Sterling Home Theater Server 8820024900 User Manual

SCC 2-Pump 12-Station Controllers  
Part Number: 882.00249.00  
Bulletin Number: CV3-650  
Effective: 10/25/05  
Write Down Your Serial Numbers Here For Future Reference:  
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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.  
2–Pump 12-Station Controllers  
Chapter 1: Safety  
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Returns  
Do not return any damaged or incorrect items until you receive shipping instructions from the  
shipping department.  
Credit Returns  
Prior to the return of any material, authorization must be given by the manufacturer. A RMS  
number will be assigned for the equipment to be returned.  
Reason for requesting the return must be given.  
All returned material purchased from the manufacturer is subject to 15% ($75.00 minimum)  
restocking charge.  
All returns are to be shipped prepaid.  
The invoice number and date or purchase order number and date must be supplied.  
No credit will be issued for material that is not within the manufacturer’s warranty period  
and/or in new and unused condition, suitable for resale.  
Warranty Returns  
Prior to the return of any material, authorization must be given by the manufacturer. A RMS  
number will be assigned for the equipment to be returned.  
Reason for requesting the return must be given.  
All returns are to be shipped prepaid.  
The invoice number and date or purchase order number and date must be supplied.  
After inspecting the material, a replacement or credit will be given, at the manufacturer’s  
discretion, if the item is found to be defective in materials or workmanship. Purchased  
components are covered under their specific warranty terms.  
2–Pump 12-Station Controllers  
Chapter 1: Safety  
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Table of Contents  
CHAPTER 1: SAFETY ................................................................6  
1-1  
How to Use This Manual .............................................................................................6  
Safety Symbols Used in this Manual.....................................................................6  
Warnings and Precautions ..........................................................................................7  
Responsibility ..............................................................................................................8  
General Responsibility...........................................................................................8  
Operator Responsibility.........................................................................................9  
Maintenance Responsibility...................................................................................9  
Reporting a Safety Defect .....................................................................................9  
1-2  
1-3  
CHAPTER 2: FUNCTIONAL DESCRIPTION............................10  
2-1  
2-2  
2-3  
Models Covered in This Manual................................................................................10  
General Description...................................................................................................10  
Standard Features.....................................................................................................11  
Mechanical Features...........................................................................................11  
Electrical Features...............................................................................................11  
Controller Features..............................................................................................11  
Optional Features......................................................................................................11  
Safety Devices and Interlocks...................................................................................12  
Safety Circuit Standards......................................................................................12  
Fail Safe Operation .............................................................................................12  
Safety Device Lock-Outs.....................................................................................12  
2-4  
2-5  
CHAPTER 3: INSTALLATION ..................................................14  
3-1  
3-2  
3-3  
Uncrating...................................................................................................................14  
Mounting the Control Panel.......................................................................................14  
Electrical Connections...............................................................................................14  
Making Control Panel Power Drop Wiring Connections......................................14  
Connecting the Control Panel to Vacuum Hoppers.............................................15  
Connecting the Control Panel to the Pump Package ..........................................15  
Main Power .........................................................................................................17  
Setup.........................................................................................................................17  
Gaining Access to the Menu System...................................................................18  
Station Settings Menu .........................................................................................19  
Pump Settings Menu...........................................................................................27  
System Settings Menu ........................................................................................32  
Service Settings Menu ........................................................................................33  
Saving Controller Settings to Flash Memory .......................................................33  
Initial Startup .............................................................................................................33  
3-4  
3-5  
CHAPTER 4: OPERATION ........................................................34  
4-1  
Startup.......................................................................................................................34  
Setting Load Times .............................................................................................34  
Enabling and Disabling Individual Stations..........................................................35  
2–Pump 12-Station Controllers  
Chapter 1: Safety  
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4-2  
Controller Description and Operation........................................................................35  
Text Area.............................................................................................................35  
Station Icons........................................................................................................37  
Status Indicators..................................................................................................38  
Controller Keypad................................................................................................39  
4-3 Operation.....................................................................................................................40  
Operation States .................................................................................................40  
4-4  
Shut-Down.................................................................................................................42  
CHAPTER 5: MAINTENANCE...................................................43  
Updating BIOS Software .....................................................................................43  
CHAPTER 6: TROUBLESHOOTING.........................................46  
6-1  
General Troubleshooting...........................................................................................46  
Controller Recovery using Flash Memory Technology........................................48  
CHAPTER 7: APPENDIX ..........................................................49  
7-1  
Warranty....................................................................................................................49  
Warranty Specifications.......................................................................................49  
Warranty Restrictions..........................................................................................49  
Warranty Liabilities..............................................................................................50  
Customer Responsibilities...................................................................................50  
Drawings and Diagrams............................................................................................51  
Spare Parts List.........................................................................................................52  
Controller Identification (Serial Number) Tag............................................................56  
Technical Assistance (Contact Information)..............................................................56  
Parts Department ................................................................................................56  
Service Department.............................................................................................56  
Sales Department................................................................................................56  
Contract Department...........................................................................................56  
7-2  
7-3  
7-4  
7-5  
CHAPTER 8: SERVICE ONLY INFORMATION ........................57  
8-1  
Service Settings Menu ..............................................................................................57  
Setting the Ramp Up Time ..................................................................................57  
Setting the Ramp Down Time..............................................................................58  
Setting the Pump Stage Time..............................................................................59  
Setting the LCD Blink Delay................................................................................60  
Setting the Hi Vacuum Sensor Delay ..................................................................61  
Setting the Hi Vacuum Vent Delay ......................................................................62  
Setting the Hi Vacuum Load Count .....................................................................63  
Using the Installation Aids Menus .......................................................................64  
Other Controller Restricted Areas .............................................................................67  
Using the OEM Service Menu .............................................................................67  
Recovering Passwords........................................................................................68  
Restoring the Controller to Factory Defaults .......................................................69  
8-2  
2–Pump 12-Station Controllers  
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.  
2–Pump 12-Station Controllers  
Chapter 1: Safety  
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Controller Safety Tags  
Read Operation and Installation  
Manual  
High Voltage Inside  
Enclosure  
1-2 Warnings and Precautions  
Our equipment is designed to provide safe and reliable operation when installed and operated  
within design specifications, following national and local safety codes. This may include, but  
is not limited to OSHA, NEC, CSA, SPI, and any other local, national and international  
regulations.  
To avoid possible personal injury or equipment damage when installing, operating, or  
maintaining this equipment, use good judgment and follow these safe practices:  
; Read and follow these operation and installation instructions when installing,  
operating, and maintaining this equipment. If these instructions become  
damaged or unreadable, additional copies are available from the manufacturer.  
; Follow all SAFETY CODES.  
; Wear SAFETY GLASSES and WORK GLOVES.  
; Work only with approved tools and devices.  
; Disconnect and/or lock out power before servicing or maintaining the equipment.  
; Use care when LOADING, UNLOADING, RIGGING, or MOVING this  
equipment.  
; Operate this equipment within design specifications.  
; OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.  
You should remove the fuses and carry them with you.  
; Make sure the equipment and components are properly GROUNDED before you  
switch on power.  
; Use extreme caution when working with your conveying system. HIGH VACUUM  
can be dangerous. Keep body parts, tools, clothing, and debris away from vacuum  
inlets.  
; When welding or brazing in or around this equipment, make sure VENTILATION is  
ADEQUATE. PROTECT adjacent materials from flame or sparks by shielding with  
sheet metal. An approved FIRE EXTINGUISHER should be close at hand and  
ready for use if needed.  
; Do not restore power until you remove all tools, test equipment, etc., and the  
equipment and related components are fully reassembled.  
; Only PROPERLY TRAINED personnel familiar with the information in this  
manual should work on this equipment.  
We have long recognized the importance of safety and have designed and manufactured our  
equipment with operator safety as a prime consideration. We expect you, as a user, to abide  
by the foregoing recommendations in order to make operator safety a reality.  
2–Pump 12-Station Controllers  
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.  
2–Pump 12-Station Controllers  
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.  
2–Pump 12-Station Controllers  
Chapter 1: Safety  
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Chapter 2: Functional Description  
2-1 Models Covered in This Manual  
This manual provides operation, installation, and maintenance instructions for 2-Pump, 12-  
Station Conveying Controllers. Model numbers are listed on the serial tag. Make sure you  
know the model and serial number of your equipment before contacting the manufacturer for  
parts or service.  
The 2-Pump, 12-Station Conveying Controller is a programmable logic controller, with 24  
VDC or 115 VAC control circuit, easy-to-use 16-key operator interface keypad and optional  
audible/visual alarm.  
2-2 General Description  
Our systems create vacuum for the automatic pneumatic conveying of most free-flowing, dry,  
pelletized, or granular materials in a central material handling system. Material  
characteristics determine the type of equipment needed to convey the material.  
A typical use for our equipment is an in-plant distribution system for plastic processing  
plants.  
Our central vacuum systems are as varied as the applications they service. The tubing and  
equipment furnished in our system is designed to convey the material(s) specified at the time  
of purchase at specific rates and distances.  
We can advise you on your system capabilities based on system makeup, distance, material,  
and conveying rates you want.  
System capacity is directly affected by the pressure drop in the overall system, such as  
number of material line bends, pipe length, Y-tubes, T-tubes, etc.  
Note: Vacuum leaks occuring anywhere in your system reduce capacity.  
Use the minimum effective amount of vinyl flex hose to maximize material line efficiency.  
Keep material lines as straight as possible. Refer to the Mechanical Components Product  
manual (Part No. A0536580) for installation recommendations.  
