: If conveying does not begin when you start the system, check to make  
sure that all needed pumps are enabled. If they are, check that all  
needed stations are enabled.  
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4-3 Basic Tasks  
This section covers tasks that can be carried out with no password or with an operator’s  
password.  
Reviewing Station Status  
The starting point for all operations is the Station Summary screen. To reach this screen from  
any other screen:  
1. Touch Stations.  
The Station Summary screen appears:  
The status of each station is color-coded, as summarized in the upper right of the screen.  
You can see an explanation of each status by using the online help. To do so from this screen:  
1. Touch anywhere in the rectangle in the upper right of the screen.  
The Help Menu appears.  
2. In the section of the Help Menu labeled Screen Symbols/Colors, touch  
Station.  
The Station Symbols help screen appears, explaining the status represented by each  
color.  
3. When you are finished reviewing the information, touch Return.  
The Help Menu appears.  
4. At the Help Menu, touch Stations(or Pumps).  
The Station Summary (or Pump Summary) screen appears.  
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The following table explains the status represented by each color at the Station Summary  
screen.  
Color  
Label  
Description  
Gray outline  
Offline  
Station is not enabled. The controller ignores any demands or  
alarms.  
Blue  
Ready  
Station is enabled and idle (full).  
Yellow  
Green  
Demand  
Loading  
Station requires material.  
Station is being loaded with material or is dumping material into  
its receiver.  
White  
Light Blue  
Blue, blinking  
Purging  
Dumping  
Blow Back  
The material line is being purged of material.  
The station is dumping material into its receiver.  
Station’s air filter is being cleaned by blowing compressed air  
backward through it.  
Black, blinking  
Green, blinking  
Bypass  
Priority  
Bypass switch at the station has been turned on, disabling the  
station.  
Station is in priority convey mode. Its pump will be temporarily  
dedicated to filling it as soon as possible.  
Station is in alarm.  
Red, blinking  
Alarm  
Red outline, blinking  
Critical  
Station is in critical alarm. The controller has disabled the station  
until the alarm is cleared.  
Additional basic information about each station (convey time, dump delay, pump assignment,  
and, if enabled, RPV setting, purge settings, and material proofing) is available at the Station  
n Operator screen. See p. 61 for details.  
Detailed configuration settings for each station are available at the Station n Setup screen. See  
p. 74 for details.  
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Reviewing Pump Status  
The Pump Summary screen is the counterpart of the Station Summary screen. To reach the  
Pump Summary screen from any other screen:  
1. Touch Pumps.  
The Pump Summary screen appears:  
The status of each pump is color-coded, as summarized in the upper right of the screen.  
You can see a more detailed explanation of each status by using the online help. To do so  
from this screen:  
1. Touch anywhere in the rectangle in the upper right of the screen.  
The Help Menu appears.  
2. In the section of the Help Menu labeled Screen Symbols/Colors, touch Pump.  
The Pump Symbols help screen appears, explaining the status represented by each  
color.  
3. When you are finished reviewing the information, touch Return.  
The Help Menu appears.  
4. At the Help Menu, touch Pumps(or Stations).  
The Pump Summary (or Station Summary) screen appears.  
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The following table explains the status represented by each color at the Pump Summary  
screen.  
Color  
Label  
Offline  
Ready  
Idle  
Description  
Gray outline  
Yellow  
Blue  
Pump is not enabled. The controller ignores any alarms.  
Pump is off, waiting for demand from a station.  
Pump is on, waiting for demand from a station. If there is no  
demand before the end of the auto shutdown delay, the pump  
will turn off.  
Green  
Blue, blinking  
Loading  
Blow Back  
Pump is conveying material to a station.  
Pump’s air filter is being cleaned by blowing compressed air  
backward through it.  
Red, blinking  
Alarm  
Pump is in alarm.  
Red outline, blinking  
Critical  
Pump is in critical alarm. The controller has disabled the pump  
until the alarm is cleared.  
Additional information about each pump, including configuration settings and the number of  
hours the pump has been running, is available at the Pump n Setup screen. For details on  
configuration settings, see p. 78. For details on the hour meter, see p. 65.  
7/50D Plus or 7/50D Controller  
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Logging On and Logging Off  
Your controller may be set up to require a password for any operation (other than reviewing  
station and pump status, silencing alarms, reviewing the alarm log, and looking at help  
screens). If so, a keypad appears when you touch a button for a screen that requires a  
password:  
Enter the four-digit password (including any leading zeros). For  
example, if the password is 1, enter 0001.  
Each digit appears as an “X” as you touch it. When you touch the fourth digit, the  
controller carries out your request. For example, it enables or disables the requested  
pump or station, or it goes to the Station n Operator screen. If you did not enter the  
correct password, the controller erases the entry. You can then try again. To give up,  
touch Return.  
Note: If you have lost the password(s), contact the manufacturer for  
assistance.  
Once you have logged on, the password remains active until you log off or the password  
expires. (Setup personnel at your facility control the number of minutes before the password  
expires.) While the password is active, you can continue to carry out password-protected  
tasks without reentering the password. If the timer expires, the controller goes to the Station  
Summary screen and you must reenter the password to continue working.  
When you have finished any tasks that require the password, you should log off. (If you  
forget to do this, the controller will log you off when the password expires.) To log off:  
1. Go to a Station Operator screen.  
To reach this screen, go to the Station Summary if needed by touching Stationsat  
any screen. Then touch and hold the icon for any station until its Station Operator  
screen appears.  
