Sterling XXX10-80 - Manuals

10-Pump, 80-Station Controller Chapter 1: Safety 6 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...

10-Pump, 80-Station Controller Chapter 2: Functional Description 9 Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, and maintenance instructions for 10-Pump, 80-Station Conveying Controllers. Model numbers are listed on the serial tag....

10-Pump, 80-Station Controller Chapter 2: Functional Description 10 Implosion Filter Cleaning. When this feature is enabled, the controller periodically pulls a vacuum on the filter chamber and then releases it to dislodge accumulated dust and debris. Grinder Empty. This feature allows a station to ...

10-Pump, 80-Station Controller Chapter 3: Installation 12 Chapter 3: Installation 3-1 Uncrating 10-Pump, 80-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 bo...

10-Pump, 80-Station Controller Chapter 3: Installation 13 8. Set up and connect vacuum receiver stations to ArmorBlocks installed in Step 3, using yellow patch cords. 9. Set up and connect vacuum pump stations and filter chambers to ArmorBlocks installed in Step 3, using yellow patch cords. 10. Dete...

10-Pump, 80-Station Controller Chapter 3: Installation 14 To install KwikLink cables: 1. Cut both black and grey cables to the proper length. 2. Use cable ties to attach KwikLink cables, black cable above grey cable, on the vacuum tubing . Attach cable to the tubing with cable ties at about three-fo...

10-Pump, 80-Station Controller Chapter 3: Installation 16 Discard the standard resistor cap to eliminate confusion. 5. Mount the mounting plate assembly on the vacuum line at the end of the cable run. See Page 14 for more information. 6. Using the straight-blade cable cutter, carefully trim each fla...

10-Pump, 80-Station Controller Chapter 3: Installation 17 The latch has two catches; the first loosely holds the connector on the cable, the second requires more pressure to close the connector tightly. The cable must be in the correct position for the connector to close properly. 3. Drive the two s...

10-Pump, 80-Station Controller Chapter 3: Installation 19 Figure 5: ArmorBlock Address Node Rotary Switches Installing ArmorBlocks The ArmorBlock cable base should already be attached to the mounting plate, aligned so it is perpendicular to the flat cables. If not, reinstall it with its proper align...

10-Pump, 80-Station Controller Chapter 3: Installation 20 To secure the seal block: 1. Start the threads of each of the four captive screws into the cable base receptacle holes. 2. Drive each of the screws about halfway down, using the proper torque sequence: Bottom screw, top screw, left screw, rig...

10-Pump, 80-Station Controller Chapter 3: Installation 21 2. Making sure that the cable is completely straight , carefully close the hinged assembly, and apply firm, even pressure until the first latch locks into place. Note: Make sure that the flat cable is completely straight before continuing! Th...

10-Pump, 80-Station Controller Chapter 3: Installation 23 Figure 8: Proper Controller and Remote Interface Connections Connecting the Power Supply Enclosure to the Network The power supply provides electrical power to make the system work. Some network layouts require more than one power supply. Loc...

10-Pump, 80-Station Controller Chapter 3: Installation 24 1. Attach a KwikLink connector included in the bag with power cables to the flat cables. One connector is used for the network grey cable and one connector is used for the auxiliary power black cable. 2. Align the square connector of the grey...

10-Pump, 80-Station Controller Chapter 3: Installation 25 Figure 9: Proper Power Supply Enclosure Connections Connecting Vacuum Receivers to the Network Make sure that all previous installation steps have been done first before starting this task. To connect a vacuum receiver to the network: 1. Atta...

10-Pump, 80-Station Controller Chapter 3: Installation 27 Figure 11: Proper Vacuum Receiver Connections Connecting Vacuum Pumps and Filter Chambers to the Network Connecting Vacuum Pumps Make sure that all previous installation steps have been done first before starting this task. To connect a vacuu...

10-Pump, 80-Station Controller Chapter 3: Installation 29 Figure 13: Proper Vacuum Pump Connections, Standard XPD/XPC Pumps

10-Pump, 80-Station Controller Chapter 3: Installation 30 Figure 14: Proper Vacuum Pump Connections, XPDB Pump Connecting Filter Chambers Make sure that all previous installation steps have been done first before starting this task. To connect a filter chamber to the network: 1. Attach patch cords f...

