SCC 1-Pump 9-Station Controller
Part Number: 882.00247.00
Bulletin Number: CV3-615
Effective: 10/27/05
Write Down Your Serial Numbers Here For Future Reference:
_________________________
_________________________
_________________________
_________________________
_________________________
_________________________
We are committed to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change without notice.
DCN No. ____________
© Copyright 2004
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 (414) 354-0970; for all other countries, call
our international desk at (414) 354-0970. Have the order number and item number available.
Hold the items until you receive shipping instructions.
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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
RMA 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 returned 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
RMA 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, and it was
manufactured by our company, purchased components are covered under their specific
warranty terms.
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Table of Contents
CHAPTER 1: SAFETY ...............................................................VI
1-1
How to Use This Manual ............................................................................................ vi
Safety Symbols Used in this Manual.................................................................... vi
Warnings and Precautions ........................................................................................viii
Responsibility ............................................................................................................. ix
General Responsibility.......................................................................................... ix
Operator Responsibility.........................................................................................x
Maintenance Responsibility...................................................................................x
Reporting a Safety Defect .....................................................................................x
1-2
1-3
CHAPTER 2: FUNCTIONAL DESCRIPTION............................11
2-1
2-2
2-3
Models Covered in This Manual................................................................................11
General Description...................................................................................................11
Standard Features.....................................................................................................12
Mechanical Features...........................................................................................12
Electrical Features...............................................................................................12
Controller Features..............................................................................................12
Optional Features......................................................................................................13
Safety Devices and Interlocks...................................................................................13
Safety Circuit Standards......................................................................................13
Fail Safe Operation .............................................................................................13
Safety Device Lock-Outs.....................................................................................14
2-4
2-5
CHAPTER 3: INSTALLATION ..................................................15
3-1
3-2
3-3
Uncrating...................................................................................................................15
Mounting the Control Panel.......................................................................................15
Electrical Connections...............................................................................................15
Making Control Panel Power Drop Wiring Connections......................................15
Connecting the Control Panel to Vacuum Hoppers.............................................16
Connecting the Control Panel to the Pump Package ..........................................16
3-4 Setup ...........................................................................................................................17
Basic Menus and Setup of Controller..................................................................17
Station Setup.......................................................................................................19
Entering Values Into Controller Fields.................................................................20
Pump Setup.........................................................................................................23
System Setup......................................................................................................26
CHAPTER 4: OPERATION .......................................................28
4-1
4-2
4-3
Overview ...................................................................................................................28
Starting and Stopping the System.............................................................................28
Alarms .......................................................................................................................28
CHAPTER 5: MAINTENANCE..................................................30
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CHAPTER 6: CONFIGURABLE SETTINGS.............................31
6-1
6-2
Options for Station Setup ..........................................................................................31
Options for Pump Setup............................................................................................32
CHAPTER 7: TROUBLESHOOTING........................................33
7-1
7-2
General Troubleshooting...........................................................................................33
Alarms .......................................................................................................................34
Station Alarms.....................................................................................................34
Pump Alarms.......................................................................................................34
CHAPTER 8: APPENDIX ..........................................................35
8-1
Warranty....................................................................................................................35
Warranty Specifications.......................................................................................35
Warranty Restrictions..........................................................................................35
Warranty Liabilities..............................................................................................36
Customer Responsibilities...................................................................................36
Optional Components................................................................................................36
Drawings and Diagrams............................................................................................37
Spare Parts List.........................................................................................................37
Controller Identification (Serial Number) Tag............................................................38
Technical Assistance (Contact Information)..............................................................38
Parts Department ................................................................................................38
Service Department.............................................................................................38
Sales Department................................................................................................38
Contract Department...........................................................................................38
8-2
8-3
8-4
8-5
8-6
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Chapter 1: Safety
1-1 How to Use This Manual
Use this manual as a guide and reference for installing, operating, and maintaining your
equipment. The purpose is to assist you in applying efficient, proven techniques that enhance
equipment productivity.
This manual covers only light corrective maintenance. No other maintenance should be
undertaken without first contacting a service engineer.
The Functional Description section outlines models covered, standard features, and optional
features. Additional sections within the manual provide instructions for installation, pre-
operational procedures, operation, preventive maintenance, and corrective maintenance.
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup
of the equipment. We can also provide the assistance of a factory-trained technician to help
train your operator(s) for a nominal charge. This section includes instructions, checks, and
adjustments that should be followed before commencing with operation of the equipment.
These instructions are intended to supplement standard shop procedures performed at shift,
daily, and weekly intervals.