2. Touch Log Off Operatornear the lower right of the screen.  
The Station Summary screen appears.  
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Enabling and Disabling Stations and Pumps  
When a station or pump is disabled, the controller makes no attempt to use it and ignores any  
alarms that occur for it. Disabling a station or pump at the controller’s screen is similar to  
bypassing a station with its bypass switch. Enabling a station or pump makes it available for  
use. (For a station to be available for the system, it must be enabled at the controller’s screen  
and its bypass switch must be in the “0” position.)  
To enable or disable a station (or pump):  
1. Go to the Station Summary (or Pump Summary) screen, if needed.  
To reach this screen from any other screen, touch Stations(or Pumps) on the  
right-hand side of the screen.  
Each disabled station (or pump) has an icon with a status of “offline” (black with a  
gray outline). All other statuses are enabled statuses.  
2. Touch the icon for the station (or pump) briefly.  
The station (or pump) switches to the new state, as indicated by the color of its icon.  
Note: If the Station n Operator (or Pump n Setup) screen appears when you  
touch the icon, then you have kept your finger on the screen too long.  
Touch Stations(or Pumps) to return to the Summary screen and  
try again. If you find it difficult to touch the icon briefly enough, ask  
the setup personnel at your facility to lengthen the touch switch delay.  
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Reviewing and Adjusting Basic Station Settings  
Reaching and Reading the Station Operator Screens  
The 7/50D Plus or 7/50D Controller has a Station Operator screen for each station, as shown  
below. This screen enables you to review and adjust all basic settings for the station.  
To reach the Station n Operator screen:  
1. Go to the Station Summary screen, if needed.  
To reach this screen from any other screen, touch Stationson the right-hand side  
of the screen.  
2. Touch and hold the icon for the station, until the controller either prompts for the  
password or displays the Station n Operator screen.  
Once you have entered the password (if needed), the Station n Operator screen  
appears:  
Settings in the box labeled Convey, the red Priority Convey Activatebutton, and  
the menu controls on the right-hand side of the screen appear for all stations. The other  
options in this screen appear if and only if the station has these features enabled.  
Buttons in light gray are settings that you can adjust at this screen. Boxes in dark gray are for  
display only. If a pump assignment or purge setting needs to be changed, this must be done at  
the Station n Setup screen.  
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Navigating among the Station Operator Screens  
The controls in the upper right-hand corner of the screen enable you to move among the  
Station Operator screens:  
1. To display the screen for the next lower-numbered station (for example, to move  
from the screen for Station 15 to the screen for Station 14), touch Back.  
2. To display the screen for the next higher-numbered station (for example, to move  
from the screen for Station 15 to the screen for Station 16), touch Next.  
3. To display the screen for a specific station, touch Goto. A keypad pops up. Enter the  
number for the desired station. Use to erase any mistakes. Use to enter the  
value.  
4. To exit to the Station Summary (or Pump Summary) screen, touch Stations(or  
Pumps).  
Adjusting Convey Time and Dump Delay  
Convey time is the length of time the station’s vacuum valve remains open to allow material  
to be drawn in. (For a volume-fill station, the valve closes when material covers the station’s  
volume-fill proximity sensor or this time elapses, whichever comes first.)  
Dump delay is the length of time allowed for material to drain from the station into its  
receiver. During this time, the controller does not attempt to deliver any more material to the  
station.  
The settings for convey time and dump delay should match the times actually required to fill  
and empty the station. The following problems may occur if these settings are incorrect:  
1. Material is backing up and causing “high vacuum” alarms (for time-fill stations  
only): Convey time is too long.  
2. System is not keeping up with the demand for material: Convey time is too short, or  
dump delay is too long.  
For your reference, the Station n Operator screen shows the length of time the controller  
actually spent conveying material during the most recent delivery under Last Convey  
Time.  
To adjust a station’s convey time (or the dump delay):  
1. Go to the Station n Operator screen (as described on p. 61), or go to the Station n  
Setup screen.  
2. Touch Convey Time (or Dump Delay).  
A keypad pops up.  
3. Enter the number of seconds desired. Use to erase any mistakes. Use to enter the  
value.  
The new setting appears under Convey Time(or Dump Delay).  
Note: If you change convey time by more than a few seconds for a station  
with a remote proportioning valve (RPV), notify the setup personnel at  
your facility. The setting for the RPV’s cycle time should be adjusted to  
divide evenly into the new convey time (see pp. 43 and 77).  
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Activating and Stopping Priority Convey for a Station  
Note: Before activating priority convey, make sure that all other stations  
using the same pump have adequate material in reserve to continue  
operation. No material will be conveyed to these stations during  
priority convey.  
If you want the controller to fill a specific station with material immediately, you can activate  
“priority convey” for that station. When you do so, the controller temporarily dedicates the  
station’s pump to it, ignoring demands from other stations assigned to that pump. Once the  
chosen station is full, normal operation resumes.  
You can also use this feature to give one station a “head start” by conveying a few loads to it  
and then stopping the priority convey.  
No more than one station for a given pump can be in “priority convey” at once.  
To activate priority convey:  
1. Go to the Station n Operator screen (as described on p. 61), or go to the Station n  
Setup screen.  
2. Touch Priority Convey Activate.  
The button changes to Priority Convey Activeand blinks until the station’s  
demand has been satisfied (or you stop the priority convey).The controller begins  
filling the chosen station only (after finishing any convey already in progress).  
