Sterling Plumbing Paint Sprayer 8220024700 User Manual

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:  
_________________________  
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_________________________  
_________________________  
_________________________  
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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 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 5: Maintenance  
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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.  
1 –Pump 9-Station Controller  
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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.  
1 –Pump 9-Station Controller  
Chapter 8: Appendix  
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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  
1 –Pump 9-Station Controller  
Chapter 8: Appendix  
37 of 38  
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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.  
1 –Pump 9-Station Controller  
Chapter 8: Appendix  
38 of 38  
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