The Operation chapter includes a description of electrical and mechanical controls, in
addition to information for operating the equipment safely and efficiently.
The Maintenance chapter is intended to serve as a source of detailed assembly and
disassembly instructions for those areas of the equipment requiring service. Preventive
maintenance sections are included to ensure that your equipment provides excellent, long
service.
The Troubleshooting chapter serves as a guide for identification of most common problems.
Potential problems are listed, along with possible causes and related solutions.
The Appendix contains technical specifications, drawings, schematics, and parts lists. A
spare parts list with part numbers specific to your machine is provided with your shipping
paperwork package. Refer to this section for a listing of spare parts for purchase. Have your
serial number and model number ready when ordering.
Safety Symbols Used in this Manual
The following safety alert symbols are used to alert you to potential personal injury hazards.
Obey all safety messages that follow these symbols to avoid possible injury or death.
Danger!
Warning!
Caution!
DANGER indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation or practice which,
if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation or practice which, if
not avoided, may result in minor or moderate injury or in property
damage.
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Controller Safety Tags
Tag Description
Tag
Description
Read Operation &
Installation Manual
High Voltage Inside
Enclosure
Protected Earth
Ground
Earth Ground
PE
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1-2 Warnings and Precautions
Our equipment is designed to provide safe and reliable operation when installed and operated
within design specifications, following national and local safety codes. This may include, but
is not limited to OSHA, NEC, CSA, SPI, and any other local, national and international
regulations.
To avoid possible personal injury or equipment damage when installing, operating, or
maintaining this equipment, use good judgment and follow these safe practices:
; Read and follow these operation and installation instructions when installing,
operating, and maintaining this equipment. If these instructions become
damaged or unreadable, additional copies are available from the manufacturer.
; Follow all SAFETY CODES.
; Wear SAFETY GLASSES and WORK GLOVES.
; Work only with approved tools and devices.
; Disconnect and/or lock out power before servicing or maintaining the equipment.
; Use care when LOADING, UNLOADING, RIGGING, or MOVING this
equipment.
; Operate this equipment within design specifications.
; OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.
You should remove the fuses and carry them with you.
; Make sure the equipment and components are properly GROUNDED before you
switch on power.
; Use EXTEREME CAUTION when working with conveying system. HIGH
VACUUM can be dangerous. Keep body parts, tools, clothing, and debris away
from vacuum inlets.
; When welding or brazing in or around this equipment, make sure VENTILATION is
ADEQUATE. PROTECT adjacent materials from flame or sparks by shielding with
sheet metal. An approved FIRE EXTINGUISHER should be close at hand and
ready for use if needed.
; Do not restore power until you remove all tools, test equipment, etc., and the
equipment and related components are fully reassembled.
; Only PROPERLY TRAINED personnel familiar with the information in this
manual should work on this equipment.
We have long recognized the importance of safety and have designed and manufactured our
equipment with operator safety as a prime consideration. We expect you, as a user, to abide
by the foregoing recommendations in order to make operator safety a reality.
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1-3 Responsibility
These machines are constructed for maximum operator safety when used under standard
operating conditions and when recommended instructions are followed in the maintenance
and operation of the machine.
All personnel engaged in the use of the machine should become familiar with its operation as
described in this manual.
Proper operation of the machine promotes safety for the operator and all workers in its
vicinity.
Each individual must take responsibility for observing the prescribed safety rules as outlined.
All warning and danger signs must be observed and obeyed. All actual or potential danger
areas must be reported to your immediate supervisor.
General Responsibility
No mater who you are, safety is important. Owners, operators and maintenance personnel
must realize that every day, safety is a vital part of their jobs.
If your main concern is loss of productivity, remember that production is always affected in a
negative way following an accident. The following are some of the ways that accidents can
affect your production:
• Loss of a skilled operator (temporarily or permanently)
• Breakdown of shop morale
• Costly damage to equipment
• Downtime
An effective safety program is responsible and economically sound.
Organize a safety committee or group, and hold regular meetings. Promote this group from
the management level. Through this group, the safety program can be continually reviewed,
maintained, and improved. Keep minutes or a record of the meetings.
Hold daily equipment inspections in addition to regular maintenance checks. You will keep
your equipment safe for production and exhibit your commitment to safety.
Please read and use this manual as a guide to equipment safety. This manual contains safety
warnings throughout, specific to each function and point of operation.
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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 and remove
your tools, rigging, and handling equipment.
Reporting a Safety Defect
If you believe that your equipment has a defect that could cause injury, you should
immediately discontinue its use and inform the manufacturer.