To stop a priority convey before the station is completely full:  
1. Touch the blinking Priority Convey Active.  
The button changes to Priority Convey Activateand stops blinking. The  
controller finishes the current convey, if any, and resumes normal operation.  
Changing the Mixture for a Remote Proportioning Valve  
A remote proportioning valve (RPV) mixes two different materials, typically virgin and  
regrind materials, during a convey cycle. If present, this valve may be set up so that you  
control the mix with a timer at the station, or it may be set up so that you control the mix with  
the controller’s touch screen. The instructions here apply only for controlling the mixture  
from the touch screen.  
The controller refers to the two materials as Material A (primary) and Material B (additive).  
The system is set up so that, if there are any inaccuracies in the proportions, the mix will  
contain more Material A and less Material B.  
To change the mixture for the remote proportioning valve:  
1. Go to the Station n Operator screen (as described on p. 61), or go to the Station n  
Setup screen.  
2. Touch RPV Material B.  
A keypad pops up.  
3. Enter the desired percentage for the additive material. Use to erase any mistakes.  
Use to enter the value.  
The new setting appears under RPV Material B.  
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Changing the Line with Material Proofing  
When this option is enabled, the controller issues an alarm for the station if the number for  
“Material set to” does not match that of the actual material. These numbers refer to material  
lines.  
To change the line when using material proofing:  
1. Go to the Station Summary screen (if needed) by touching Stationson the right-  
hand side of any other screen.  
2. Disable the station (take it offline) by touching its icon briefly.  
The icon becomes black with a gray outline.  
3. Switch lines physically.  
4. At the controller, go to the Station n Operator screen (as described on p. 61), or go to  
the Station n Setup screen.  
5. Touch Material Set To.  
A keypad pops up.  
6. Enter the number for the new material line. Use to erase any mistakes. Use to  
enter the value.  
The new setting appears under Material Set To.  
7. Touch Stations.  
The Station Summary screen appears.  
8. Enable the station (put it online) by touching its icon briefly.  
The color of the icon changes to show the new status.  
4-4 Advanced Tasks  
This section describes the procedures carried out during operation that are normally reserved  
for setup personnel. These procedures require use of the setup password (if your facility has  
defined one). The procedure for logging on with the setup password is the same as for  
logging on with the operator password; see p. 59. Logging off is also the same, except that  
operators can log off only at the Station n Operator screen, while most screens accessible to  
setup personnel offer Log Offas an option.  
You can also change the setup for stations, pumps, and the system during operation. See  
Chapter 4, “System Setup,” for information on the procedures and options.  
7/50D Plus or 7/50D Controller  
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Reviewing and Resetting a Pump Hour Meter  
The controller keeps two meters for the length of time a pump has run. One, like a car’s  
odometer, keeps a running total and cannot be reset. The other, like a car’s trip odometer,  
counts the running time since the last reset.  
To review and reset the hour meter:  
1. At any screen, touch Pumps.  
The Pump Summary screen appears.  
2. Touch and hold the icon for the pump.  
The Pump n Setup screen appears:  
The box labeled x Hours (Resettable)shows the running time since the last  
reset. The box labeled x Hours (Not Resettable)shows total running time.  
3. To reset the resettable meter, touch Hour Meter Reset.  
The time above Hours (Resettable)changes to 0.  
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Transferring Stations to a Standby Pump  
If a pump fails, you can transfer all of the controller’s station assignments for that pump to a  
standby pump. To do this, you must disable (take offline) both the source pump and the  
standby pump, and the standby pump must have no stations already assigned to it.  
The transfer operation at the controller’s touch screen merely changes the pump assignment  
for every station on the failed pump. It does not transfer any pumps settings for auto  
shutdown delay, alarms, or blow-back to the standby pump. Mechanical connections must be  
changed manually.  
To transfer stations from a pump to a standby pump:  
1. At any screen, touch Pumps.  
The Pump Summary screen appears.  
2. Both the source pump and the standby pump must be offline. If either pump is any  
other state, disable it by touching its icon briefly.  
The icon becomes black with a gray outline.  
3. Move the vacuum hose from the failed pump to the standby pump, and carry out any  
other mechanical procedures needed to use the standby pump.  
4. At the Pump Summary screen, touch and hold the icon for any pump until the Pump  
n Setup screen appears.  
5. At the Pump n Setup screen, touch Transfer Stations To Standby Pump.  
The Transfer to Standby Pump screen appears:  
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1. Touch Source Pump.  
The keypad pops up.  
2. Enter the number of the failed pump. Use to erase any mistakes. Use to enter the  
value.  
The number appears under Source Pump.  
3. Touch Standby Pump.  
The keypad pops up.  
4. Enter the number of the standby pump. Use to erase any mistakes. Use to enter  
the value.  
The number appears under Standby Pump, and a button labeled Transfer to  
Standby Pumpappears on the screen:  
Note: When you enter the second pump number, the controller checks to  
make sure that both pumps are offline and that the standby pump has  
no stations assigned to it. If these conditions are not all met, error  
messages appear on the screen instead of a Transfer to Standby  
Pumpbutton. If you get an error message, first check to make sure that  
you have entered the correct numbers and reenter if necessary.  
If the error message tells you to disable the source pump and/or the standby pump, touch  
Returnat this screen, then Pumpsat the Pump n Setup screen. Take the pumps offline and  
then return to the Transfer to Standby Pump screen.  