2–Pump 12-Station Controllers  
Chapter 2: Functional Description  
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2-3 Standard Features  
Mechanical Features  
Time-fill Capability. The length of time a station’s vacuum valve remains open to allow  
material to be drawn into its receiver.  
Volume-fill Capability. The length of time a station’s vacuum valve remains open to allow  
material to be drawn in. The vacuum valve will close when material covers the station’s  
volume-fill proximity sensor or this time elapses, whichever comes first.  
Pump Blowback Filter Cleaning Outputs. When this feature is enabled, the controller  
periodically sends compressed air backward through the pump’s air filter to dislodge  
accumulated dust and debris.  
Electrical Features  
115/1/60 supply voltage  
24 VDC control voltage  
Single-point power and ground connection  
Non-fused disconnect switch, lockable  
Branch circuit fusing  
Fully accessible NEMA 12-style electrical control enclosure  
Controller Features  
Monitors Station status and Pump status  
Allows operator to transfer stations to a standby pump when a pump fails  
Electronic time delay between pump startups to prevent an excessive power demand at  
your facility  
2-4 Optional Features  
Options marked with “*” indicate options that can be factory installed or retrofitted in the  
field.  
230/1/60 Operation. Required to operate with a 230/1/60 supply voltage.  
Audible/visual alarm. Alarm light and horn assembly that can be remote mounted and  
wired into the controller to indicate an alarm condition.  
CE Package for 220/1/50 Operation. Required in Europe and other areas that need  
220/1/50 supply voltage.  
2–Pump 12-Station Controllers  
Chapter 2: Functional Description  
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2-5 Safety Devices and Interlocks  
This section includes information on safety devices and procedures that are inherent to the  
Controller. This manual is not intended to supersede or alter safety standards established by  
the user of this equipment. Instead, the material contained in this section is recommended to  
supplement these procedures in order to provide a safer working environment.  
At the completion of this section, the operator and maintenance personnel will be able to do  
the following:  
Identify and locate specific safety devices.  
Understand the proper use of the safety devices provided.  
Describe the function of the safety device.  
Safety Circuit Standards  
Safety circuits used in industrial systems protect the operator and maintenance personnel  
from dangerous energy. They also provide a means of locking out or isolating the energy for  
servicing equipment.  
Various agencies have contributed to the establishment of safety standards that apply to the  
design and manufacture of automated equipment. The Occupational Safety and Health  
Administration (OSHA) and the Joint Industrial council (JIC) are just a few of the  
organizations that have joined with the plastics industry to develop safety standards.  
Every effort has been made to incorporate these standards into the design of the conveying  
system; however, it is the responsibility of the personnel operating and maintaining the  
equipment to familiarize themselves with the safety procedures and the proper use of any  
safety devices.  
Fail Safe Operation  
If a safety device or circuit should fail, the design must be such that the failure causes a  
“Safe” condition. As an example, a safety switch must be a normally open switch. The switch  
must be held closed with the device it is to protect. If the switch fails, it will go to the open  
condition, tripping out the safety circuit.  
At no time should the safety device fail and allow the operation to continue for example, if a  
safety switch is guarding a motor, and the safety switch fails, the motor should not be able to  
run.  
Safety Device Lock-Outs  
Some safety devices disconnect electrical energy from a circuit. The safety devices that are  
used in this Controller are primarily concerned with electrical power disconnection.  
WARNING! Always disconnect and lockout all electrical power and pneumatic (i.e. compressed air)  
sources prior to servicing the 2-Pump, 12-Station Controller. Failure to do so may  
result in serious injury. No one but the person who installed the lockout may remove  
it.  
2–Pump 12-Station Controllers  
Chapter 2: Functional Description  
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2–Pump 12-Station Controllers  
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Chapter 3: Installation  
3-1 Uncrating  
2-Pump, 12-Station Controllers are shipped mounted on a skid, enclosed in a plastic wrapper,  
and contained in a cardboard box.  
1. Pry the crating away from the skid.  
Note: Remove the nails holding the box to the skid and lift the box off  
carefully; avoiding staples in the 1’ x 4’ wood supports. Cut the steel  
banding.  
2. Use a pry bar to remove the blocks securing the unit to the skid.  
3. Lift unit from sides. Lift slowly and only high enough to clear the skid. Use a pry bar  
if necessary to carefully remove the skid from the unit.  
4. Lower slowly.  
3-2 Mounting the Control Panel  
Note: Before you mount the panel, consider how you run wiring to the  
vacuum hoppers, the filter chamber atmospheric valve (if so equipped)  
and the pump motor starter(s), vacuum switch(es), and vent valve(s).  
Mount the panel on a flat, vertical area. It should be a visible area that gives your operator  
access to the control. The panel requires a low voltage power drop as listed on the serial tag.  
3-3 Electrical Connections  
Refer to local electrical codes, the schematic and connection diagrams supplied with this unit  
and the serial tag for wiring considerations. Run all wiring in conduit if codes require it.  
Making Control Panel Power Drop Wiring Connections  
Plug the power cord supplied with your unit into a properly grounded, 3-slot, 115/1/50-60 VAC  
or 230/1/50-60 VAC receptacle specified on the control panel serial tag. The control enclosure  
draws less than five (5) amps during normal operation at 115/1/50-60 VAC.  
Caution!  
We recommend that you protect PLC memory by providing the control  
panel with a dedicated circuit, a true earth ground, and a spike/surge  
protector.  
2–Pump 12-Station Controllers  
Chapter 3: Installation  
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Connecting the Control Panel to Vacuum Hoppers  
Refer to the wiring connection diagram in Figure 1 on the next page that applies to your  
application.  
Note: Wire size depends on control voltage, distance, number of vacuum  
hoppers, and the number of wires in each raceway. Consult a qualified  
electrician.  
1. On 24 VDC control voltage systems, run a common +24 VDC wire and a common 0  
(zero) VDC wire from the controller to each vacuum hopper in the system.  
Note: For safety, make sure that the +24 volt line is fused. The size of the  
fuse depends on the number of stations installed.  
A 4 amp fuse is sufficient for a 12-station installation.  
2. On all systems, run two wires to each vacuum hopper: one each from the controller  
to the Bin-Full switch (LS) and to the Atmospheric/Sequence-T solenoid (SOL)  
valve.  
3. Make sure that the solenoid and the proximity switch (if supplied) on vacuum  
hoppers are the same voltage (24 VDC) as the control panel voltage. Consult the  
control panel serial tag and the solenoid valve nameplates.  
4. Wire size depends on control voltage, distance, number of vacuum hoppers, and the  
number of wires in each raceway. Consult a qualified electrician.  
5. Properly ground each hopper to reduce static build up generated by material  
conveying.  
Connecting the Control Panel to the Pump Package  
1. Wire the pump package motor starter coil (M) to the terminal provided in the control  
panel enclosure.  
2. Wire the pump package vacuum relief valve solenoid (SOL A) to the terminal  
provided in the control panel enclosure.  
3. Wire the pump package vacuum switch (VS) to the terminal located in the control  
panel enclosure.  
4. On vacuum pumps with blowback, wire the pump package blowback solenoid (SOL  
B) to the terminal located in the control panel enclosure.  
5. On 24 VDC control voltage systems, run a common +24 VDC wire and a common 0  
(zero) VDC wire from the controller to each pump package in the system.  
2–Pump 12-Station Controllers  
Chapter 3: Installation  
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Figure 1: Typical 24-Volt Junction Box Wiring Diagram  
SOL A/B  
KAY VALVE  
LOCATED ON  
PUMP  
GRD  
FROM CONTROLLER OUTPUT  
FOR VACUUM SOLENOID  
VACUUM  
(NEUTRAL)/(+24VDC)  
TO TERMINAL A1 (NEUTRAL)/(+24 VDC)  
ON MOTOR STARTER (M)  
COMMON  
L1  
L2  
TO  
JUNCTION  
BOX  
L3  
FROM CONTROLLER OUTPUT  
FOR BLOWBACK SOLENOID  
BLOWBACK  
A1  
3
5
L3  
1
L1  
L2  
13  
M
A09  
T1  
2
T2  
4
T3  
6
14  
TO UPPER VALVE  
PROCESS AIR  
CONNECTION  
A2  
A2  
J1  
TEST  
96  
RESET  
TRIPPED  
97  
95  
98  
OL  
FROM CONTROLLER OUTPUT  
FOR PUMP MOTOR STARTER  
T
1
T
2
T
3
2
4
6
T1  
T2  
T3  
TO MOTOR  
(MTR)  
(115VAC)/(0VDC)  
VS  
TO CONTROLLER INPUT FOR  
PUMP HIGH-VACUUM  
3 PHASE / 4 WIRE SERVICE AND  
FUSED DISCONNECT SWITCH TO  
BE PROVIDED BY CUSTOMER  
SUBPANEL LAYOUT AND CONNECTION DIAGRAM  
A0544675  
LEGEND  
(115V AC AND 24V DC)  
FIELD WIRING  
DISC  
INTERNAL  
WIRING  
M
OL  
FU  
FU  
FU  
L1  
L2  
L3  
L1  
L2  
L3  
T1  
T2  
T3  
WIRE LUG  
MTR  
5 HP PUMP  
POWER WIRING  
GRD  
1PS  
TO CONTROLLER INPUT FOR  
PUMP HIGH VACUUM  
(115V AC)  
N. O.  
(NEUTRAL)  
1M  
J1  
VACUUM PUMP  
FROM CONTROLLER OUTPUT  
1M  
MOTOR STARTER  
FOR MOTOR STARTER  
96  
95  
A2  
A1  
1SOL  
VACUUM  
FROM CONTROLLER OUTPUT  
FOR VACUUM PUMP SOLENOID  
SOLENOID ON PUMP  
1SOL  
BLOWBACK SOLENOID  
ON PUMP  
FROM CONTROLLER OUTPUT  
FOR PUMP BLOWBACK SOLENOID  
CONTROL WIRING  
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Main Power  
Your 12-station controller system can operate from a 115 VAC or 220 VAC source at 50 Hz  
or 60 Hz. The main power switch on the controller is located on the right side of the housing.  