The principle factors that can result in injury are failure to follow proper operating procedures
(i.e. lockout/tagout), or failure to maintain a clean and safe working environment.
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Chapter 2: Functional Description
2-1 Models Covered in This Manual
This manual provides operation, installation, and maintenance instructions for 1-Pump, 9-
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 1-Pump, 9-Station Conveying Controller is a programmable logic controller, with 24
VDC control circuit, easy-to-use operator interface terminal and optional audible/visual
alarm.
2-2 General Description
Our material conveying systems create vacuum for the automatic conveying of most free-
flowing, dry, pelletized, or granular materials. Material characteristics determine the type of
equipment needed to convey the material.
A typical use for our equipment is an in-plant distribution system for plastic processing
plants.
Our central vacuum systems are as varied as the applications they service. The tubing and
equipment furnished in our system is designed to convey the material(s) specified at the time
of purchase at specific rates and distances.
We can advise you on your system capabilities based on system makeup, distance, material,
and conveying rates you want.
System capacity is directly affected by the pressure drop in the overall system, such as
number of material line bends, pipe length, Y-tubes, T-tubes, etc.
Use the minimum effective amount of vinyl flex hose to maximize material line efficiency.
Keep material lines as straight as possible. Refer to Vacuum Pump Product manual (Part No.
A0571050) for installation recommendations.
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2-3 Standard Features
Mechanical Features
Time-fill Capability. A station’s vacuum valve remains open for a specific period of time to
allow material to be drawn in.
Volume-fill Capability. The vacuum valve will close when material covers the station’s
volume-fill proximity sensor or a specific period of time elapses, whichever comes first.
Vent Valve. The vent valve extends vacuum pump life by allowing the pump to run
unloaded (not drawing a vacuum on a station) for a specified period of time before it shuts
off. The alternative, without the vent valve would be to constantly turn the pump on and off
whenever a convey cycle is initiated.
Closed-Loop Conveying (Dry or Ambient Air). This feature allows material to be
conveyed and processed without being contaminated by outside influences (such as moisture,
other materials, etc.).
Common Purge Valve Output Control for Each Pump. This feature allows any remaining
material to be cleaned out of the material lines.
Blowback Filter Cleaning. 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
Controller Features
• Mitsubishi programmable control with LED display and keypad interface
• Monitors Station status and Pump status
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2-4 Optional Features
Options marked with “*” indicate options that can be factory installed or retrofitted in the
field.
CE Package for 220/1/50 Operation. Required in Europe and other areas that need
220/1/50 supply voltage.
*Remote audible/visual alarm. Alarm light and horn assembly that can be remote mounted
and wired into the controller to indicate an alarm condition.
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.
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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 1-Pump, 9-Station Controller. Failure to do so may
result in serious injury. No one but the person who installed the lockout may remove
it.
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Chapter 3: Installation
3-1
Uncrating
1-Pump, 9-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. Use a pry bar if necessary to carefully remove the
skid from the unit.
4. Lower slowly.
3-2
3-3
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.
Electrical Connections
Refer to local electrical codes, the schematic and connection diagrams supplied with this
unit and the serial tag for wiring considerations. Run all wiring in conduit if codes require
it.
Making Control Panel Power Drop Wiring Connections
Hardwire the input power at 115/1/60 VAC or 220V/1/50 VAC, depending on the
specifications, which are located on the Control Panel Serial Tag. The main power
switch is located on the front of the enclosure.
Caution! We recommend that you protect PLC memory by providing the control
panel with a dedicated circuit, a true earth ground, and a spike/surge
protector.
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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. 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. 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 (10 SOL) 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 implosion filter cleaning, wire the clearing valve (11 SOL)
and sealing valve (12 SOL) solenoids.
5. On vacuum pumps with compressed air filter cleaning, wire the blowback solenoid
(11 SOL) to the terminal located in the control panel enclosure.
6. Wire the pump package motor overload to the terminal provided in the control panel
enclosure.
7. 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.
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3-4 Setup
This section provides the procedures for configuring your 1-pump, 9-station controller.
Configuration of your controller includes setting the number of stations and pumps, setting
variables such as convey time and blow-back intervals. 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 Conveying Systems manual.
Basic Menus and Setup of Controller
Once power has been applied to a properly installed system, turn the disconnect switch to the
ON position. The controller will display the title screen (Shown below) after the initial
Mitsubishi controller serial number screen has been displayed.
Figure 1: Title Screen
The operator will then have to press the F6 key to enter the Main Menu (Figure 2).