If the error message tells you that the standby pump has stations assigned, you must either use  
a different standby pump or you must remove the pump assignment for all stations assigned  
to the standby pump. To remove the assignments, touch Returnat this screen, then  
Stationsat the Pump n Setup screen.  
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Hold a station icon to go to its Station Operator screen, then touch Setup to go to the Station n  
Setup screen. Use Back. and Next to review all pump assignments and, where  
necessary, choose Assigned to Pump x to set station assignments to 0 (unassigned).  
Then return to the Transfer to Standby Pump screen.  
1. Touch Transfer To Standby Pump.  
“Transfer in Progress” appears briefly on the screen, followed by “Transfer  
Complete,” in place of the Transfer To Standby Pumpbutton. The controller  
switches the setting for Source Pumpto the new pump and switches the setting for  
Standby Pumpto 0 (unassigned).  
2. Touch Return.  
The Pump n Setup screen appears.  
3. Touch Pumps.  
The Pump Summary screen appears.  
4. Put the standby pump online by briefly touching its icon.  
The icon changes color to show the new status, and the system begins using the  
pump. In addition, all Station n Operator and Setup screens show the new pump  
assignment.  
When the failed pump is operational again, you can repeat this process, this time using the  
standby pump’s number as the setting for Source Pumpthe repaired pump’s number as the  
setting for Standby Pump.  
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3-5 Alarms  
Reviewing Alarms  
At the Station Summary or Pump Summary screen:  
1. Touch Alarms.  
The Alarm Log screen appears, with the newest alarm listed first:  
To scroll up and down through the list:  
Touch and at the bottom of the list.  
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Clearing the Alarm Log  
The controller saves all alarm messages, together with the date and time the alarm occurred.  
When you no longer need the history, or when the list becomes too long to manage, you can  
erase the log. To do so:  
1. At the Station Summary or Pump Summary screen, touch Alarms.  
The Alarm Log appears.  
2. Touch Systemon the right-hand side of the screen.  
The System Setup screen appears:  
3. Touch Clear Alarm Log.  
A warning message pops up, asking for confirmation.  
4. Touch Continue.  
The System Setup screen appears. To confirm that the log has been erased, you can  
return to the Station Summary or Pump Summary screen and touch Alarms.  
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Silencing Alarms  
Whenever a new alarm occurs, your controller sounds the horn and turns on the strobe light at  
each central alarm. If the alarm is for a specific station or pump, and if the station or pump  
has a local alarm, the controller also turns on the local alarm light. In addition, the  
manufacturers’ logo on the controller’s screen changes to an Alarm Silencebutton.  
To silence the alarm:  
1. Touch Alarm Silencein the lower right-hand corner of the screen.  
The horns and lights at the central alarms turn off. (The local alarm light stays on.)  
The button changes back to the company logo. Your controller has separate,  
configurable settings for how long the horns should remain silent and how long the  
lights should remain off. If the alarm condition still exists when either of these times  
elapses, the corresponding devices (horns or lights) turn on again. If a new alarm  
occurs, both the horns and the lights turn on.  
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Chapter 5: Maintenance  
5-1 Preventative Maintenance  
No preventative maintenance is required on this unit.  
5-2 Corrective Maintenance  
Network Scanner Module Considerations  
The manufacturer includes a network scanner software diskette with your controller; this  
diskette and instructions are located in your Customer Information Packet. Keep this diskette  
and the instructions in a safe place.  
Should the network scanner module require replacement, use the scanner software to restore  
the program. You can:  
Purchase a programmed replacement scanner module from the  
manufacturer  
In extreme cases, you can purchase the module from your local Allen-  
Bradley dealer and program it yourself with the scanner software  
diskette; you can also have your A-B dealer do that for you  
We suggests that you have a preprogrammed spare network scanner module on hand for such  
conditions.  
7/50D Plus or 7/50D Controller  
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Chapter 6: Configurable Settings  
This section describes the proper setup of the 7/50D Plus or 7/50D 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 Memory Module Considerations  
The operator interface and the PLC central processing unit use memory modules to store the  
operating program. The modules are installed in the back of the controller interface chassis  
and on the PLC CPU card.  
The memory module returns the controller to the factory default settings if an electrical fault  
occurs, or if the hardware is replaced. Keep in mind that this condition is extremely rare.  
You will then need to set up the controller once again with the settings you programmed in  
this chapter.  
6-2 Options for Station Setup  
Name  
Description  
Options  
Default  
Conveying Options  
Convey time  
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.)  
1–999 sec.  
30 sec.  
Adjust this value to match the actual time  
needed to fill the station.  
(Last convey time)  
Dump delay  
Display only. Length of time the station’s  
vacuum valve was open for receiving material  
during the most recent convey. This information  
is displayed for your reference when adjusting  
convey time and dump delay.  
Length of time allowed for material to drain from 1–99 sec.  
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.  
7/50D Plus or 7/50D Controller  
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Name  
Description  
Options  
Default  
Conveying Options  
Assigned to pump n  
Number (address) of the pump to which this  
station’s vacuum line is connected.  
0–7 (0 = not  
assigned)  
0
No more than 20 stations can be assigned to  
one pump.  
Volume fill  
When this option is enabled, the station’s  
vacuum valve closes when material covers the  
station’s proximity sensor or the convey time  
elapses, whichever comes first. When disabled,  
the station’s vacuum valve remains open until  
the convey time has elapsed.  
disabled,  
enabled  
disabled  
disabled  
Enable this option for volume-fill stations and  
disable it for time-fill stations.  