Built into the power switch are the controller fuses. Also, the configuration of the fuse holder  
determines the voltage setting of the controller (115/220 VAC).  
Marked on the faceplate of the fuse holder shows the configuration for the desired voltage.  
Using a small screwdriver, remove the fuse holder. To select the operating voltage, align the  
arrow marker on the holder and the switch as shown in the following section.  
The 12 station controller has a standard IEC power cord. Plug the cord into any standard 115  
VAC outlet. If you selected the 220 VAC option, remove the end connector and install a  
standard 220 VAC plug. Doing so does NOT effect the controllers warranty.  
DC Controller Power Sources  
Although main controller power is 115/220 VAC, control power is actually unregulated 24  
VDC. The 24 VDC control power supplies the power for all solenoids, sensors, and the  
controller itself. The unregulated supply can deliver up to five (5) amps of continuous current  
to drive a very large system.  
Inputs  
Station connections  
High vacuum connections  
System error connections  
Outputs  
Station connections  
Pump/blowback  
Spare  
3-4 Setup  
This section provides the procedures for configuring your 2-pump, 12-station controller.  
Configuration of your controller includes setting the number of stations and pumps, setting  
variables such as convey time and blow-back interval, and setting up passwords. We  
recommend that you carry out these procedures in the order given here.  
Note: Before carrying out these procedures, install all equipment as  
described in this section and in the Mechanical Components manual.  
To help you set up the controller quickly, this section walks you through the setup using the  
menu system. This procedure will work for most applications, but you may need to perform  
some minor adjustments afterwards to achieve the best conveying performance.  
Note: The controller must be in Offline mode to permit access to the menu  
system.  
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Gaining Access to the Menu System  
To enter the menu system, make sure that the controller is in the OFFLINE state. Press the  
MENU key to initiate the menu system.  
The menu has three (3) top level menus:  
1. Station Settings  
2. Pump Settings  
3. System Settings  
Press the CLEAR key in the menu system to bring you up one level.  
Figure 2: Menu Tree Structure  
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Station Settings Menu  
To access the Station Settings menu, place the controller in the OFFLINE state:  
1. Press the ENTER/MENU key to enter the menu system.  
2. Continue to press the ENTER/MENU key until the following screen displays:  
STATION SETTINGS?  
NO/YES  
To enter the Station settings menu:  
Press the YES key.  
To bring you up one level within any menu:  
Press the CLEAR key.  
Operation Mode, Station Settings Menu  
In most applications, each loading station can use different types of hoppers. The two  
common types are standard hoppers and sight glass loaders. You’ll need to set up your  
controller for the type of hopper you are using for each of the 12 loading stations.  
The first submenu in the Station Settings menu is the Operation Mode.  
To enter the Operation Mode submenu:  
Press the YES key at the following screen prompt.  
OPERATION MODE?  
NO/YES  
Each station in the conveying system can be a standard configuration or a sight glass  
configuration. Each hopper design operates in a slightly different manner.  
In Standard mode, a flapper sensor detects a demand on the system. The volume fill sensor  
senses when the hopper is filled with material. These two (2) sensors are wired in series and a  
single input of the controller reads them. The controller determines the difference in the  
signals, depending on load sequence timing.  
In Sight Glass mode, only one single sensor detects demand. This mode has no volume fill  
operation, and you’ll need to disable that function. Properly setting the operation mode lets  
the controller correctly sequence station loading.  
Upon entering the Operation Mode menu, the controller prompts you to set all 12 stations to  
Normal (default) mode.  
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To set all the stations to Normal mode and return to the Station Settings menu:  
Press the YES key at the following screen prompt.  
ALL NORMAL MODE?  
NO/YES  
This function lets you use the fast setup feature of the controller. Normal mode is the factory  
default, so if no sight glass loaders are on your system, you won’t need to alter this setting.  
Pressing the NO key moves to the All Sight Glass Mode screen. Again, this function lets you  
quickly change all stations to Sight Glass mode if all stations have sight glass loaders.  
ALL SIGHTGLASS MODE?  
NO/YES  
To move on to the individual settings screen:  
Press the NO key.  
The following screen displays.  
STATION: 1 NORMAL  
Y=NORMAL N=SIGHTGLS  
Starting with Hopper 1, the controller now lets you individually set the operation mode of  
each station.  
1. Press the YES key to set the station to Normal mode.  
2. Press the NO key to set the station to the Sight Glass mode.  
3. Press the SET key to save the new setting into controller memory and increment to  
the next station in sequence.  
4. Press the CLEAR key to exit to the Station Settings menu.  
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Set Dump Delay, Station Settings Menu  
The second submenu in Station Settings is the Set Dump Delay submenu.  
SET DUMP DELAY?  
NO/YES  
To set dump delay time:  
Press the YES key.  
After a hopper finishes loading, the next hopper in the queue usually gets loaded. The time it  
takes to load the new hopper(s) usually gives ample time for the first hopper to dump its  
material. However, in a situation where a single hopper is being loaded, a demand may be  
generated during the dump cycle from material catching on the flapper switch. This may  
cause an inadvertent load while the hopper is still dumping material.  
To prevent this from occurring, a dump delay timer starts after each hopper loads. The  
controller then waits until the timer elapses before loading the station. Setting this timer is  
critical to an efficiently operating conveying system. If you set the timer too short,  
inadvertent loads result. If you set the timer too long, unneccessary sequence delays occur.  
To determine the proper setting, fill the hopper with material and measure the time it takes to  
dump the material. Add one second (1 sec.) for smaller hoppers and three seconds (3 sec.) for  
larger hoppers to this time. Enter the setting into controller memory using the following  
procedure. You may have to adjust the time setting for the best overall system efficiency.  
TO SELECT A STATION  
PRESS STATION <1-12>  
To alter station dump delay time:  
Select the station requiring the dump delay time change, and press the related Station  
STnn key. nn is the number of the station you want to alter.  
The following screen displays.  
DUMP DELAY 11: 15.0s  
PRESS ENTER TO SAVE  
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The screen displays the station you selected (11 in the above example), and the current dump  
delay time setting. Using number keys 1 to 0, enter the new dump delay time (in seconds)  
into controller memory. Keep in mind that the value shifts to the left as you enter. Use the 0  
key to shift to the next multiple of ten.  
To exit from the Dump Delay menu and return to the Station Settings menu:  
Press the CLEAR key.  
To save the new value and escape from the Dump Delay menu:  
Press the ENTER key.  
To save the new value to the controller memory and increment to the next station in the  
sequence:  
Press the SET key.  
If you press the SET key without entering a value, the original value is retained and the  
controller moves to the next station in the sequence.  
Set Input Delay, Station Settings Menu  
The third submenu under Station Settings is the Set Input Delay submenu.  
To set input delay time:  
Press the YES key.  
The following screen displays.  
SET INPUT DELAY?  
NO/YES  
The Input Delay function protects the system from erroneous inputs caused by noise or  
mechanical vibration. The signal must be present for the input delay time setting duration for  
the input to be recognized.  
To alter input delay time:  
Press the YES key.  
The following screen displays.  
TO SELECT A STATION  
PRESS STATION <1-12>  
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To alter station input delay time:  
Select a station to alter, then press the related Station STnn key. nn is the station  
number you selected.  
The screen displays the selected station (11 in the following example) and the current input  
delay time setting.  
INPUT DLY 11: 0.250s  
PRESS ENTER TO SAVE  
Using number keys 1 to 0, enter the new time in seconds into controller memory.  
Keep in mind that the value shifts to the left as you enter it. Use the Zero 0 key to shift  
to the next multiple of ten.  
To exit from the Input Delay time menu and return to the Station Settings menu:  
Press the CLEAR key.  
To save the new value and escape from the Input Delay menu:  
Press the ENTER key.  
To save the new value to the controller memory and increment to the next station in the  
sequence:  
Press the SET key.  
If you press the SET key without entering a value, the original value is retained and the  
controller moves to the next station in the sequence.  
Set Station Alarms, Station Settings Menu  
The fourth submenu under Station Settings is the Set Station Alarms submenu.  
To set station alarms:  
Press the YES key.  
The following screen displays.  
SET STATION ALARMS?  
NO/YES  
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Each station has its own No Convey alarm settings. You can enable or disable alarms as  
needed. If a station doesn’t receive (or dump) material after a user definable number of load  
attempts, the controller activates an alarm condition. Perform the following procedure to set  
alarm conditions.  
To alter the Input Delay time:  
Press the YES key.  
The following screen displays.  
TO SELECT A STATION  
PRESS STATION <1-12>  
To alter stations alarm settings:  
Select a station to alter, then press the related Station STnn key. nn is the station  
number you selected.  
The screen displays the selected station (11 in the following example) and the current  
station alarm setting.  
ALARM 11: ENABLED  
Y=ENABLE N=DISABLE  
To enable the alarm:  
Press the YES key.  
The alarm is enabled on the station you selected.  
If you want to disable the alarm:  
Press the NO key.  
The alarm is disabled on the station you selected.  
The controller increments to the next station in sequence.  
To retain the original setting:  
Press the SET key.  
The next station in the sequence displays.  
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To exit from the Alarm Setting time menu and return to the Station Settings menu:  
Press the CLEAR key.  