10-Pump, 80-Station Controller Chapter 3: Installation 31 Figure 15: Proper Filter Chamber Connections, Blowback XFC-S

10-Pump, 80-Station Controller Chapter 3: Installation 32 Figure 16: Proper Filter Chamber Connections, Implosion Type Note: Retain the terminal caps from the ArmorBlock. They may be used later. 2. Dress the excess patch cord cables with cable ties so they do not interfere with operation and to give...

10-Pump, 80-Station Controller Chapter 3: Installation 33 Connecting Central Alarms to the Network Make sure that all previous installation steps have been done first before starting this task. First, determine where the best location for central alarms should be , and install the alarm module(s) th...

10-Pump, 80-Station Controller Chapter 3: Installation 34 Figure 17: Proper Central Alarm Connections 3. Attach one connector of a yellow patch cord to the terminal on the alarm silence switch module. Tighten the cord grip ring until snug. 4. Attach the other connector to the upper left terminal of ...

10-Pump, 80-Station Controller Chapter 3: Installation 35 Figure 18: 4-Connector ArmorBlock Connections for Central Alarms Alarm Silence Pushbutton (A-I0)Alarm Silence Pushbutton (A-I1) 4 Input / 4 Output ArmorBlock for Central Alarms Alarm Strobe Light (C-O0)Alarm Horn (C-O1) Alarm Silence Pushbutt...

10-Pump, 80-Station Controller Chapter 3: Installation 36 Setting Up the System Setting the Number of Stations and the Number of Pumps 1. Touch System Setup at the Station Status (or Pump Status) screen. The System Setup screen appears: Note: Touching Help in the lower right of this screen gives you...

10-Pump, 80-Station Controller Chapter 3: Installation 39 The current settings are displayed under Alarm Strobe Suppression and Alarm Horn Silence . When a station node is configured for the default 2 stations per block (see Setting up the System on page 37), one option input and one option output p...

10-Pump, 80-Station Controller Chapter 3: Installation 40 Setting Up Stations Before starting the system, you must define several settings for each station, such as which pump conveys material to it and whether the station has a slide gate. This section first discusses how to use the controller’s me...

10-Pump, 80-Station Controller Chapter 3: Installation 42 2. You can enter a name of up to four (4) alpha-numeric characters. If you would like to enter a longer name, you can go back to the Station n Setup screen and press Name Line 2 to repeat the process . Using Name Line 2 will allow you to ente...

10-Pump, 80-Station Controller Chapter 3: Installation 43 4. As appropriate, either continue copying to other stations, or touch Station Setup to go back to the Station n Setup screen. To copy the selected station’s settings to a range of other stations 1. Touch First Station button next to the gree...

10-Pump, 80-Station Controller Chapter 3: Installation 44 2. Touch the icon for the pump you want to set up, and hold it for several seconds. The Pump n Setup screen appears: 3. Touching Help in the lower right of this screen gives you a menu of online help for the choices in this screen. 4. Adjust ...

10-Pump, 80-Station Controller Chapter 3: Installation 46 To copy the selected pump’s settings to one other pump 1. Touch the gray Copy to Pump button next to the green Copy To Single Pump button. The keypad pops up. 2. Enter the pump number for the pump you are copying to. Use ← to erase any mistak...

10-Pump, 80-Station Controller Chapter 3: Installation 48 2. Touch Operator Password or Setup Password, as appropriate. A keypad pops up. 3. Enter up to eight (8) alpha-numeric characters. If you want to remove the password protection, simply leave the entry blank. Use ← to erase any mistakes. Use ↵...

10-Pump, 80-Station Controller Chapter 3: Installation 49 3-6 Initial Startup Once you have finished all the setup described above, you are ready to start the system. To do so: 1. At any screen, touch Stations on the right-hand side of the screen. The Station Status screen appears. 2. For each stati...

10-Pump, 80-Station Controller Chapter 4: Operation 50 Chapter 4: Operation 4-1 Overview Your 10/80 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 respon...

10-Pump, 80-Station Controller Chapter 4: Operation 51 4-3 Basic Tasks This section covers tasks that can be carried out with no password or with an operator’s password. Reviewing Station Status The starting point for all operations is the Station Status screen. To reach this screen from any other s...

10-Pump, 80-Station Controller Chapter 4: Operation 52 The following table explains the status represented by each color at the Station Status screen. Color Label Description Silver Offline Station is not enabled. The controller ignores any demands or alarms. Blue Ready Station is enabled and idle (...