Special convey  
When this option is enabled, the station’s  
vacuum valve remains open for the convey  
time, even if the station is not demanding  
material and is indicating that it is full. When  
disabled, the station’s vacuum valve opens  
when there is demand from the station, and it  
remains open until the convey time has elapsed  
or material trips the volume-fill proximity switch.  
Enable this option if and only if the station has  
no flapper.  
disabled,  
enabled  
Alarm Options  
No convey  
When this option is enabled, 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  
the next setting.)  
disabled,  
enabled  
disabled  
Usually this option should be enabled. At times,  
you may wish to disable it during operation as a  
stopgap measure for dealing with an alarm.  
# attempts B4 alarm  
Number of attempts before alarm: the number of 1–99  
times the controller will attempt to convey  
material to a station before it issues a “no  
convey” alarm.  
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.  
7/50D Plus or 7/50D Controller  
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Name  
Partial convey  
Description  
Options  
disabled,  
enabled  
Default  
disabled  
When this option is enabled, the controller  
issues a “partial convey” alarm if it has  
repeatedly attempted to convey material to the  
station, and material has moved from the station  
into the receiver, but the volume-fill proximity  
sensor has never signaled that the station is full.  
(The number of attempts is controlled by the  
next setting.)  
For a volume-fill station, this option should  
usually be enabled. At times, you may wish to  
disable it during operation as a stopgap  
measure for dealing with an alarm. For a time-fill  
station, disable this option.  
Alarm Options  
# attempts B4 alarm  
Number of attempts before alarm: the number of 1–99  
times the controller will attempt to convey  
material to a station before it issues a “partial  
convey” alarm.  
3
The setting for this option depends on the same  
considerations as those given above for number  
of attempts before a “no convey” alarm.  
Local alarm  
When this option is enabled, the controller turns disabled,  
disabled  
disabled  
on the local alarm light for any alarm at this  
specific station.  
enabled  
Enable this option if and only if your facility has  
installed a local alarm light for this station.  
Miscellaneous Options  
Receiver low level  
When this option is enabled, the controller  
issues a “receiver level” alarm if material in the  
receiver drains below the level of the receiver’s  
low-level sensor.  
disabled,  
enabled  
Enable this option if and only if your facility has  
installed a low-level sensor for this station’s  
receiver. At times, you may wish to disable it  
during operation as a stopgap measure for  
dealing with an alarm.  
Blow Back Options (Only available on 7/50D Plus systems)  
Blow back  
When this option is enabled, the controller  
periodically sends compressed air backward  
through the station’s air filter to dislodge  
accumulated dust and debris.  
disabled,  
enabled  
disabled  
Enable this option if and only if the station has  
the equipment for compressed-air filter cleaning.  
Number of conveying cycles 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.  
Number of pulses of compressed air sent  
through the station’s filter during cleaning.  
If blow-back is not working as desired, the  
service department may ask you to change this  
setting.  
Every n loads  
1–99  
1–99  
5
5
# pulses  
7/50D Plus or 7/50D Controller  
Chapter 6: Configurable Settings  
75  
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Name  
Description  
Options  
Default  
On time  
Number of seconds that the each air pulse lasts 0.1–99.0 sec. 1.0 sec.  
during filter cleaning.  
If blow-back is not working as desired, the  
service department may ask you to change this  
setting.  
Off time  
Number of seconds between air pulses during  
filter cleaning.  
0.5–99.0 sec. 1.0 sec.  
If blow-back is not working as desired, the  
service department may ask you to change this  
setting.  
Slide Gate Options (Only available on 7/50D Plus systems)  
Slide gate  
When this option is enabled, the controller  
opens the slide gate between the station and  
the receiver during the dump delay and during  
blow-back.  
Enable this option if and only if the station has a  
slide gate instead of a flapper and demand  
switch.  
disabled,  
enabled  
disabled  
disabled  
Purge Options  
Purge  
When enabled, this option allows the system to  
empty the material line completely after every  
convey to this station. The station’s pump  
continues to draw without picking up material for  
an extra period of time after conveying is  
finished.  
disabled,  
enabled  
Enable this option if and only if you are using a  
purge valve for this station. This option cannot  
be used with a volume-fill station.  
Purge duration  
Purge valve  
Number of seconds allowed for purging. The  
station’s vacuum valve remains open for the  
convey time plus this time.  
Adjust this setting to the amount of time  
required for material to travel from the pickup  
point (purge valve) to the station.  
Ø–999 sec.  
20 sec.  
Number (address) for the purge valve used with 1–154  
this station.  
0 (= not  
assigned)  
Set this to match the number (address) for the  
purge valve that services this station. If another  
station has the purge valve that services this  
station, enter the number of that station (range:  
1–50). If a central purge valve services this  
station, enter the number (address) of that valve  
(range: 51–154).  
Material Proofing Options  
Material proofing  
When this option is enabled, the controller  
issues an alarm for the station if the number for  
“Material set to” does not match the number for  
the actual material. These numbers refer to  
material lines.  
disabled,  
enabled  
disabled  
Enable this option if and only if your facility has  
installed the option of material proofing and you  
want to check the material line connected to this  
station.  
7/50D Plus or 7/50D Controller  
Chapter 6: Configurable Settings  
76  
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Name  
Material set to n  
Description  
Number for the material line that should be  
connected to this station.  
Options  
Ø –150  
Default  
0 (= not  
assigned)  
(Material actual)  
Display only. Number (address) for the material  
line that is actually connected to this station.  
