Page 3 - Shipping Information; Do not; contact the shipping department immediately
2–Pump 12-Station Controllers Chapter 1: Safety 2 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 hard...
Page 4 - Credit Returns
2–Pump 12-Station Controllers Chapter 1: Safety 3 Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department. Credit Returns Prior to the return of any material, authorization must be given by the manufacturer. A RMS number will be assig...
Page 5 - Table of Contents
2–Pump 12-Station Controllers Chapter 1: Safety 4 Table of Contents CHAPTER 1: SAFETY ................................................................ 6 1-1 How to Use This Manual ............................................................................................. 6 Safety Symbols Used in t...
Page 7 - -1 How to Use This Manual
2–Pump 12-Station Controllers Chapter 1: Safety 6 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...
Page 8 - -2 Warnings and Precautions
2–Pump 12-Station Controllers Chapter 1: Safety 7 Controller Safety Tags 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 lim...
Page 11 - Chapter 2: Functional Description; -1 Models Covered in This Manual
2–Pump 12-Station Controllers Chapter 2: Functional Description 10 Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, and maintenance instructions for 2-Pump, 12-Station Conveying Controllers. Model numbers are listed on the serial tag. ...
Page 12 - -3 Standard Features; Pump Blowback Filter Cleaning Outputs.; -4 Optional Features
2–Pump 12-Station Controllers Chapter 2: Functional Description 11 2-3 Standard Features Mechanical Features Time-fill Capability. The length of time a station’s vacuum valve remains open to allow material to be drawn into its receiver. Volume-fill Capability. The length of time a station’s vacuum v...
Page 13 - Devices and Interlocks
2–Pump 12-Station Controllers Chapter 2: Functional Description 12 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 t...
Page 15 - Chapter 3: Installation; -2 Mounting the Control Panel
2–Pump 12-Station Controllers Chapter 3: Installation 14 Chapter 3: Installation 3-1 Uncrating 2-Pump, 12-Station Controllers are shipped mounted on a skid, enclosed in a plastic wrapper, and contained in a cardboard box. 1. Pry the crating away from the skid. Note: Remove the nails holding the box ...
Page 17 - Figure 1: Typical 24-Volt Junction Box Wiring Diagram
2–Pump 12-Station Controllers Chapter 3: Installation 16 Figure 1: Typical 24-Volt Junction Box Wiring Diagram A0544675 (115VAC)/(0VDC) TO CONTROLLER INPUT FOR PUMP HIGH-VACUUM 6 4 3 T 2 T 1 T 2 RESET TRIPPED TEST 98 97 96 95 A2 14 6 T3 4 T2 A2 A09 A1 13 L3 5 L2 3 L1 1 T1 2 L1 L2 L3 M OL T1 T2 T3 VS...
Page 18 - DC Controller Power Sources
2–Pump 12-Station Controllers Chapter 3: Installation 17 Main Power Your 12-station controller system can operate from a 115 VAC or 220 VAC source at 50 Hz or 60 Hz. The main power switch on the controller is located on the right side of the housing. Built into the power switch are the controller fu...
Page 19 - Figure 2: Menu Tree Structure
2–Pump 12-Station Controllers Chapter 3: Installation 18 Gaining Access to the Menu System To enter the menu system, make sure that the controller is in the OFFLINE state. Press the MENU key to initiate the menu system. The menu has three (3) top level menus: 1. Station Settings 2. Pump Settings 3. ...
Page 20 - Operation Mode, Station Settings Menu
2–Pump 12-Station Controllers Chapter 3: Installation 19 STATION SETTINGS? NO/YES OPERATION MODE? NO/YES Station Settings Menu To access the Station Settings menu, place the controller in the OFFLINE state: 1. Press the ENTER/MENU key to enter the menu system. 2. Continue to press the ENTER/MENU key...
Page 22 - Set Dump Delay, Station Settings Menu
2–Pump 12-Station Controllers Chapter 3: Installation 21 TO SELECT A STATION PRESS STATION <1-12> SET DUMP DELAY? NO/YES DUMP DELAY 11: 15.0s PRESS ENTER TO SAVE Set Dump Delay, Station Settings Menu The second submenu in Station Settings is the Set Dump Delay submenu. To set dump delay time: ...
Page 23 - TO SELECT A STATION; Set Input Delay, Station Settings Menu
2–Pump 12-Station Controllers Chapter 3: Installation 22 SET INPUT DELAY? NO/YES TO SELECT A STATION PRESS STATION <1-12> The screen displays the station you selected (11 in the above example), and the current dump delay time setting. Using number keys 1 to 0, enter the new dump delay time (in...
Page 24 - PRESS ENTER TO SAVE; Set Station Alarms, Station Settings Menu
2–Pump 12-Station Controllers Chapter 3: Installation 23 INPUT DLY 11: 0.250s PRESS ENTER TO SAVE SET STATION ALARMS? NO/YES To alter station input delay time: • Select a station to alter, then press the related Station ST nn key. nn is the station number you selected. The screen displays the select...