ALARM AFTER 3 LOADS  
PRESS ENTER TO SAVE  
Assigning a Pump to a Station  
This function lets you easily set all 12 stations.  
From the main operating screen:  
1. Press the MENU key until the following screen displays:  
STATION SETTINGS?  
NO/YES  
To enter the Station Settings menu:  
1. Press the YES key.  
2. Press the MENU key again until the following screen displays:  
ASSIGN PUMP>STATION?  
NO/YES  
To assign pumps to stations:  
1. Press the YES key.  
The following screen displays:  
TO SELECT A STATION  
PRESS HOPPER <1-12>  
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To assign a station to a pump:  
1. Press the related station ST key.  
The following menu screen displays:  
STATION 10: PUMP 1  
SELECT PUMP 1 OR 2  
To assign Pump 1 to the station you selected:  
Press 1.  
Instead of assigning Pump 1 to the station you selected, you can assign Pump 2:  
Press 2.  
To save the new setting and display the Station Assignment screen:  
Press the ENTER key.  
To save the new pump assignment and increment to the next station sequence:  
Press the SET key.  
To exit the Station Settings menu:  
1. Press the CLEAR key.  
2. Press the CLEAR key repeatedly to exit to the next higher menu, or to exit the menu  
system.  
Caution!  
You must assign the correct pump to a hopper before starting the  
conveying process.  
Failure to properly assign pumps can result in damage to the conveying  
system!  
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Pump Settings Menu  
The Pump Settings menu lets you set all pump parameters. These include:  
Pump Mode  
Blowback  
Delay Time  
Setting the Pump Mode  
The first setting to be configured is the Pump mode. This function tells the controller how  
many pumps are connected to the system and how the pumps are to be controlled.  
You can select two pump modes: Single Pump mode and Dual Pump mode. In Single Pump  
mode (default), one (1) pump is used to convey material to all 12 stations. In Dual Pump  
mode, two (2) pumps are used simultaneously, resulting in a more efficient conveying  
process.  
From the main operating display (OFFLINE):  
1. Press the MENU key repeatedly until the screen displays the following:  
PUMP SETTINGS?  
NO/YES  
To enter the Pump Settings menu:  
1. Press the YES key.  
2. Press the NO or MENU key repeatedly until the screen displays the following:  
PUMP MODE?  
NO/YES  
To enter the Pump Mode setting menu:  
1. Press the YES key.  
The screen displays the following:  
SET PUMP MODE?  
Y=SINGLE N=DUAL  
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If you have a single pump system (default):  
1. Press the YES key.  
Selecting Single Pump mode requires the assignment of the default pump; the screen then  
displays the following:  
SET ACTIVE PUMP  
SELECT PUMP 1 OR 2  
Selecting Dual Pump mode requires ALL stations to be assigned to a pump. Do so in the  
Station Settings Menu.  
The pump mode is now set.  
To exit from the Pump Settings Menu:  
1. Press the CLEAR key.  
Note: You can always press the CLEAR key repeatedly to bring you up one  
level in the menu system.  
Selecting the Dual Pump option immediately returns you to the Pump Settings menu.  
Caution!  
If you select Dual Pump mode, you MUST assign each station to a pump.  
Each station defaults to Pump 1 if not assigned.  
Caution!  
Not assigning a station to its related pump can cause damage to the loading  
system!  
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Changing Blowback Settings, Pump Settings Menu  
As an option, you can equip the conveying system filter chamber with a blowback feature to  
pulsate compressed air through the filter. This function cleans the filter after a pre-set number  
of load sequences.  
To set up the controller blowback feature, enter the Pump Settings menu, then:  
Press the MENU key until the Blowback Settings prompt screen displays:  
BLOWBACK SETTINGS?  
NO/YES  
Press the YES key to alter the blowback settings.  
The following screen displays.  
SELECT PUMP 1 OR 2  
USE KEYPAD TO ENTER  
Each pump can have separate blowback settings. To alter pump settings, select a pump:  
Using the keypad, enter the pump number (1 or 2).  
The following screen displays.  
ENABLE BLOWBACK?  
NO/YES  
To disable the blowback feature:  
Press the NO key.  
The screen returns to the Pump Settings menu.  
If you want to enable the blowback feature:  
Press the YES key.  
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The screen continues to the next prompt.  
BLOWBACK PULSES: 10  
SETTING FOR PUMP 1  
The first setting for the blowback feature is the number of blowback pulses. This setting  
determines the number of pulses of air that will be pushed through the filter during the  
blowback cycle. It has a range of 1 to 99, with a factory default of ten (10) pulses.  
Using the number keys, enter the new blowback pulse setting, then press ENTER to  
save the new value.  
To save the current set value and move to the next menu item:  
Press ENTER without entering a value.  
If a value is entered beyond the limits such as less than 1 or greater than 99, the screen  
displays question marks ?? in the settings area. If this happens:  
Simply re-enter the new value or press CLEAR to restore the value to the original  
setting.  
If you’ve properly entered the value, the following screen displays.  
ON TIME: 0.500 s  
SETTING FOR PUMP 1  
Next, set the Pulse On time value. This is the duration that the blowback solenoid is turned  
ON.  
Using the number keys, enter the new On Time setting, then press ENTER to save the  
new value.  
To save the current On Time setting and move to the next menu item:  
Press ENTER without entering a value.  
The following screen displays.  
OFF TIME: 0.500 s  
SETTING FOR PUMP 1  
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Next, set the Pulse Off time value. This is the duration that the blowback solenoid is turned  
OFF.  
Using the number keys, enter the new Off Time setting, then press ENTER to save the  
new value.  
To save the current Off Time setting and move to the next menu item:  
Press ENTER without entering a value.  
The following screen displays.  
BLBK AFTER 12 LOADS  
SETTING FOR PUMP 1  
The last blowback setting tells the controller how many loads on stations assigned to the  
selected pump must be completed before starting a blowback cycle.  
After you define this setting, the controller returns to the Pump Settings menu screen.  
Idle Delay Time Settings, Pump Settings Menu  
After a station load is complete, the controller looks for a new demand on the system. If all  
stations are satisfied with material, the controller enters IDLE (No Activity) state. During this  
state, the atmospheric vent valve is open and vacuum vents. During IDLE (No Activity) state  
time, the controller monitors inputs looking for a demand on the system. Eventually, if no  
demand is on the system, the controller shuts down the pump(s) and waits for a demand  
signal. This process saves energy and prolongs the life of the vacuum pump.  
The Idle time is the length of time in which the controller waits with no demand until the  
pump is turned off.  
To set up the controller Idle Delay time, enter the Pump Settings menu, then:  
Press the MENU key until the Idle Delay Time prompt screen displays as follows:  
IDLE DELAY TIME?  
NO/YES  
Press the YES key to alter the Idle Delay time.  
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The following screen displays.  
SELECT PUMP 1 OR 2  
USE KEYPAD TO ENTER  
Each pump can have separate idle delay times. To alter idle delay, select a pump:  
Using the keypad, enter the pump number (1 or 2).  
The following screen displays.  
IDLE TIME: 10.000 s  
SETTING FOR PUMP 1  
Using the keypad, enter the idle delay time.  
The controller is now properly set up and ready for operation.  
System Settings Menu  
Audio Alarm Time  
Video Alarm Time  
Password Enable/Disable  
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Service Settings Menu  
The settings in this menu are not meant to be modified by floor personnel (operators). See  
the section at the end of this manual for these settings.  
Saving Controller Settings to Flash Memory  
Your 12 station controller uses a new technology called flash memory. This type of memory  
writes and reads like normal memory, but the advantage is that the data is retained after  
power is shut down. If you alter any parameter, the controller saves the new data to flash  
memory. This procedure takes several seconds and takes all the processor time. For this  
reason, the controller does not write to flash memory while running. Any changes to load  
times are saved when you press the STOP key and the controller shuts down completely.  
Note: Let the controller save parameter changes to flash memory completely  
before you shut down the controller.  
It is also possible for a write error to occur during this operation. If this occurs, the system  
always saves a backup of the data. See the Maintenance Section for instructions on how to  
restore the previous settings.  
3-5 Initial Startup  
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Chapter 4: Operation  
4-1 Startup  
???????????????  
Setting Load Times  
You can alter load times anytime while not in the menu system by pressing the SET key. The  
controller screen then prompts you to select the station you want to alter:  
TO SELECT A STATION  
PRESS STATION <1-12>  
To select a station to alter:  
1. Press the related station ST key of the station you want to alter.  
The screen prompts you to enter a load time in seconds.  
LOAD TIME 10: 63sec  
PRESS ENTER TO SAVE  
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2. Using number keys 1 to 0, enter the new time.  
3. Press the ENTER key to save the new setting into controller memory.  
If several stations require altering:  
1. Press the SET key instead of the ENTER key.  
The new settings are saved and the station number increments to the next station in sequence.  
Press the SET key without entering a value to retain the original value in controller memory.  
The load time range of the station is from 1 to 360 seconds. Entering values beyond this  
range result in the screen displaying three (3) question marks (???).  
To abort this erroneous entry and return to normal operation mode:  
1. Press the CLEAR key.  
Enabling and Disabling Individual Stations  
Except while you are in the menu system and when you are altering system parameters, you  
can enable or disable any station in the system.  
To enable or disable a loading station:  
1. Press the STnn key (where nn is the station number you want) to toggle between  
station enable or disable mode.  
4-2 Controller Description and Operation  
Your 12-station controller system has been designed for quick setup and easy, low  
maintenance operation. Before you begin operation, make sure you become familiar with the  
functions and features of your controller.  