This information is displayed for your reference  
in troubleshooting.  
RPV Options  
RPV (Remote  
Proportioning Valve)  
This option allows the system to use a remote  
proportioning valve to mix two different  
materials, typically virgin and regrind materials,  
during a convey cycle. Touching RPVrepeatedly  
at the Station n Setup screen steps through the  
three choices.  
disabled,  
enabled PLC,  
enabled local  
disabled  
Enable this option with PLC control if you will be  
adjusting the mix from the controller’s touch  
screen.  
Enable this option with local control if the station  
operator will be adjusting the mix using a timer  
box at the station.  
RPV material B  
Percentage of the additive material to be  
included in the mix. This setting applies only  
when RPV is enabled with PLC control. The  
system is set up so that, if there are any  
inaccuracies in the proportions, the mix will  
contain more Material A and less Material B  
than specified here.  
Ø –99%  
30%  
Cycle time  
Number of seconds for each cycle in depositing 5–999 sec.  
Material A and Material B during the convey  
time. This setting applies only when RPV is  
enabled with PLC control. Example: If you set  
convey time to 30 seconds, cycle time to 10  
seconds, and Material B to 30% (so Material A  
is 70%), the system will convey as follows:  
Material A for 7 seconds  
10 sec.  
Material B for 3 seconds (end cycle 1)  
Material A for 7 seconds  
Material B for 3 seconds (end cycle 2)  
Material A for 7 seconds  
Material B for 3 seconds (end cycle 3)  
In a volume-fill station, a cycle will be truncated  
before completion if the station becomes full.  
The cycle time should divide evenly into the  
convey time.  
7/50D Plus or 7/50D Controller  
Chapter 6: Configurable Settings  
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6-3 Options for Pump Setup  
Several of the items in this screen are not setup options but are instead intended for use  
during operation. These items (hour meter and transferring stations to a standby pump) are  
described in Chapter 4, “Operation.”  
Name  
Description  
Options  
Default  
Idle Time Options  
Auto shutdown delay  
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.  
0–999 sec.  
45 sec.  
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.  
Alarm Options  
Local alarm  
When this option is enabled, the controller turns disabled,  
disabled  
disabled  
on the local alarm light for any alarm at this  
specific pump.  
enabled  
Enable this option if and only if your facility has  
installed a local alarm light for this pump.  
The ArmorBlock for each pump has two inputs  
that you can wire to generate alarms for  
situations of your choosing. For example, you  
may have a sensor that turns on when material  
reaches the top of a filter-chamber waste bin.  
When this option is enabled, the controller  
issues an alarm if the sensor wired to the input  
for Pump Fault #1 turns on.  
Pump fault #1  
disabled,  
enabled  
Enable this option if and only if your facility has  
installed a miscellaneous alarm on the input for  
Pump Fault #1 for this pump.  
Pump fault #2  
See the explanation for Pump fault #1 above.  
Enable this option if and only if your facility has  
installed a miscellaneous alarm on the input for  
Pump Fault #2 for this pump.  
disabled,  
enabled  
disabled  
disabled  
Blow Back Options  
Blow back  
When this option is enabled, the controller  
periodically sends compressed air backward  
through the pump’s air filter to dislodge  
accumulated dust and debris.  
disabled,  
enabled  
Enable this option if and only if the pump has  
the equipment for compressed-air filter cleaning.  
Every n loads  
Number of conveying cycles to stations between 1–99  
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
5
# pulses  
Number of pulses of compressed air sent  
through the pump’s filter during cleaning.  
If blow-back is not working as desired, the  
service department may ask you to change this  
setting.  
1–99  
7/50D Plus or 7/50D Controller  
Chapter 6: Configurable Settings  
78  
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Name  
Description  
Options  
Default  
On time  
Number of seconds that the air compressor  
remains on for each pulse during filter cleaning.  
If blow-back is not working as desired, the  
service department may ask you to change this  
setting.  
0.1–99.0 sec. 1.0 sec.  
Off time  
Number of seconds between air pulses during  
filter cleaning.  
0.5–99.0 sec. 1.0 sec.  
If blow-back is not working as desired, the  
service department may ask you to change this  
setting.  
7/50D Plus or 7/50D Controller  
Chapter 6: Configurable Settings  
79  
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Chapter 7: Troubleshooting  
7-1 General Troubleshooting  
Problem  
Possible cause  
The controller panel is not  
plugged in.  
Solution  
Plug in the controller panel.  
The external disconnect  
(recommended) in the dedicated Close the switch (on).  
circuit is open (off).  
The controller panel doesn’t light  
up at all.  
Fuse/circuit breaker in the power  
drop is blown/tripped.  
Replace/reset.  
Broken controller power switch.  
Replace.  
Reset the circuit breaker and  
check the motor for the proper  
amp draw on tag.  
Replace the fuse/reset circuit  
breaker.  
The motor circuit breaker/  
overload has tripped.  
A pump package doesn’t run,  
even though it is on line and its  
indicator is lit.  
Main fuse in power drop circuit  
breaker has blown.  
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 field-installed station bypass Normal operation. Set the switch  
The hopper is off line.  
A vacuum hopper is being  
bypassed in the loading cycle.  
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. Repair as  
needed. Reset the conveying  
times to a reasonable value, and  
adjust as needed.  
Repair shorting circuit.  
Replace fuse with one that has a  
proper rating.  
Vacuum hoppers are over-filling.  
Controller blows fuses.  