10-Pump, 80-Station Controller Chapter 4: Operation 53 2. Touch anywhere in the rectangle in the upper right of the screen or the Help button on the lower right side of the screen. The Help Menu appears. 3. In the section of the Help Menu labeled Screen Symbols/Colors , touch Pump . The Pump Symbols...

10-Pump, 80-Station Controller Chapter 4: Operation 54 • Enter the alphanumeric password. Each digit appears as an “ * ” as you touch it. Press ↵ when complete. If you have lost the password(s), contact the manufacturer for assistance. Once you have logged on, the password remains active until you l...

10-Pump, 80-Station Controller Chapter 4: Operation 55 Reviewing and Adjusting Basic Station Settings Reaching and Reading the Station Operator Screens The 10/80 Controller has a Station Operator Settings screen for each station, as shown below. This screen enables you to review and adjust all basic...

10-Pump, 80-Station Controller Chapter 4: Operation 58 4-4 Advanced Tasks This section describes the procedures carried out during operation that are normally reserved for setup personnel. These procedures require use of the setup password (if your facility has defined one). The procedure for loggin...

10-Pump, 80-Station Controller Chapter 4: Operation 61 3-5 Alarms Reviewing Alarms At the Station Status or Pump Status screen: 1. Touch Alarms . The Alarm Log screen appears, with the newest alarm listed first: To scroll up and down through the list: • Touch ▲ and ▼ at the bottom of the list. Silen...

10-Pump, 80-Station Controller Chapter 5: Maintenance 62 Chapter 5: Maintenance 5-1 Preventative Maintenance To maintain cooling fan, check and clean and/or replace filter.

10-Pump, 80-Station Controller Chapter 6: Configurable Settings 63 Chapter 6: Configurable Settings This section describes the proper setup of the 24-pump 128-station control system parameters. These parameters are operator changeable; however, these items should require setup only during the initia...

10-Pump, 80-Station Controller Chapter 6: Configurable Settings 67 Name Description Options Default RPV (Remote Proportioning Valve) This option allows the system to use a remote proportioning valve to mix two different materials, typically virgin and regrind materials, during a convey cycle. Touchi...

10-Pump, 80-Station Controller Chapter 6: Configurable Settings 68 6-3 Options for Pump Setup Several of the items in this screen are not setup options but are instead intended for use during operation. These items (hour meter and transferring stations to a standby pump) are described in Chapter 4, ...

10-Pump, 80-Station Controller Chapter 7: Troubleshooting 70 Chapter 7: Troubleshooting 7-1 General Troubleshooting Problem Possible cause Solution The controller panel is not connected to a power source. Plug in the controller panel. Fuse/circuit breaker in the power drop is blown/tripped. Replace/...

10-Pump, 80-Station Controller Chapter 7: Troubleshooting 71 7-2 Alarms The format for all station alarms is “Station n [alarm text],” for example, “Station 12 receiver low level.” The format for all pump alarms is “Pump n [alarm text].” Any alarm that does not start with “Station” or “Pump” is a sy...

10-Pump, 80-Station Controller Chapter 8: Appendix 74 Chapter 8: Appendix 8-1 Optional Components The following is a list of options that your controller may be equipped with: 230/1/60 Operation. Required to operate with a 230/1/60 supply voltage. Additional audible/visual alarm with silence button....

10-Pump, 80-Station Controller Chapter 8: Appendix 75 8-2 Drawings and Diagrams Figure 20: 10-Pump, 80-Station Controller with 10" Display Also, review electrical drawings supplied in the packet with this manual. Note: Allow 12” of clearance on each side of the controller for ventilation and cab...

10-Pump, 80-Station Controller Chapter 8: Appendix 76 Figure 21: Typical System Installation Layout 8-3 Main Control Panel Spare Parts List Quantity Part Number Description 1 Filter only- Clean as needed 1 A0569859 Fan grill with filter 1 739.00017.00 4A Power supply 1 A0542203 2A MDL fuse 1 A056890...

10-Pump, 80-Station Controller Chapter 8: Appendix 77 8-4 Returned Material Policy Credit Returns Prior to the return of any material, authorization must be given by the manufacturer. A RMS number will be assigned for the equipment to be returned. Reason for requesting the return must be given. All ...

10-Pump, 80-Station Controller Chapter 8: Appendix 78 8-5 Safety Tag Information Controller Safety Tags 8-6 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. XXX10-80 ...