The controller screen displays the status of the controller at any given time. By a simple  
glance, you can know exactly what the controller is doing. The screen has three areas:  
Text area, a 2-line, 20-character screen  
Station icons for displaying the status of each individual station  
Status indicators for displaying the operation of the pump.  
Text Area  
The text area is separated into four (4) sections. The appearance of the screen depends on the  
setting of the Pump mode.  
SECTION 1 SECTION 2  
SECTION 3 SECTION 4  
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Pump Modes  
Single Pump Mode  
In Single Pump mode, the screen displays as shown below. The upper left corner displays the  
active station being loaded. If the system has no active station, two (2) hyphens --in the  
station area display. The lower left corner displays the load time in seconds. When a station is  
loading, this area displays how much time elapses during the load cycle. If no station is  
active, three (3) hyphens ---display.  
The upper right area displays the status of the control. This section displays the condition of  
the controller, and what action is occurring in the loading sequence. The different status  
displays are described on Pages 24 and 25.  
The lower right section of the display is not used in Single Pump mode. It simply displays the  
manufacturer’s logo.  
STATION:-- OFFLINE  
TIME: --- LOGO  
Dual Pump Mode  
In Dual Pump mode, the screen displays as shown on the following page. The first line of the  
screen displays information for Pump 1 and the second line of the screen displays information  
for Pump 2.  
Each line has twenty (20) characters divided into two (2) groups of ten (10). From the left  
character position, P0 S:--:--- is read as “Pump 0 Station --:Load Time ---.” This screen  
displays important information in an easy-to-read display. The right ten (10) character group  
displays the status of the specific pump. Again, the different status displays are described on  
Pages 24 and 25.  
P1:S--:--- OFFLINE  
P2:S—-:--- OFFLINE  
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Station Icons  
Below the text portion of the screen, 12 station icons display the status of each station in the  
system. Each station icon contains four segments.  
Figure 3: Station Icon Segments  
Label  
Description  
The top segment indicates the status of the valve above each station. When  
the valve is open (control output energized), this icon highlights. In Single  
Pump mode, only one valve indicator is active at a time. In Dual Pump  
mode, up to two valve indicators can be active at a time. When this  
indicator flashes, it indicates the assignment of a priority convey.  
Segment 1  
The center square segment indicates the existence of a station specific alarm  
condition. The alarm is typically related to a No Convey condition, but can  
also indicate the station with a high vacuum condition.  
Segment 2  
Segment 3  
Located on the bottom of the station icon, the lower segment indicates the  
station demand input. This is a real time indicator, displaying when the  
station demand input is active. This indicator may toggle on and off during  
the load cycle, and should be considered normal.  
Segment 4 is the indicator word ON, located below the station icon. When  
ON displays, the related station loads when the system senses a demand  
signal. When ON does not display, the station demand input signal is  
ignored and the related station does not load. Segment 4 blinks with  
Segment 2 in a high vacuum condition.  
Segment 4  
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Status Indicators  
Four (4) status indicators are located below the station icons at the bottom of the display.  
These indicators include PUMP, BLOWBACK, HIGH VACUUM, and SYSTEM. Each icon  
word has a 1 and a 2 icon with it, indicating Pump 1 or Pump 2.  
Figure 4: Status Indicator Icons  
Icon  
Label  
Description  
The PUMP status indicator specifies an active pump.  
PUMP displays when any pump is active, and the 1 or 2  
icon indicates which (or both) pump is active.  
Pump Status  
Indicator  
1
2
PUMP  
When enabled during the Blowback sequence, the  
BLOWBACK icon displays. The 1 or 2 icon indicates the  
activity of the blowback solenoid.  
Blowback  
Indicator  
1
2
BLOWBACK  
The High Vacuum indicator displays when a high vacuum  
condition is present. The 1 or 2 icon indicates the pump  
that has the high vacuum condition. The Alarm icon  
(Segment 2) and the ON icon (Segment 4) flash at the  
hopper with the high vacuum condition.  
High  
Vacuum  
Indicator  
1
2
HIGH VACUUM  
The Check System indicator displays any system errors.  
Three input for each pump, when active, prompts the  
CHECK SYSTEM icon to display. The 1 or 2 icon  
indicates which pump has the System input(s) active.  
System errors can include Dirty Filter, … are common  
uses for these inputs.  
Check  
System  
Indicator  
1
2
CHECK SYSTEM  
2–Pump 12-Station Controllers  
Chapter 4: Operation  
38  
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Controller Keypad  
Your 12-station controller has a 16-position keypad to let you operate and alter controller  
parameters. With the exception of the SET key, each key has at least two functions. The  
status of the controller determines what function is recognized.  
Figure 4: Controller Keypad  
1
2
3
START  
STOP  
ST 1  
ST 2  
ST 3  
4
5
6
SET  
ST 4  
ST 5  
ST 6  
7
8
9
CLEAR  
PRIOR  
ENTER  
MENU  
ST 7  
ST 8  
ST 9  
NO  
0
YES  
ST 10  
ST 11  
ST 12  
Key Descriptions  
Label  
Description  
Use the ten (10) numeric keys marked 1 to 0 to enter numerical information  
on the controller.  
Number  
Keys  
Press one of the 12 station keys marked ST1 to ST12 to select or activate the  
specific station or hopper you want.  
Station Keys  
Press the START/STOP key once to start the loading sequence. Press the  
START/STOP key again to stop the loading sequence.  
Start/Stop  
Key  
Press the SET key to set hopper loading times. Using the SET key also  
permits you to increment through each of the twelve (12) stations/hoppers  
when setting loading times. Press the SET key to save the updated value of  
the parameter you set, then increments to the next station.  
Set Key  
Press the CLEAR/PRIOR key to initiate the priority convey sequence; this  
key also acts much like an escape key.  
Clear/Prior  
Key  
Press the NO or YES keys to answer questions or prompts while you are  
using the menu system.  
No/Yes  
Keys  
Press the ENTER/MENU key to save any data you entered in the controller  
memory. You can also press the key to let you enter the menu system.  
Enter/Menu  
Key  
2–Pump 12-Station Controllers  
Chapter 4: Operation  
39  
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4-3 Operation  
Your 12 station controller electrically controls valves and solenoids to convey material from a  
central location to individual stations as needed. The controller works within this process by  
sensing a material demand and responds in a timely fashion to that demand.  
An active signal sent from a demand sensor prompts the controller to place the station in a  
demand queue. The controller responds to this condition by loading the stations in a first  
come, first served basis. This is the most efficient manner of conveying material to different-  
sized stations.  
The basic sequence of a normal load operation is:  
1. Sense the demand from a station.  
2. Add that station demand into the queue.  
3. When required, remove the station from the queue.  
4. If required, start the vacuum pump.  
5. Open the sequence valve.  
6. Load the station until the volume sensor activates or load time expires.  
7. Close the sequence valve.  
8. Continue on to load the next station in the queue.  
9. If no demand is present in system after a short delay, then shut down the system  
vacuum pump.  
Operation States  
Label  
Description  
The OFFLINE operation state is the default state at the point when you apply  
power to the controller. While in this state, all outputs in the system are  
deactivated and access to the menu system is permitted. All station demands  
are ignored.  
OFFLINE  
If you press the START/STOP key in the OFFLINE state, the controller  
enters the IDLE (Startup) state. If no demand is on the system, the controller  
immediately enters the READY state. With a valid demand, the IDLE  
(Startup) state allows the pump to get up to speed before starting to load a  
station.  
IDLE (Startup)  
While in the IDLE (Startup) state, all station sequence valves are closed and  
the vent valve is open. The vent valve allows the vacuum pump to vent to  
atmosphere, keeping the system from becoming depressurized.  
2–Pump 12-Station Controllers  
Chapter 4: Operation  
40  
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Label  
Description  
Following the IDLE (Startup) state, the vent valve is closed and the first  
station in demand loads when that station sequence valve opens. This is the  
LOADING state. You can define load times for each station. The controller  
loads the station in demand until one of the two events below occur:  
LOADING  
1. The volume fill sensor becomes active.  
2. The load time is exhausted.  
At the end of the LOADING cycle, the controller closes the sequence valve  
and continues to the next station in the queue. If all stations are satisfied, the  
controller enters the IDLE (No Activity) state.  
The IDLE (No Activity) state acts as an energy saver and pump lifetime  
extender. During this state, the atmospheric valve is open, allowing the  
vacuum to be vented. All sequence valves are closed and all inputs are  
monitored for demand activity. This feature reduces repeated starting and  
stopping of pumps, extending pump operation life.  
IDLE  
(No Activity)  
If the controller senses a demand during the IDLE (No Activity) state, the  
controller re-enters the LOADING state by closing the vent valve and opening  
the sequence valve of the station in demand.  
If no demand exists in the system for the duration of the IDLE (No Activity)  
time setting, the controller then enters the READY state.  
Note: IDLE is any condition in the conveying system when the pump  
runs but no station loads.  
The READY state is a monitoring function. All outputs are off and the  
controller waits for a demand signal to be fulfilled. If the controller senses a  
demand condition, the controller then re-enters the STARTING state and  
returns to load material into the hoppers.  
READY  
When enabled, the controller enters the BLOWBACK state following a user-  
definable number of station loads. The blowback function is to pulse air  
through the filter system to keep the filter from clogging. The number and  
duration of the air pulses is also user-definable; see the Blowback menu on  
Pages 54-58 for more information.  
BLOWBACK  
In Dual Pump mode, if you start the controller with demand from stations  
assigned to both pumps, both pumps start at the same time. In many plants,  
such a resulting power surge can momentarily exceed the electrical limits of  
the plant. To prevent this condition, the pumps are staged in sequence  
separated by a short duration. Pump 1 always starts first, followed by Pump 2.  