Maximum conveying times are  
too long and/or the controller  
does not recognize the Hopper  
Full proximity switch(es).  
Power supply shorting out.  
Improper fuse installed.  
7/50D Plus or 7/50D Controller  
Chapter 7: Troubleshooting  
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7-2 Alarms  
The format for all station alarms is “Station n [alarm text],” for example, “Station 12 receiver  
low level.” The format for all pump alarms is “Pump n [alarm text].” Any alarm that does not  
start with “Station” or “Pump” is a system alarm.  
The following 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 Summary or the  
Pump Summary screen, or touch Helpat any other screen. When you  
are finished reviewing the help. touch Return.  
Station Alarms  
Alarm message  
Possible cause  
Solenoid patch cord is disconnected.  
Solenoid patch cord has been cut.  
Solenoid valve has malfunctioned.  
Blow back output failure  
(Critical)  
Material line is blocked.  
Vacuum line is blocked.  
Convey time is too long (time-fill station only).  
Sequence valve has malfunctioned.  
High vacuum  
Vacuum switch has malfunctioned.  
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.  
Local alarm’s light bulb is defective.  
Patch cord for local alarm is disconnected.  
Patch cord for local alarm has been cut.  
Local alarm output failure  
Note: As a stopgap measure, you can disable the alarm output for this  
station until the problem can be remedied. See pp. 43 and 74.  
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. See pp. 43 and 74.  
Not assigned to a pump  
(Critical)  
Station has not been assigned to a pump  
ArmorBlock is not installed.  
ArmorBlock is not addressed properly.  
ArmorBlock is defective.  
Base of ArmorBlock is defective.  
Not present  
(Critical)  
Network flat cable is not installed in base properly  
Power supply is not turned on.  
Power supply is not connected properly  
Power supply’s incoming fuse(s) have failed.  
Power supply’s output circuit breaker has tripped.  
ArmorBlock is defective.  
Output power failure  
(Critical)  
Base of ArmorBlock is defective.  
Power flat cable for network is not installed in ArmorBlock base properly  
7/50D Plus or 7/50D Controller  
Chapter 7: Troubleshooting  
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Alarm message  
Possible cause  
Pick-up wand is not positioned properly.  
Convey time is too short.  
Take-off compartment is not adjusted properly.  
Vacuum line has a leak.  
Partial convey  
Note: As a stopgap measure, you can disable the “partial convey” alarm for  
this station until the problem can be remedied. See pp. 43 and 74.  
Solenoid patch cord is disconnected.  
Solenoid patch cord has been cut.  
Solenoid valve has failed.  
Purge output failure  
(Critical)  
Purge valve not assigned  
(Critical)  
Station has not been assigned to a purge valve  
Conveying system has malfunctioned.  
Station has been disabled at controller’s touch screen.  
Station’s bypass switch is active.  
Receiver low level  
Note: As a stopgap measure, you can disable the “receiver low level” alarm  
for this station until the problem can be remedied. See pp. 43 and 75.  
Patch cord for remote proportioning valve is disconnected.  
Patch cord for remote proportioning valve has been cut.  
Solenoid A for remote proportioning valve has malfunctioned.  
Patch cord for remote proportioning valve is disconnected.  
Patch cord for remote proportioning valve has been cut.  
Solenoid B for remote proportioning valve has malfunctioned.  
Patch cord for sequence valve is disconnected.  
Patch cord for sequence valve has been cut.  
RPV material A failure  
(Critical)  
RPV material B failure  
(Critical)  
Sequence valve output failure  
(Critical)  
Solenoid for sequence valve has malfunctioned.  
Patch cord for slide gate is disconnected.  
Patch cord for slide gate has been cut.  
Slide gate output failure  
(Critical)  
Solenoid for slide gate has failed.  
Pump Alarms  
Alarm message  
Possible cause  
Patch cord for solenoid for blow back valve is disconnected.  
Patch cord for solenoid for blow back valve valve has been cut.  
Solenoid for blow-back valve has malfunctioned.  
Local alarm’s light bulb is defective.  
Blow back output failure  
(Critical)  
Patch cord for local alarm is disconnected.  
Patch cord for local alarm has been cut.  
Note: As a stopgap measure, you can disable the local alarm output  
for this pump until the problem can be remedied. See pp. 47 and 48.  
ArmorBlock is not installed.  
Local alarm output failure  
ArmorBlock is not addressed properly.  
ArmorBlock is defective.  
Base of ArmorBlock is defective.  
Not present  
(Critical)  
Network flat cable is not installed in base properly  
Power supply is not turned on.  
Power supply is not connected properly  
Power supply’s incoming fuse(s) have failed.  
Power supply’s output circuit breaker has tripped.  
ArmorBlock is defective.  
Output power failure  
(Critical)  
Base of ArmorBlock is defective.  
7/50D Plus or 7/50D Controller  
Chapter 7: Troubleshooting  
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Alarm message  
Output power failure  
(Critical)  
Possible cause  
Power flat cable for network is not installed in ArmorBlock base  
properly  
Pump failure  
(Critical)  
Circuit breaker or overload protector has tripped.  
Contactor has malfunctioned.  
Pump fault #1  
Pump fault #2  
(Function determined by your facility.)  
(Function determined by your facility.)  
Patch cord for contactor is disconnected.  
Patch cord for contactor has been cut.  
Contactor coil is defective.  
Pump starter output failure  
(Critical)  
Patch cord for vent is disconnected.  
Patch cord for vent has been cut.  
Vent solenoid valve has malfunctioned.  