Figure 2: Main Menu Screen
The Main Menu will provide access to the following controller functions and features:
• Turning the system On and Off
• Viewing the status of the system
• Setting station features
• Setting pump features
• Setting system features
Activating and Deactivating the System
To activate or deactivate the system, press the F1 key on the controller keypad.
Note: The system can also be turned On and Off by pressing F1 in additional screens
which will be mentioned later in this manual.
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Viewing System Status
The station and pump status screen (Shown below) can be viewed by pressing the F2 key on
the controller keypad.
Figure 3: Status Screen
This screen will show whether stations 1-9 and the pump (shown in the bottom right of the
screen- “P1”) are Ready or Offline. For a list of additional station and pump status names
and their description which may be displayed on this screen, see below.
Figure 4: Station Status Names & Descriptions
Name
Description
OFFLINE
READY
DEMAND
CONVEY
UNLOAD
NOCONV
PURGE
Station is disabled or not installed.
Normal idle condition.
Station is in demand, waiting to convey.
Convey to station is in progress.
Convey is complete, station is now unloading.
Station has a no convey alarm.
Station convey is complete – lines are being purged.
High vacuum alarm.
HIVAC
Figure 5: Pump Status Names & Descriptions
Name
Description
OFFLINE
READY
IDLE
CONVEY
HIVAC
PMP FLT
GEN FLT
FLTR CAN
Pump is disabled.
Pump is idle and off.
Pump is idle and running.
Pump is conveying or purging.
High vacuum alarm.
Pump Verify alarm.
User input alarm.
Filter can limit switch alarm.
Note: Pressing F1 while this screen is active will turn On or Off the conveying
system.
Press F6 to return to the Main Menu.
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Station Setup
To set the station settings and features of your conveying system, press the F4 key on the
controller keypad while in the Main Menu screen. The initial (of three) Station Setup screen
will be shown (below):
Figure 6: Initial Station Setup Screen
This screen will allow you to set the following features:
• Convey time - Convey time is the length of time the station’s vacuum valve remains
open to allow material to be drawn in. (For a volume-fill station, the valve closes when
material covers the station’s volume-fill proximity sensor or this time elapses,
whichever comes first.) This setting is shown in seconds and the duration can be set
from 1-999.
• Last Convey – This screen is meant for display only and shows the duration time (in
seconds) of the most recent convey.
• Unload Time - This is the length of time allowed for material to drain from the station
into its receiver. The unload duration is shown in seconds and can be set from 1-999.
Note: See the next page for instructions on entering numerical data into the
controller.
Once the values have been entered for the settings listed above, the operator can choose to do
the following:
• Turn this station On or Off (Press F1 while in this screen)
• Enter additional values for this station in the second setup screen (Press F3).
• Enter the same values listed above for the next station in sequence (Press F5).
• Return to the Main Menu (Press F6).
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Entering Values Into Controller Fields
When it is necessary to change the settings for a particular feature, you will need to do the
following:
1. Use the arrow keys to select the value.
2. Select the value in the field to be changed by pressing the SET key.
3. Press the numbers you want to enter into the field from the numeric keypad (Shown
below).
4. Press the green ENT (Enter) key to enter those values or the red ESC (Escape) key to
return the values back to their original setting.
5. Use the arrow keys to scroll up or down to set the values in the next or previous field.
Note: Values entered into the fields must be set into the controller using the ENT key
before moving on to the next field or data will be lost.
Figure 7: Controller Keypad
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Second Station Setup Screen
Once the settings have been entered into the initial Station Setup Screen, press F3 to access
the next set of configurable station settings. The second station setup screen (Figure 8) will
be shown.
Figure 8: Second Station Setup Screen
This screen will allow you to set/activate the following features:
• Purge Time – this is the length of time allowed for material to be cleaned out of the
system. Purge time duration is displayed in seconds and can be set from 1-999.
• Purge F2- this allows you to enable or disable the purge cycle by pressing the F2
button on the keypad.
• CL Loop F4 – this allows you to enable or disable the closed loop feature for this
station by pressing the F4 button on the keypad.
Once the values and settings have been entered, the operator can choose to do the following:
• Enter the settings from this screen for the next station in sequence (Press F5 while in
this screen)
• Enter additional settings for this station in the third setup screen (Press F3).
• Return to the Main Menu (Press F6).
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Third Station Setup Screen
Once the settings have been entered into the second Station Setup Screen, press F3 to access
the next set of configurable station settings. The third station setup screen (Figure 9) will be
shown.