LOADING/IDLE  
(2 Pump Mode  
Only)  
This state also applies when both pumps are in the OFFLINE state and  
demand occurs on both systems at the same time.  
2–Pump 12-Station Controllers  
Chapter 4: Operation  
41  
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4-4 Shut-Down  
2–Pump 12-Station Controllers  
Chapter 4: Operation  
42  
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Chapter 5: Maintenance  
Updating BIOS Software  
Occasionally, BIOS software updates are available to enhance the operation of the controller.  
These updates are available through the Service Deptartment or for download from the  
internet. To find out what the current BIOS software version is, call the Service Department  
for details.  
You can update the software with a laptop computer and an RS-232 serial connection through  
the COM1 serial port. As shown in the electrical diagrams and the electrical diagram on the  
following page, connect a serial cable as shown. Follow the installation program instructions  
supplied with the software update. The installation program automatically updates the BIOS.  
2–Pump 12-Station Controllers  
Chapter 5: Maintenance  
43  
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Figure 5: BIOS Connection, Electrical Diagram; Drawing 1  
LINE  
2–Pump 12-Station Controllers  
Chapter 5: Maintenance  
44  
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Figure 6: BIOS Connection, Electrical Diagram; Drawing 2  
+0 VDC  
+24 VDC  
20 I/O CONTROLLER  
AEC P/N: A0560950  
2
4
4
1SOL  
2SOL  
3SOL  
4SOL  
5SOL  
6SOL  
7SOL  
8SOL  
9SOL  
10SOL  
1LS  
2LS  
2
STATION 1 SENSORS  
STATION 2 SENSORS  
STATION 3 SENSORS  
STATION 4 SENSORS  
STATION 5 SENSORS  
STATION 6 SENSORS  
STATION 7 SENSORS  
STATION 8 SENSORS  
STATION 9 SENSORS  
2
2
2
2
2
2
Station 1 sequence valve  
TB2-2L  
TB2-2U  
TB2-3U  
TB2-4U  
TB2-5U  
TB2-6U  
TB2-7U  
TB2-8U  
TB2-9U  
TB2-10U  
TB2-11U  
TB2-14U  
TB2-15U  
N. C.  
N. C.  
N. C.  
N. C.  
N. C.  
N. C.  
4
N. O.  
N. O.  
N. O.  
N. O.  
N. O.  
N. O.  
N. O.  
N. O.  
N. O.  
N. O.  
N. O.  
1PRS  
3PRS  
5PRS  
7PRS  
9PRS  
11PRS  
2
4
4
Station 2 sequence valve  
Station 3 sequence valve  
Station 4 sequence valve  
Station 5 sequence valve  
Station 6 sequence valve  
Station 7 sequence valve  
Station 8 sequence valve  
Station 9 sequence valve  
Station 10 sequence valve  
Station 11 sequence valve  
Station 12 sequence valve  
TB2-3L  
TB2-4L  
TB2-5L  
TB2-6L  
TB2-7L  
TB2-8L  
TB2-9L  
TB2-10L  
TB2-11L  
N. C.  
N. C.  
N. C.  
4
4
4
4
4
N. O.  
2PRS  
4PRS  
3LS  
4LS  
2
N. O.  
2
4
4
N. O.  
5LS  
2
N. O.  
6LS  
2
4
4
N. O.  
7LS  
2
6PRS  
8PRS  
2
2
2
2
2
2
N. O.  
4
4
8LS  
2
4
4
4
4
4
N. C.  
N. O.  
9LS  
2
N. O.  
4
4
4
10LS  
11LS  
12LS  
2
STATION 10 SENSORS  
STATION 11 SENSORS  
STATION 12 SENSORS  
N. C.  
N. O.  
11SOL  
N. O.  
12SOL  
N. O.  
10PRS  
12PRS  
2
TB2-14L  
TB2-15L  
N. O.  
2
N. C.  
N. O.  
4
13SOL  
N. O.  
14SOL  
N. O.  
13LS  
4
4
2
HIGH VACUUM SENSOR 1  
2
2
2
2
2
2
2
2
2
2
2
2
Pump 1 solenoid  
Pump 2 solenoid  
Vent solenoid 1  
Vent solenoid 2  
Blowback solenoid 1  
Blowback solenoid 2  
Audible alarm  
TB2-16L  
TB2-17L  
TB2-18L  
TB2-19L  
TB2-20L  
TB2-21L  
TB2-22L  
TB2-23L  
TB2-12L  
TB2-13L  
TB2-12U  
TB2-13U  
TB2-16U  
TB2-17U  
TB2-18U  
TB2-19U  
TB2-20U  
TB2-21U  
TB2-22U  
TB2-23U  
TB2-1U  
N. O.  
4
4
4
14LS  
2
HIGH VACUUM SENSOR 2  
N. O.  
15SOL  
15LS  
2
MACHINE ALARM SENSOR 1  
4
4
4
4
4
4
4
4
4
4
N. O.  
N. O.  
N. O.  
N. O.  
16SOL  
17SOL  
18SOL  
16LS  
2
MACHINE ALARM SENSOR 2  
MACHINE ALARM SENSOR 3  
MACHINE ALARM SENSOR 4  
SPARE 1  
4
4
4
4
4
N. O.  
17LS  
2
N. O.  
18LS  
2
N. O.  
N. O.  
19SOL  
N. O.  
20SOL  
N. O.  
19LS  
2
N. O.  
20LS  
2
SPARE 2  
Visual alarm  
N. O.  
4
4
4
4
2
2
2
2
TB2-24U  
TB2-1L  
TB2-24L  
LEGEND  
A0560970  
FIELD WIRING  
OPTION/SERVICE WIRING  
NOTE: ALL WIRES ARE #18 AWG  
UNLESS OTHERWISE NOTED  
2–Pump 12-Station Controllers  
Chapter 5: Maintenance  
45  
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Chapter 6: Troubleshooting  
6-1  
Problem  
General Troubleshooting  
Possible cause  
Solution  
The controller panel is not  
plugged in.  
Plug in the controller panel.  
The external disconnect  
The controller panel doesn’t light (recommended) in the dedicated Close the switch (on).  
up at all.  
circuit is open (off).  
Fuse/circuit breaker in the power  
drop is blown/tripped.  
Replace/reset.  
Broken controller power switch.  
Replace.  
Reset the overload and check  
The motor overload has tripped. the motor for the proper amp  
draw on tag.  
Main fuse in power drop or  
A pump package doesn’t run,  
even though it is on line and its  
indicator is lit.  
optional fused disconnect has  
blown.  
Replace the fuse.  
Motor contact is faulty.  
Repair or replace as required.  
Normal operation. When the  
level drops, material conveys to  
the hopper.  
The bin below it is full if its  
amber indicator light is off.  
Using the controller, place the  
hopper on line.  
The hopper is off line.  
A vacuum hopper is being  
bypassed in the loading cycle.  
The convey time for the hopper  
is set to zero.  
Using the controller, enter a  
reasonable convey time.  
The field-installed station bypass Normal operation. Set the switch  
switch is simulating a Bin Full  
condition.  
so the hopper is back in the  
loading sequence.  
The field-installed station bypass  
switch is bad or mis-wired.  
Repair, replace, or rewire.  
Time the hopper(s) during  
loading, and set conveying times  
to a few seconds less.  
Conveying times are too long  
(Time Fill mode only).  
Check proximity sensors for  
proper operation and proper  
wiring to the PCB. Repair as  
needed. Reset the conveying  
times to a reasonable value, and  
adjust as needed.  
Vacuum hoppers are over-filling.  
Maximum conveying times are  
too long and the PCB does not  
recognize the Hopper Full  
proximity switch(es).  
2–Pump 12-Station Controllers  
Chapter 6: Troubleshooting  
46  
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Problem  
Possible cause  
Defective wiring.  
Solution  
Correct/replace wiring.  
Replace defective terminal  
block.  
Replace defective PCB.  
Replace defective solenoid.  
Output icon comes on,  
solenoid doesn’t.  
Defective terminal block.  
Defective PCB.  
Defective solenoid.  
Power supply shorting out.  
Repair shorting circuit.  
Verify proper solenoid use. Call  
Engineering for assistance.  
Replace fuse with one that has a  
proper rating.  
Eliminate source of static.  
Ground the controller properly.  
Cold-boot the controller. Restore  
the controller to factory defaults;  
see Section 8-5 on Page 75 for  
more information.  
Excessive loading on solenoids.  
Improper fuse installed.  
Excessive static.  
Controller blows fuses.  
Erratic operation.  
Corrupt RAM data.  
Ground the controller properly.  
Replace PCB.  
I/O logic failing.  
False input signal.  
No Convey alarm does not light. False input signal.  
Increase input delay time.  
Increase input delay time.  
2–Pump 12-Station Controllers  
Chapter 6: Troubleshooting  
47  
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Controller Recovery using Flash Memory Technology  
It is possible for a write error to occur while information is being saved in the controller’s  
memory. If this occurs, the system always saves a backup of the data.  
To recover from a write failure:  
Shut off the controller, wait 15 seconds, then restart the controller.  
The boot sequence detects the write error and attempts to restore the  
backup file.  
It is also possible, although rare, that the backup and original file could both become corrupt.  
If this occurs, then reset the controller to factory default parameters before proceeding.  
However, all parameters you’ve previously stored are lost and you’ll need to set up the  
controller from the beginning. You should record what settings you use in the controller  
system if this occurs.  
The following screens display while the controller writes to flash memory. Again, do not  
cycle power while these two screens display.  