Vent solenoid output failure  
(Critical)  
System Alarms  
Alarm message  
Possible cause  
Patch cord for horn or strobe light is disconnected.  
Patch cord for horn or strobe light has been cut.  
Central alarm failure  
All horns and strobe lights for this central alarm are defective.  
Power supply for a centralized purge valve is not turned on.  
Power supply for a centralized purge is not connected properly.  
An ArmorBlock for centralized purge valves is defective.  
Base of an ArmorBlock for centralized purge valves is defective.  
Power flat cable for network is not properly installed in the base of an  
ArmorBlock for centralized purge valves.  
Centralized purge output power  
failure  
(Critical)  
Patch cord for a centralized purge valve is disconnected.  
Patch cord for a centralized purge valve has been cut.  
Solenoid for a centralized purge valve has malfunctioned.  
An ArmorBlock for centralized purge valves is defective.  
Base of an ArmorBlock for centralized purge valves is defective.  
Network flat cable is not properly installed in the base of an  
ArmorBlock for centralized purge valves.  
Note: Once you have found and corrected the cause of this alarm,  
enable a station (p. 60) that uses the purge valve for which the alarm  
occurred. (To identify such a station, go to a Station Operator screen  
(p. 61) and navigate among the stations (p. 62) until you find a  
station assigned to this purge valve.) Once the system successfully  
uses this purge valve, it clears the alarm and enables all other  
stations that use this valve.  
Centralized purge valve failure  
(Critical)  
Battery for the controller is defective.  
Battery for the controller is old and drained.  
PLC low battery  
Power supply for network is not turned on.  
Scanner communication failure  
(Critical)  
Power supply for network is not connected properly.  
Main enclosure is not connected properly.  
DeviceNet scanner is defective.  
Scanner duplicate node  
(Critical)  
Two nodes (stations, pumps, central alarms, or centralized purge  
valves) are assigned the same address.  
Scanner incorrect node  
assignment  
(Critical)  
The ArmorBlock for a pump has an address for a station.  
The ArmorBlock for a central alarm has an address for a station.  
The ArmorBlock for a station has an address for a pump.  
7/50D Plus or 7/50D Controller  
Chapter 7: Troubleshooting  
83  
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Chapter 8: Appendix  
8-1 Warranty  
The manufacturer warrants all equipment manufactured by it to be free from defects in  
workmanship and material when used 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 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 the manufacturer’s equipment carry an additional one-year service policy.  
Consult your sales representative for specific details.  
8-2 Optional Components  
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.  
Additional audible/visual alarm with silence button. Alarm light and horn assembly that  
can be remote mounted and wired into the controller to indicate an alarm condition.  
Remote Interface.  
Central Purge Capability.  
Material Line Proofing – includes an additional PLC located near the quick change  
manifold.  
CE Package for 220/1/50 Operation. Required in Europe and other areas that need  
220/1/50 supply voltage.  
7/50D Plus or 7/50D Controller  
Chapter 8: Appendix  
84  
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8-3 Drawings and Diagrams  
Figure 19: 7 pump 50 station Controller with ???" Display  
??”  
??”  
??”  
* Depth dimension is ??”  
Also, review electrical drawings supplied in the packet with this manual.  
7/50D Plus or 7/50D Controller  
Chapter 8: Appendix  
85  
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Figure 20: Typical System Installation Layout  
7/50D Plus or 7/50D Controller  
Chapter 8: Appendix  
86  
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7/50D Plus or 7/50D Controller  
Chapter 8: Appendix  
87  
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8-4 Spare Parts List  
AC Voltage  
Quantity  
Part Number  
A0563932  
A0569862  
A0572817  
A0569859  
A0541611  
A0540997  
A0540993  
A0505812  
Description  
2.1A Power Supply  
Input Card  
1
1
1
2
3
4
1
1
Output Card  
Air Grill with Filter  
Fuse, MDL – .75  
Fuse, MDL – 1  
Fuse, MDL – .5  
Fuse, MDL – 1.25  
DC Voltage  
Quantity  
Part Number  
A0563993  
A0551976  
A0572817  
A0569859  
A0540997  
A0542204  
A0542208  
A0544790  
Description  
10A Power Supply  
Input Card  
1
1
1
2
3
4
1
1
Output Card  
Air Grill with Filter  
Fuse, MDL – 1  
Fuse, MDL – 2.25  
Fuse, MDL – 3.2  
Fuse, MDL - 8  
8-5 Returned Material Policy  
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.  
7/50D Plus or 7/50D Controller  
Chapter 8: Appendix  
88  
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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.  
8-6 Safety Tag Information  
Controller Safety Tags  
High Voltage Inside  
Read Operation and  
Enclosure  
Installation Manual  
8-7 Controller Identification (Serial Number) Tag  
(Located on the side of the controller box)  
Street Address  
Town, State, Zip Code  
Telephone Number  
Fax Number  
XXX CONTROL PANEL  
Model No. XXX7-50  
Serial No. 31K0182  
Ph  
115 Volt  
60 Hz  
1
Control Voltage 24VDC  
7/50D Plus or 7/50D Controller  
Chapter 8: Appendix  
89  
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8-8 Technical Assistance (Contact Information)  
Parts Department  
[
]
[
]
Call toll-free 7am–5pm CST 800 423-3183 or call 630 595-1060, Fax [630] 475-7005  
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.  
7/50D Plus or 7/50D Controller  
Chapter 8: Appendix  
90  
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