Figure 9: Third Station Setup Screen
This screen will allow you to set/activate the following features:
• No CNVY F2 – This feature allows you to enable or disable the station no convey
alarm.
• No Conveys – This is the number of times the system will allow unsuccessful conveys
before setting off an alarm. This number can be set between 0 and 99.
• SP CNVY F4 – Pressing F4 allows the operator to turn the Special Convey feature On
or Off.
Once the values and settings have been entered, the operator can choose to do the following:
• Return to the Main Menu (Press F6).
• Return to the Initial Station Setup Screen (Press F3).
• Enter these features for the next station in sequence (Press F5 while in this screen)
Note: Repeat the steps listed in the previous pages to set the features and settings for
each station in your system.
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Pump Setup
To set the pump settings and features of your conveying system, press the F5 key on the
controller keypad while in the Main Menu screen. The initial (of three) Pump Setup screen
will be shown (below):
Figure 10: Initial Pump Setup Screen
This screen will allow you to set the following features:
• FC ENABLE F2 – Pressing F2 allows you to enable or disable the filter cleaning
feature.
• FC TYPE F5- This feature allows you to toggle between blowback and implosion
cleaning (Press F5). This setting must match the equipment that was installed in your
system.
• CNVYS/CLEAN – This is the number of convey cycles allowed between filter
cleanings. This value can be set between 1 and 99.
Once the values have been entered for the settings listed above, the operator can choose to do
the following:
• Turn the pump On or Off (Press F1 while in this screen)
• Enter additional values for this pump in the second setup screen (Press F3).
• Return to the Main Menu (Press F6).
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Second Pump Setup Screen
Once the settings have been entered into the initial Pump Setup Screen, press F3 to access the
next set of configurable pump settings. The second pump setup screen (Figure 11) will be
shown.
Figure 11: Second Pump Setup Screen
This screen will allow you to set the following features:
• CLEAN PULSES – This is the number of blowback/implosion pulses allowed during
filter cleaning. This value can be set between 1 and 99.
• ON PULSE- This feature allows you to set the amount of time that the
blowback/implosion pulse will remain on during filter cleaning. This value can be set
between 0.1 and 99.9 seconds.
• OFF PULSE- This feature allows you to set the amount of time in between
blowback/implosion pulses during filter cleaning. This value can be set between 0.1
and 99.9 seconds.
Once the values have been entered for the settings listed above, the operator can choose to do
the following:
• Turn the pump On or Off (Press F1 while in this screen)
• Enter additional values for this pump in the third setup screen (Press F3).
• Return to the Main Menu (Press F6).
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Third Pump Setup Screen
Once the settings have been entered into the second Pump Setup Screen, press F3 to access
the next set of configurable pump settings. The third pump setup screen (Figure 12) will be
shown.
Figure 12: Third Pump Setup Screen
This screen will allow you to set the following features:
• RAMP UP TIME- This is the delay in seconds from when the pump starts till the
conveying system starts. This value can be entered between 1 and 99.
• RAMP DN TIME- This is the delay in seconds from when the pump stops till the next
time the pump starts again. This value can be entered between 1 and 99.
Note: There must be sufficient time for the motor to completely stop before starting
again.
• IDLE TIME- This is the delay in seconds from when the pump last conveyed material
till the pump stops. This value can be entered between 1 and 999.
Once the values have been entered for the settings listed above, the operator can choose to do
the following:
• Turn the pump On or Off (Press F1 while in this screen)
• Return to the initial setup screen to review settings or make additional changes (Press
F3).
• Return to the Main Menu (Press F6).
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System Setup
To set the system settings and features of your conveying system, press the F6 key on the
controller keypad while in the Main Menu screen. The initial (of three) System Setup screen
will be shown (below):
Figure 13: Initial System Setup Screen
This screen will allow you to set the following features:
• INSTALLED HOPPERS – This will allow you to input the number of stations present
in the system. Values can be entered between 0 and 9 total hoppers.
• HI VAC DEBOUNCE- This is the minimum amount of time (in seconds) that a High
Vacuum Signal will occur before being recognized by the system. This value can be
entered between 0.1 and 9.9.
• HI VAC DELAY- This is the amount of time (in seconds) before the High Vacuum
Alarm will occur once a High Vacuum Signal has been recognized. This value can be
set between 2.0 and 9.9.
Once the values have been entered for the settings listed above, the operator can choose to do
the following:
• Turn the system On or Off (Press F1 while in this screen)
• Enter additional values for the system in the second setup screen (Press F3).