WRITING PARAMETERS  
TO FLASH-PLEASE WAIT  
SAVING BACKUP  
TO FLASH-PLEASE WAIT  
Note: The controller needs about 30 seconds for saving to flash  
memory. If the controller doesn’t clear this display within 60  
seconds, you may need to cycle power. This rare type of problem  
is caused by a write failure not detected by the controller. This  
rare condition usually requires a complete factory default reset  
for full recovery.  
2–Pump 12-Station Controllers  
Chapter 6: Troubleshooting  
48  
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Chapter 7: Appendix  
7-1 Warranty  
Unless otherwise specified, this product includes a Standard ONE YEAR PARTS AND  
LABOR WARRANTY.  
Warranty Specifications  
The manufacturer hereby expressly warrants all equipment manufactured by it to be free from  
defects in workmanship and material when used under recommended conditions, as set forth  
in the operating manuals for such equipment. THE FOREGOING EXPRESS WARRANTY  
IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, GUARANTIEES,  
AGREEMENTS, AND SIMILAR OBLIGATIONS OF THE COMPANY AND/OR  
MANUFACTURER (UNLESS OTHERWISE SPECIFIED IN THE SPECIFIC PRICE  
PAGE OR LIMITED BY THE MANUFACTURERS’ WARRANTY FOR PARTS). The  
Company’s obligation is limited to repair or replace FOB the factory any parts that are  
returned, prepaid, within one year of equipment shipment to the original purchaser, and  
which in the Company’s opinion, are defective. Any replacement part assumes the unused  
portion of this warranty.  
Warranty Restrictions  
This parts warranty does not cover any labor charges for replacement of parts, adjustment  
repairs, or any other work. This warranty does not apply to any equipment which, in the  
Company’s opinion, has been subjected to misuse, negligence, or operation in excess of  
recommended limits, including freezing or which has been repaired or altered without the  
Company’s express authorization. If the serial number has been defaced or removed from the  
component, the warranty on that component is void. Defective parts become the property of  
the warrantor and are to be returned immediately, without any further use or handling.  
2–Pump 12-Station Controllers  
Chapter 7: Appendix  
49  
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Warranty Liabilities  
THE COMPANY EXPRESSLY DISCLAIMS ANY AND ALL LIABILITY FOR ANY  
SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES OR EXPENSES THAT  
RESULT FROM THE USE OF THIS PRODUCT. Some states do not allow the exclusion or  
limitation of special, consequential or incidental damages, so the above limitation may not  
apply to you. The Company’s obligation for parts not furnished as components of its  
manufactured equipment is limited to the warranty of the manufacturers of said parts. The  
company neither assumes nor authorizes any other persons to assume for it any liability in  
connection with the sale of its equipment not expressed in this warranty. No person, agent,  
manufacturer, distributor, dealer, installer or company is authorized to change, modify or  
extend the terms of this warranty in any manner whatsoever.  
The time within which an action must be commenced to enforce any obligation of the  
Company’s arising under this warranty, or under any statute or law of the United States or  
any state thereof, is hereby limited to the duration of this warranty. Some states do not permit  
this limitation, so the above may not apply to you. This warranty gives you specific legal  
rights and you may also have other rights which vary from state to state. For transactions  
involving the potential applicability of international law or that of a foreign country,  
this warranty policy and the procedures hereunder shall be governed by  
applicable federal and state law, but not by the United Nations Convention on Contracts for  
the Sale of Goods.  
Customer Responsibilities  
Any sales, use, or other tax incident to the replacement of parts under this warranty is the  
responsibility of the purchaser.  
2–Pump 12-Station Controllers  
Chapter 7: Appendix  
50  
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7-2 Drawings and Diagrams  
Figure 7: 2 pump 12 station Controller Control Panel  
SECTION 1 SECTION 2  
SECTION 3 SECTION 4  
Depth dimension of subpanel: 8.0” D (20.3 cm).  
Also, review electrical drawings supplied in the packet with this manual.  
2–Pump 12-Station Controllers  
Chapter 7: Appendix  
51  
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7-3 Spare Parts List  
Figure 8: Typical 12-Station Controller Exterior Components, Exploded View  
8
7
13  
6
5
12  
10  
4
places  
11  
10  
15  
14  
2
4
2
4
places  
places  
5
4
3
2
9
1
1
4
places  
16  
A0560974  
Power cord  
A0560954  
2–Pump 12-Station Controllers  
Chapter 7: Appendix  
52  
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Figure 9: Exterior Components Parts List  
Refer to Figure 8 on Page 51 when identifying parts.  
Item Qty. Part no.  
Description  
ENCL, CARLON, MOUNT FLNG, MNK10L  
ENCL, CARLON, 12 X 10 BODY, NP1210B  
SW, PWR, SHAFNR W/FLTR & FUSE  
1.  
2.  
1
1
1
2
1
1
1
1
2
4
1
1
1
A0560963  
A0560964  
A0560955  
3.  
4.  
W00015317 SCR, RHM, 4-40 X 5/8  
5.  
6.  
7.  
8.  
A0560962  
A0560965  
A0803341  
A0560501  
ENCL, CARLON, COLLAR, NH1210C  
ENCL, CARLON, 12 X 10 LID, NH1210L  
KYP, LONG TACTILE  
GRPH, 12 STATION, VAC-TRAC  
9.  
W00000960 NUT, HEX HD, PLT, 4-40  
10.  
11.  
12.  
13.  
A0560968  
A0559156  
A0560969  
A0560967  
NUT, HEX HD, PLT, 2-56  
DSPLY, LCD, CRYSTALOID, CRUSM1056  
SPCR, NYLON, 0.091 ID, 0.185 OD, 1/8”  
SCR, PAN HD, SLTD, PLT, 2-56 X 3/4”  
2–Pump 12-Station Controllers  
Chapter 7: Appendix  
53  
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Figure 10: Typical 12-Station Controller Interior Components, Exploded View  
13  
11  
12  
10  
9
11  
8
7
6
5
4
3
2
1
A0560974  
2–Pump 12-Station Controllers  
Chapter 7: Appendix  
54  
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Figure 11: Interior Components Parts List  
Refer to Figure 10 on Page 53 when identifying parts.  
Item Qty. Part no. Description  
1.  
2.  
3.  
4.  
5.  
6.  
7.  
8.  
9.  
10.  
11.  
12.  
13.  
4
1
4
1
4
1
1
1
2
1
5
1
1
W00001055 WASH, #6 SAE FLAT, PLD  
A0560961  
A0530780  
A0560958  
A0101507  
A0539383  
A0560956  
A0539387  
PNL, SUB, CARLON, JP1210, 10 X 8  
STND, OFF (M/F) #6-32 X 0.5” LG. HE  
PCB, DNTL, 201/O, 128 K RAM/ROM  
SCR, RHM, PLD, 6-32 X 1/4  
RECT, BRIDGE, 25 AMPS, GBPC2510  
ELEK, RES, 50 OHM, 50 WATT, CLEROSTAT  
XFMR, 16 VCT, 112 VA, MCI 4-07-8016  
W00015057 SCR, PAN HD, SLTD, PLT, 4-40 X  
A0069176  
A0102356  
A0539389  
A0539382  
SCR, RHM, PLD, 10-32 X 3/4  
SCR, RHM, PLD, 8 X 32 X 3/8  
CAP, BRKT, MT, VRIO, MALLORY  
CAP, ELEC, 22000UFD, 30 VDC, ALUCAN  
2–Pump 12-Station Controllers  
Chapter 7: Appendix  
55  
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7-4 Controller Identification (Serial Number) Tag  
(Located on the side of the controller box)  
Street Address  
Town, State, Zip Code  
Telephone Number  
Fax Number  
XXX CONTROL PANEL  
Model No. XXX2-12  
Serial No. 31K0182  
Ph  
230 Volt  
60 Hz  
1
Control Voltage 24VDC  
7-5 Technical Assistance (Contact Information)  
Parts Department  
[
]
[
]
Call toll-free 7am–5pm CST 800 423-3183 or call 630 595-1060, Fax [630] 475-7005  
The ACS Customer Service Group will provide your company with genuine OEM quality parts  
manufactured to engineering design specifications, which will maximize your equipment’s performance  
and efficiency. To assist in expediting your phone or fax order, please have the model and serial  
number of your unit when you contact us. A customer replacement parts list is included in this manual  
for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to providing  
excellent customer service.  
Service Department  
[
]
[
]
Call toll-free 8am–5pm CST 800 233-4819 or call 630 595-1060  
[
]
Emergencies after 5pm CST, call 847 439-5655  
We have a qualified service department ready to help. Service contracts are available for most  
products.  
Sales Department  
[
]
Call 630 595-1060 Monday–Friday, 8am–5pm CST  
Our products are sold by a world-wide network of independent sales representatives. Contact our Sales  
Department for the name of the sales representative nearest you.  
Contract Department  
[
]
Call 630 595-1060 Monday–Friday, 8am–5pm CST  
Let us install your system. The Contract Department offers any or all of these services: project planning;  
system packages including drawings; equipment, labor, and construction materials; and union or non-  
union installations.  
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Chapter 8: Service Only Information  
Note: Hidden, programmable features and hidden menu pages should not be  
made available to floor operators. These pages include the Service  
Information located in this section. Unauthorized changes to these  
factory settings by inexperienced operators may prevent the controller  
from operating properly, and may void part or all of the warranty.  
Note: If this manual is to be used on the floor by the operator, keep this  
section separate from the rest.  
8-1 Service Settings Menu  
Setting the Ramp Up Time  
Ramp up time is a delay that allows the pump to establish full speed before the valve opens.  
This delay defaults to 1.5 seconds and should not be altered unless instructed to do so by  
the Service Department.  
