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2-Pump 18-Station Controllers
Part Number: 882.00217.00
Bulletin Number: CV3-625
Effective: 10/1/05
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 describe
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Please note that our address and phone information has changed. Please reference this page for updated contact information. These manuals are obsolete and are provided only for their technical information, data and capacities. Portions of these manuals detailing procedures or precautions in the operation, inspection, maintenance and repair of the products may be inadequate, inaccurate, and/or incomplete and shouldn’t be relied upon. Please contact the ACS Group for more current information
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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
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Table of Contents CHAPTER 1: SAFETY ................................................................V 1-1 How to Use This Manual ............................................................................................. v Safety Symbols Used in this Manual..................................................................... v 1-2 Warnings and Precautions ......................................................................................... vi 1-3 Responsibility.....................
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Reviewing Station Status ....................................................................................23 Reviewing Pump Status ......................................................................................25 Logging On and Logging Off ...............................................................................26 Enabling and Disabling Stations and Pumps.......................................................26 Starting and Stopping the System.................................
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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 featu
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1-2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes. This may include, but is not limited to OSHA, NEC, CSA, SPI, and any other local, national and international regulations. To avoid possible personal injury or equipment damage when installing, operating, or maintaining this equipment, use good judgment and follow these safe practices: Read and f
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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
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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 ma
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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, 18- 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, 18-Station Conveying Controller is a programmable logic controller, with 24 VDC control circuit, easy-to-use touchscreen oper
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2-3 Standard Features Mechanical Features Time-fill Capability. The length of time allowed for material to drain from the station to its receiver. During this time, the controller does not attempt to deliver any more material to the station. Volume-fill Capability. The length of time a station’s vacuum valve remains open to allow material to be drawn in. The vacuum valve will close when material covers the station’s volume-fill proximity sensor or this time elapses, whichever comes fi
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2-4 Optional Features Options marked with “*” indicate options that can be factory installed or retrofitted in the field. 230/1/50 Operation. Required to operate with a 230/1/50 supply voltage. Audible/visual alarm. Alarm light and horn assembly that can be remote mounted and wired into the controller to indicate an alarm condition. Ethernet Capability. Enables controller to be connect to an ethernet network. Line Filter/Surge Suppressor. Recommended for additional protection of elect
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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, 18-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 18-
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Chapter 3: Installation 3-1 Uncrating 2-Pump, 18-Station Controllers are shipped mounted on a skid, enclosed in a plastic wrapper, and contained in a cardboard box. 1. Pry the crating away from the skid. Note: Remove the nails holding the box to the skid and lift the box off carefully; avoiding staples in the 1’ x 4’ wood supports. Cut the steel banding. 2. Use a pry bar to remove the blocks securing the unit to the skid. 3. Lift unit from sides, inserting forklift under the base. Th
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Connecting the Control Panel to Vacuum Hoppers 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. 2. 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
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Setting the Number of Stations and the Number of Pumps Figure 1: Default “Station Status” Screen Before Setup 1. At the “Station Status” screen (Figure 1), touch the MENU button. The “Main Menu” screen opens. 2. Once in the Main Menu Screen, press the SYSTEM SETUP button. The “System Setup” screen opens. Figure 2: “System Setup” Screen 3. At the “System Setup” screen, (Figure 2), touch STATIONS ACTIVE, or PUMPS ACTIVE. A keypad pops up (Shown below) once that particular button is
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Setting Up Alarm Silences When an alarm occurs, a horn sounds and a strobe light flashes at each installed central alarm. An alarm banner appears in the center of the screen. An alarm message and Silence button are on the banner. Touching this button silences the horn and turns off the lights for configurable periods of time and causes the alarm banner to disappear. You can set different lengths of time for keeping the horn silent and keeping the light turned off. If a new alarm occurs
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Setting Up Stations Before starting the system, you must define several settings for each station, such as which pump conveys material to it. This section first discusses how to use the controller’s menu system to configure stations. The table on pages 35–36 discusses the individual choices. To set up each station, perform the following: 1. Go to the “Station Status” screen if needed. To reach this screen press station status button on the Main Menu. Figure 4: “Station Status” Screen
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3. On the “Station Operator” screen (Figure 5), touch the SETUP button. The “Station Setup” screen opens. Figure 6: “Station Setup” Screen On the “Station Setup” screen (Figure 6), adjust settings as required. Touching any white box in the lower half of the screen provides you with a keypad to set new values (See page 15 for keypad entry instructions). From this screen, the operator can also configure the convey settings for each station by pressing NEXT or PREV (The screen above sh
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Setting Up Pumps Before starting the system, you must define several settings for each pump, such as how quickly to shut it down when it is not in use. This section first discusses how to use the controller’s menu system to configure pumps. The table on page 37 discusses the individual choices. In order to setup up the pumps properly, perform the following: 1. Go to the “Pump Status“ screen if needed. To reach this screen, touch the PUMP STATUS button on the Main Menu. The “Pump Status” s