• Return to the Main Menu (Press F6).
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Second System Setup Screen
Once the settings have been entered into the initial System Setup Screen, press F3 to access
the next set of configurable system settings. The second system setup screen (Figure 14) will
be shown.
Figure 14: Second System Setup Screen
This screen will allow you to set the following feature:
• Station Demand Debounce- This is the minimum amount of time in seconds before the
demand signal is recognized by the system. Values can be set between 0.5 and 2.0.
Once the values have been entered for the settings listed above, the operator can choose to do
the following:
• Press the F5 key once while in this screen to view and set the Debounce settings for
Stations 4-6. If the F5 key is pressed again while in the Debounce settings for Stations
4-6, the screen will display and allow the operator to set the Debounce settings for
Stations 7-9.
• Return to the Main Menu (Press F6).
Third System Setup Screen
Once the Debounce settings have been entered into the second System Setup Screen, press F3
to access the next system setting. The third (really the fifth) system setup screen (Figure 15)
will be shown.
Figure 15: Third System Setup Screen
This screen will allow you to set the Alarm Silence Duration. This feature is the length of
time (in minutes) before an alarm horn will reactivate while in an alarm condition. The value
can be set between 1 and 50.
Once the value has been entered for the setting listed above, the operator can choose to do the
following:
• Return to the Initial System Setup Screen (Press F5).
• Return to the Main Menu (Press F6).
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Chapter 4: Operation
4-1 Overview
Your 1-pump, 9-station controller electrically controls valves and solenoids to convey
material from a central location to individual stations as needed. The controller senses
demands for material at the stations and responds to the demands in a timely fashion.
This section provides the procedures necessary for using your controller.
Note: Before you carry out any of the procedures in this chapter, the system must be
set up as described in Chapter 3.
4-2 Starting and Stopping the System
1. Press F1 to start the conveying system. The controller will display “F1 SYS ON” in
the upper left corner of the Main Menu screen.
Note: The conveying system can also be activated by pressing the F1 key when in the
Status screen. The controller will display “F1 SYS ON”in the middle of the
bottom of the screen.
Once the system has been started, each active station is polled in sequence for a
demand signal. The convey sequence upon initiation, will continue until the set
convey time has elapsed or the demand signal stops, whichever happens first. If the
Special Timed Convey feature is enabled, conveying will continue until the convey
time has elapsed. (Once station dump delay has been initiated during the convey
sequence, a new demand signal will be ignored.) If the blowback sequence begins
immediately following the convey sequence, the sequence valve will remain open
throughout the blowback sequence.
2. To stop conveying, press F1 again when in the Main Menu or Status screen. The
controller will display “F1 SYS OFF.”
4-3 Alarms
No Convey
If no convey is enabled and the station conveys the specified number of times unsuccessfully,
the alarm horn/light will activate. The status for that station will display “NO CNVY.” If the
station is currently in convey or unload, the status will alternate between “NO CNVY” and
“CONVEY” or “UNLOAD.” Pressing F2 while the status screen is displayed will silence the
alarm. The status screen will continue to show “NO CNVY” until a successful convey
occurs.
High Vacuum
If a high vacuum condition is detected during the convey sequence, the alarm horn/light will
activate. The status for the affected station will display “HI VAC.” If the station is currently
in convey or unload, the status will alternate between “HI VAC” and “CONVEY” or
“UNLOAD.” Pressing F2 while the status screen is displayed will silence the alarm. The
status screen will continue to show “HI VAC” until a convey occurs where no high vacuum
condition is sensed.
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Pump Fault
If the pump verify signal is not present after the pump is started, the alarm horn/light will
activate. The pump will be stopped and set to an offline condition. The Status screen will
display “PMP FLT.” Pressing F2 while the status screen is displayed will silence the alarm.
Filter Can
If the filter can limit switch signal is not present after the pump is started, the alarm horn/light
will activate. The Status screen will display “FLTR CAN”. Pressing F2 while the status
screen is displayed will silence the alarm.
General Fault
If the general fault signal is present after the pump is started, the alarm horn/light will
activate. The pump will be stopped and set to an offline condition. The Status screen will
display “GEN FLT.” Pressing F2 while the status screen is displayed will silence the alarm.
All Faults
If after silencing an alarm, the condition remains beyond the time specified for ALARM
SILENCE DURATION, the alarm horn/light will reactivate. Pressing F2 from the status
screen will silence the alarm.
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Chapter 5: Maintenance
No Periodic maintenance is required on this unit.
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Chapter 6: Configurable Settings
This section describes the proper setup of the 1-pump, 9-station control system parameters.