10-Pump, 80-Station Controller Chapter 8: Appendix 81 Table of Contents CompactLogix L35E Setup (Brand New Processor )…………………………… 82 CompactLogix L35E Upgrade …......................................................................... 86 VersaView CE 1000H Setup …………………………………………………… 89 Remote Display...

10-Pump, 80-Station Controller Chapter 8: Appendix 82 CompactLogix L35E Setup Use this procedure to setup a new CompactLogix PLC for use on a 10 Pump – 80 Station Convey Control. 1. Verify that the control is powered down and the PLC CPU key switch is in the RUN position. 2. Insert the configuration...

10-Pump, 80-Station Controller Chapter 8: Appendix 84 9. Go to the System Setup Screen ( Fig 3 ) by pressing the System Setup button on any screen. Fig 3 10. Go to the Save / Restore Screen ( Fig 4) by pressing the Save / Restore button on the right side of the screen. Fig 4 11. Restore Settings by ...

10-Pump, 80-Station Controller Chapter 8: Appendix 85 15. Save Settings by pressing the yellow Save Settings button. 16. Wait for the “ Save Complete ” message. ( This message is only displayed for 10 seconds ). 17. Go to the System Setup screen by pressing the System Setup button. 18. Verify that t...

10-Pump, 80-Station Controller Chapter 8: Appendix 86 CompactLogix L35E Upgrade Use this procedure to upgrade the software on a CompactLogix PLC for use on a 10 Pump – 80 Station Convey Control. 1. If the control is off, turn it on and wait for the control to power up. 2. Verify that the key switch ...

10-Pump, 80-Station Controller Chapter 8: Appendix 87 5. Go to the System Setup Screen ( Fig 6 ) by pressing the System Setup button on any screen. Fig 6 6. Go to the Save / Restore Screen ( Fig 7) by pressing the Save / Restore button on the right side of the screen. Fig 7 7. Save Settings by press...

10-Pump, 80-Station Controller Chapter 8: Appendix 90 4. If you are upgrading a VersaView that has been configured to work with 10 Pump – 80 Station control an Error screen ( Fig 10 ) will appear. Press the “ OK [F7] ” button to close the screen. Fig 10

10-Pump, 80-Station Controller Chapter 8: Appendix 94 9. The Load Application Screen ( Fig 14 ) will appear. Fig 14 10. Press the “ Source [F1] ” button so the circle next to “ External Storage 1 ” is filled. 11. Use the up and down arrows to select the “ VersaViewCE_LockDown.mer ” application. 12. ...

10-Pump, 80-Station Controller Chapter 8: Appendix 99 39. A window will appear showing the contents of the “ My Computer ” folder ( Fig 19 ). Fig 19 40. Double tap the “ Storage Card2 ” folder.

10-Pump, 80-Station Controller Chapter 8: Appendix 100 41. A window will appear showing the contents of the “ Storage Card2 ” folder ( Fig 20 ). Fig 20 42. Double tap the “ BRutil ” icon.

10-Pump, 80-Station Controller Chapter 8: Appendix 101 43. The System Backup/Recover Window ( Fig 21 ) will appear. Fig 21 44. Press the “ Restore system ” button. DO NOT PRESS THE “BACK UP SYSTEM” BUTTON.

10-Pump, 80-Station Controller Chapter 8: Appendix 102 45. A Warning Window ( Fig 22 ) will appear. Fig 22 46. Press the “ OK ” button in the upper right corner of the Warning Window ( Fig 22 ). 47. After a short delay the VersaView will reboot. 48. If the calibration screen ( Fig 18 ) appears, foll...

10-Pump, 80-Station Controller Chapter 8: Appendix 104 20. The Startup Options Screen ( Fig 24 ) will appear. Fig 24 21. Press the enter “ ” button to select “ RSView ME Station Startup ” button.

10-Pump, 80-Station Controller Chapter 8: Appendix 106 30. The Networks and Communications Menu ( Fig 26 ) will appear. Fig 26 31. Press the down arrow “ ▼ ” button to highlight “ Network Connections ”. 32. Press the enter “ ” button to select “ Networks Connections ” .

10-Pump, 80-Station Controller Chapter 8: Appendix 110 40. A keyboard will appear ( Fig 30 ). Fig 30 41. Enter the appropriate IP Address for the display you are setting up: • Remote Display #1 - Enter “ 192.168.10.2 ” via the keyboard. • Remote Display #2 - Enter “ 192.168.10.3 ” via the keyboard. ...