SET RAMP UP TIME?  
NO/YES  
At the above message prompt:  
Press the YES key to enter the Ramp Up Time menu.  
SELECT PUMP 1 OR 2  
USE KEYPAD TO ENTER  
Select the pump for altering ramp up time.  
RAMP UP DLY: 1.500s  
SETTING FOR PUMP n  
Using the keypad:  
Enter the new time and press the ENTER key to save the new setting.  
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Setting the Ramp Down Time  
Ramp down time is a delay that allows the pump to come to a full stop when needed. The  
control cannot restart until this delay is completed. This is also known as the Shutdown delay.  
This delay defaults to 8.0 seconds and should not be altered unless instructed to do so by  
the Service Department.  
SET RAMP DOWN TIME?  
NO/YES  
At the above message prompt:  
1. Press the YES key to enter the Ramp Down Time menu.  
2. Select the pump for altering ramp down time.  
SELECT PUMP 1 OR 2  
USE KEYPAD TO ENTER  
The following screen displays.  
RAMP DN DLY: 8.000s  
SETTING FOR PUMP n  
Using the keypad:  
3. Enter the new time and press the ENTER key to save the new setting.  
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Setting the Pump Stage Time  
Pump stage time is a delay that prevents both pumps from engaging at the same time.  
Although rare in a two-pump system, both pumps can sometimes start at the same time. This  
condition causes an excess of current on the electrical system from such a surge.  
The pump stage time delay defaults to 3.0 seconds and should not be altered unless you are  
instructed to do so by the Service Dept.  
SET PUMP STAGE TIME?  
NO/YES  
At the above message prompt:  
1. Press the YES key to enter the Pump Stage Time menu.  
STAGE DELAY: 3.000s  
PRESS ENTER TO SAVE  
Using the keypad:  
2. Enter the new time and press the ENTER key to save the new setting.  
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Setting the LCD Blink Delay  
LCD Blink Delay lets you alter the ON/OFF time that the LCD blinks during an alarm. This  
delay does not effect the Visual or Audible alarm outputs. The delay defaults to 0.5 seconds  
and should not be altered unless you are instructed to do so by the Service Department.  
SET LCD BLINK DELAY?  
NO/YES  
At the above message prompt:  
1. Press the YES key to enter the LCD Blink Delay menu.  
BLINK DELAY: .500s  
PRESS ENTER TO SAVE  
Using the keypad:  
2. Enter the new time and press the ENTER key to save the new settings.  
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Setting the Hi Vacuum Sensor Delay  
Hi vac sensor delay is the time that a high vacuum condition must exist before it is sensed by  
the controller. This delay eliminates the annoying Hi Vacuum errors which self-clear or are  
erroneous. This delay defaults to 3.0 seconds and should not be altered unless you are  
instructed to do so by the Service Department.  
HI VAC SENSOR DELAY?  
NO/YES  
At the above message prompt:  
1. Press the YES key to enter the Hi Vacuum Sensor Delay Time menu.  
SELECT PUMP 1 OR 2  
USE KEYPAD TO ENTER  
At the above message prompt:  
2. Select the pump for altering vacuum sensor delay.  
The following screen displays:  
HIVAC DELAY: 3.000s  
SETTING FOR PUMP n  
Using the keypad:  
3. Enter the new time and press the ENTER key to save the new setting.  
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Setting the Hi Vacuum Vent Delay  
Hi vacuum vent delay is the vent time initiated by a high vacuum condition. This delay  
defaults to 10.0 seconds and should not be altered unless you are instructed to do so by the  
Service Department.  
HI VAC VENT DELAY?  
NO/YES  
At the above message prompt:  
1. Press the YES key to enter the Hi Vacuum Vent Delay Time menu.  
SELECT PUMP 1 OR 2  
USE KEYPAD TO ENTER  
At the above screen prompt:  
2. Select the pump for altering vacuum vent delay.  
The following screen displays.  
HV VENT DLY: 10.000s  
SETTING FOR PUMP n  
Using the keypad:  
3. Enter the new time and press the ENTER key to save the new setting.  
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Setting the Hi Vacuum Load Count  
Hi vacuum load count sets the maximum number of loads on a station in a high vacuum  
condition. If a station repeatedly experiences a high vacuum condition for the selected  
number of loads without being cleared or attended to, it goes off line to prevent damage to  
the conveying system. This parameter defaults to 7 loads and should not be altered unless  
you are instructed to do so by the Service Department.  
HI VAC LOAD COUNT?  
NO/YES  
At the above message prompt:  
1. Press the YES key to enter the Hi Vacuum Load Count menu.  
SELECT PUMP 1 OR 2  
USE KEYPAD TO ENTER  
At the above screen prompt:  
2. Select the pump for altering the high vacuum load count.  
The following screen displays.  
HV LOAD CNT: 7  
SETTING FOR PUMP n  
Using the keypad:  
3. Enter the new time and press the ENTER key to save the new setting.  
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Using the Installation Aids Menus  
Input Monitor Screen  
To assist in the installation process or to aid in problem diagnoses, the controller uses two (2)  
OEM menu functions. The Input Monitor screen displays all 20 inputs in real time. 0  
represents no input and 1 indicates an active input.  
INPUT MONITOR?  
NO/YES  
At the above message prompt:  
1. Press the YES key to enter the Input Monitor menu.  
You now have access to the OEM menu system and Input Monitor menu.  
The following screen displays:  
IN BNK0: 0000000000  
IN BNK1: 0000000000  
The top row (Bank 0 [IN BNK0]) shows the input status of the first ten (10) inputs. The  
bottom row shows the status of inputs 11-20 (Bank 1 [IN BNK0]).  
To exit this menu:  
2. Press the CLEAR key.  
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Output Control Menu  
The Output Control menu gives you direct access to all 20 outputs of the controller. The  
menu has two (2) modes: Manual and Automatic. Automatic mode cycles each output on and  
off. Manual mode gives you access to each individual output.  
OUTPUT CONTROL?  
NO/YES  
At the above message prompt:  
1. Press the YES key to enter the Output Control menu.  
The following screen displays.  
AUTOMATIC OR MANUAL?  
N=AUTO Y=MANUAL  
To start the automatic cycle:  
Press the NO key.  
To increase speed:  
Press the START/STOP key.  
To decrease speed:  
Press the SET key.  
To exit the Output Control menu and turn all outputs OFF:  
2. Press the CLEAR key.  
Caution!  
Automatically cycling outputs with the pump in Active mode can damage  
the conveying system.  
Caution!  
Do not perform this action unless directed to do so by the Service  
Department.  
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To access the outputs manually, at the AUTOMATIC OR MANUAL? screen prompt:  
1. Press the YES key.  
The following screen displays.  
OUTBNK0: 0000000000  
OUTBNK1: 0000000000  
A cursor displays on the screen.  
To move the cursor left:  
Press the 4 key.  
To move the cursor right:  
Press the 6 key.  
To move the cursor up:  
Press the 2 key.  
To move the cursor down:  
Press the 8 key.  
To toggle output ON or OFF:  
Press the START/STOP key.  
To exit this menu:  
2. Press the CLEAR key.  
Caution!  
Enabling the Pump output without opening any sequence valves can cause  
damage to the conveying system.  
Caution!  
Do not perform this action unless directed to do so by the Service  
Department.  
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8-2 Other Controller Restricted Areas  
Using the OEM Service Menu  
The OEM service menu (Original Equipment Manufacturer) lets you set parameters not  
commonly used. It also contains functions to aid in the installation of the controller. Access  
to this menu should be restricted to setup and maintenance personnel only.  
To gain access to the OEM service menu:  
1. Remove power from the controller.  
2. Press and hold the Zero 0 key and re-apply power. While holding the Zero 0 key,  
allow the controller to initialize.  
The controller displays the message below and permits access to the OEM service  
menu.  
OEM MENU ACCESS  
IS NOW AVAILABLE!  
Gain access to the OEM service menu by entering the menu system. An additional menu  
screen is shown below.  
OEM SETTINGS?  
NO/YES  
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Recovering Passwords  
By following this procedure, passwords can be displayed should they be lost or forgotten.  
Note: In the interest of system security and integrity, make sure that  
only setup people and supervisors know this procedure.  
Follow these steps to recover passwords.  
1. Remove power from the controller.  
2. Press and hold the 3 key.  
3. Reapply power as you continue to hold down the 3 key.  
4. The screen displays up to four (4) password settings during controller initialization.  
Note the sample screen below.  
5. Press the CLEAR key to contine with initialization.  
PWL1:1111 PWL2:2222  
PWL3:3333 PWL4:4444  
Note: Passwords shown on this screen are illustration only.  
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Restoring the Controller to Factory Defaults  
Although rare, you may experience a condition when you need to perform a total reset of the  
controller. To do so, perform the following procedure.  
Note: All parameters you set are lost when doing this procedure,  
including passwords and OEM Service settings.  
Follow these steps to restore the controller to factory defaults.  
1. Remove power from the controller.  
2. Press and hold the CLEAR key.  
3. Re-apply power while holding down the CLEAR key.  
During initialization, the screen displays a message indicating that factory default  
settings are set.  
Verifying Software Checksums  
Follow these steps to verify software checksum values.  
1. Remove power from the controller.  
2. Press and hold the SET key.  
3. Re-apply power while holding down the SET key.  
During initialization, the screen displays a message while the controller calculates the  
software check sum. This number is in hexadecimal format (Base 16) and displays in  
numbers and letters.  
Example: 0x1FC9 is a valid checksum format.  
ROM CHECKSUM: 0x0000  
PRESS YES TO RESUME  
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