These parameters are operator changeable; however, these items should require setup only
during the initial installation. Only authorized personnel should change them.
Many of the variables and setup parameters have been preset at the factory and do not need to
be changed. However, this section of the manual will address all of the setup parameters that
were available at the time of printing. The purpose of this is to familiarize the reader with all
the setup parameters and their usage.
6-1 Options for Station Setup
Name
Description
Default
Conveying Components
Convey time
Length of time the station’s vacuum valve remains open to
allow material to be drawn in. (For a volume-fill station, the
valve closes when material covers the station’s volume-fill
proximity sensor or this time elapses, whichever comes first.)
15 sec.
Adjust this value to match the actual time needed to fill the
station. To disable a station, set the convey time to Ø
(zero).
Unload Time
Length of time allowed for material to drain from the station into
the receiver. The controller will not attempt to deliver more
material to the station until this time has elapsed.
Adjust this value to match the actual time needed to drain the
station. If it is set too short, the controller may attempt to refill
the station before it is empty, causing material to back up
and/or underusing the station’s capacity. If it is set too long, the
system may be unable to keep up with your equipment’s
demand for material. DO NOT SET TO “Ø”.
10 sec.
No conveys
The controller issues a “no convey” alarm if it has repeatedly
attempted to convey material to the station but the flapper
never opened during the dump delay. (The number of attempts
is controlled by this setting.)
The setting for this option depends on (a) how much material
your injection mold uses to make each part compared with the
capacity of the receiver and (b) how important it is to keep your
injection mold from running out of material and shutting down.
A higher setting will give you fewer alarms, at the risk of
emptying the receiver without warning. A lower setting will give
more frequent alarms, at the risk of disrupting operations
unnecessarily. DO NOT SET TO “Ø”.
3
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6-2 Options for Pump Setup
The ramp time represents the amount of time it takes for the vacuum blower to come up to
full speed once it has been turned on. The ramp down time represents the amount of time it
takes the blower to stop once it has been turned off.
The ramp up time lets the blower reach full speed unloaded. When the ramp up time is
reached, the vent valve will open and allow the pump to draw a vacuum on the main vacuum
line. This in turn will open the receiver sequence valve connected to the main vacuum line
and allow material to be drawn into the vacuum receiver.
The ramp down time allows the vacuum blower to come to a full stop before it can be started
again. This prevents the blower motor from becoming a generator and blowing fuses.
Name
Description
Default
Pump Settings
Idle Time
Length of time the pump continues to run unloaded without
demand from any station. After this time has elapsed, the pump
shuts down to save power and to prevent wear on the pump.
Adjust this setting to fit the needs of your facility in trading off the
savings against the costs associated with waiting for a pump to
start up when there is a demand for material.
45 sec.
Ramp Up Time
Ramp Down Time
Cnvys/Clean
This feature specifies the time (in seconds) allowed for the pump
motor to reach operating speed.
This feature specifies the time (in seconds) allowed for the pump
motor to come to a complete stop.
When this option is enabled, the controller periodically sends
compressed air backward through the pump’s air filter to dislodge
accumulated dust and debris.
5 sec.
5 sec.
enabled
Enable this option if and only if the pump has the equipment for
compressed-air filter cleaning. Set to Ø to Disable Blowback.
Number of conveying cycles to stations between filter cleanings.
Adjust this setting based on experience. The more dust and
debris in your material line, the smaller this number needs to be.
5
On Pulse
Off Pulse
Tenths of seconds that the air pulse remains on for each cleaning
pulse during filter cleaning.
If blow-back is not working as desired, the service department
may ask you to change this setting.
Tenths of seconds between air pulses during filter cleaning.
If blow-back is not working as desired, the service department may ask
you to change this setting.
1.6 sec.
0.8 sec.
1
Numbler of cleaning
pulses (No. Pulses)
Clean Pulses
Number of pulses of compressed air sent through the pump’s
filter during cleaning.
If blow-back is not working as desired, the service department
may ask you to change this setting. Set to Ø to Disable
Blowback.
FC Type
Vacuum or Implosion – Must match equipment.
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Chapter 7: Troubleshooting
7-1 General Troubleshooting
Problem
Possible Cause
Solution
The control panel doesn’t light up The control panel is not turned
Turn on the control panel.
at all
on.
The external disconnect
(recommended) in the dedicated
circuit is open (off).
Close the switch (on).
Fuse/circuit breaker in the power Replace/reset.
drop is blown/tripped.
Control power switch is broken.
The motor overload has tripped.
Replace.
A pump package doesn’t run,
even though it is on-line and its
indicator is lit.
Reset the overload and check
the motor for the proper amp
draw on tag.
Main fuse in power drop or
optional fused disconnect has
blown.
Replace the fuse.
Motor contact is faulty.
The vacuum receiver is off-line.
Repair or replace as required.
Use the controller to put the
vacuum receiver on-line.
A vacuum receiver is being by-
passed in the loading cycle.
The convey time for the vacuum
receiver is set to zero.
Use the controller to enter a
longer convey time.
The field-installed station bypass Normal operation. Set the switch
switch is simulating a Bin Full
condition.
so the vacuum receiver is back in
the loading sequence.
The field-installed station bypass Repair, replace, or re-wire.
switch is bad or mis-wired.
The vacuum receiver was
assigned to the wrong pump
during setup.
Repeat the setup procedure.
Vacuum receivers are overfilling. Conveying times are too long
(Time Fill Mode only).
Time the vacuum receiver (s)
during loading, and set the
conveying times to a few
seconds less.
Maximum conveying times are
too long, and the PLC does not
recognize the Vacuum Receiver
Full Proximity Switch(es).
Check proximity sensors for
proper operation and proper
wiring to the PLC. Repair as
needed. Reset the conveying
times to a reasonable value, and
adjust as needed.
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7-2 Alarms
The format for all station alarms is “Station n [alarm text],” for example, “Station 9 receiver
low level.” The format for all pump alarms is “Pump n [alarm text].” Any alarm that does not
start with “Station” or “Pump” is a system alarm.
The following tables list all alarms alphabetically, together with possible causes. A “critical”
alarm is one that causes the affected device to stop.
Note: You can also see a list of alarms and their causes in the controller’s online
help. To display this information, touch the color key of statuses in the upper
right-hand corner of either the “Station Status” or the “Pump Status” screen,
or touch Help at any other screen. When you are finished reviewing the help,
touch Return.
Station Alarms
Alarm message
Possible cause
Material line is blocked.
Vacuum line is blocked.
Convey time is too long (time-fill station only).
Sequence valve has malfunctioned.
Vacuum switch has malfunctioned.
High vacuum
Note: After you have corrected the cause of this alarm, the alarm will be
cleared when the controller has conveyed a full load to this station.
Material container is empty.
Material line is disconnected from material source.
Vacuum line is disconnected from station.
Take-off compartment is not adjusted properly.
Convey time is too short.
No convey
Note: As a stopgap measure, you can disable the “no convey” alarm for
this station until the problem can be remedied.
Pump Alarms
Alarm message
Pump failure
Possible cause
Circuit breaker or overload protector has tripped.
Contactor has malfunctioned.
(Critical)
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Chapter 8: Appendix
8-1 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, GUARANTEES,
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.
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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.
8-2 Optional Components
The following is a list of options that your controller may be equipped with:
CE Package for 220/1/50 Operation. Required in Europe and other areas that need
220/1/50 supply voltage.
Remote audible/visual alarm. Alarm light and horn assembly that can be remote
mounted and wired into the controller to indicate an alarm condition.
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8-3 Drawings and Diagrams
Figure 1: 1-Pump 9 Station Controller
16”
3.30”
6” Display
4.69”
16”
* Depth dimension is 8”
Also, review electrical drawings supplied in the packet with the manual.
8-4 Spare Parts List
Quantity
Part Number
Description
Relay
2
2
1
1
1
1
2
1
A0569870
A0569859
A0540997
A0542210
A0544790
A0542203
A0542200
A0542207
Air Grill with Filter
Fuse, MDL –1
Fuse, MDL – 5
Fuse, MDL – 8
Fuse, MDL – 2
Fuse, MDL – 1.5
Fuse, MDL - 3
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8-5 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. XXX1-9
Serial No. 31K0182
Ph
115 Volt
60 Hz
1
Control Voltage 24VDC
8-6 Technical Assistance (Contact Information)
Parts Department
[
]
[414]
Call toll-free 7am–5pm CST 800 423-3183 or call 354-0970, Fax [414] 354-6421
The ACS Customer Service Group will provide your company with genuine OEM quality parts
manufactured to 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
[
]
[
] 3
Call toll-free 8am–5pm CST 800 657-4679 or call 414 54-0970
[
]
Emergencies after 5pm CST, call 847 439-5655
We have a qualified service department ready to help. Service contracts are available for most of our
products.
Sales Department
[414]
Call
354-0970 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 414 354-0970 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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