Page 26 - Assigning a Pump to a Station
2–Pump 12-Station Controllers Chapter 3: Installation 25 ALARM AFTER 3 LOADS PRESS ENTER TO SAVE STATION SETTINGS? NO/YES ASSIGN PUMP>STATION? NO/YES TO SELECT A STATION PRESS HOPPER <1-12> To exit from the Alarm Setting time menu and return to the Station Settings menu: • Press the CLEAR k...
Page 27 - SELECT PUMP 1 OR 2
2–Pump 12-Station Controllers Chapter 3: Installation 26 STATION 10: PUMP 1 SELECT PUMP 1 OR 2 To assign a station to a pump: 1. Press the related station ST key. The following menu screen displays: To assign Pump 1 to the station you selected: • Press 1. Instead of assigning Pump 1 to the station y...
Page 28 - Setting the Pump Mode
2–Pump 12-Station Controllers Chapter 3: Installation 27 PUMP SETTINGS? NO/YES PUMP MODE? NO/YES SET PUMP MODE? Y=SINGLE N=DUAL Pump Settings Menu The Pump Settings menu lets you set all pump parameters. These include: • Pump Mode • Blowback • Delay Time Setting the Pump Mode The first setting to be...
Page 29 - SET ACTIVE PUMP
2–Pump 12-Station Controllers Chapter 3: Installation 28 SET ACTIVE PUMP SELECT PUMP 1 OR 2 If you have a single pump system (default): 1. Press the YES key. Selecting Single Pump mode requires the assignment of the default pump; the screen then displays the following: Selecting Dual Pump mode requi...
Page 30 - Changing Blowback Settings, Pump Settings Menu
2–Pump 12-Station Controllers Chapter 3: Installation 29 BLOWBACK SETTINGS? NO/YES SELECT PUMP 1 OR 2 USE KEYPAD TO ENTER ENABLE BLOWBACK? NO/YES Changing Blowback Settings, Pump Settings Menu As an option, you can equip the conveying system filter chamber with a blowback feature to pulsate compress...
Page 32 - Idle Delay Time Settings, Pump Settings Menu
2–Pump 12-Station Controllers Chapter 3: Installation 31 BLBK AFTER 12 LOADS SETTING FOR PUMP 1 IDLE DELAY TIME? NO/YES Next, set the Pulse Off time value. This is the duration that the blowback solenoid is turned OFF. • Using the number keys, enter the new Off Time setting, then press ENTER to save...
Page 33 - Audio Alarm Time
2–Pump 12-Station Controllers Chapter 3: Installation 32 SELECT PUMP 1 OR 2 USE KEYPAD TO ENTER IDLE TIME: 10.000 s SETTING FOR PUMP 1 The following screen displays. Each pump can have separate idle delay times. To alter idle delay, select a pump: • Using the keypad, enter the pump number (1 or 2). ...
Page 34 - before; Startup
2–Pump 12-Station Controllers Chapter 3: Installation 33 Service Settings Menu The settings in this menu are not meant to be modified by floor personnel (operators). See the section at the end of this manual for these settings. Saving Controller Settings to Flash Memory Your 12 station controller us...
Page 35 - Chapter 4: Operation
2–Pump 12-Station Controllers Chapter 4: Operation 34 TO SELECT A STATION PRESS STATION <1-12> LOAD TIME 10: 63sec PRESS ENTER TO SAVE Chapter 4: Operation 4-1 Startup ??????????????? Setting Load Times You can alter load times anytime while not in the menu system by pressing the SET key. The ...
Page 36 - SECTION 1 SECTION 2; -2 Controller Description and Operation
2–Pump 12-Station Controllers Chapter 4: Operation 35 SECTION 1 SECTION 2 SECTION 3 SECTION 4 2. Using number keys 1 to 0, enter the new time. 3. Press the ENTER key to save the new setting into controller memory. If several stations require altering: 1. Press the SET key instead of the ENTER key. T...
Page 37 - Dual Pump Mode
2–Pump 12-Station Controllers Chapter 4: Operation 36 STATION:-- OFFLINE TIME: --- LOGO P1:S--:--- OFFLINE P2:S—-:--- OFFLINE Pump Modes Single Pump Mode In Single Pump mode , the screen displays as shown below. The upper left corner displays the active station being loaded. If the system has no act...
Page 38 - Figure 3: Station Icon Segments
2–Pump 12-Station Controllers Chapter 4: Operation 37 Station Icons Below the text portion of the screen, 12 station icons display the status of each station in the system. Each station icon contains four segments. Figure 3: Station Icon Segments Label Description Segment 1 The top segment indicates...
Page 39 - Figure 4: Status Indicator Icons
2–Pump 12-Station Controllers Chapter 4: Operation 38 Status Indicators Four (4) status indicators are located below the station icons at the bottom of the display. These indicators include PUMP, BLOWBACK, HIGH VACUUM, and SYSTEM. Each icon word has a 1 and a 2 icon with it, indicating Pump 1 or Pum...
Page 40 - Figure 4: Controller Keypad
2–Pump 12-Station Controllers Chapter 4: Operation 39 Controller Keypad Your 12-station controller has a 16-position keypad to let you operate and alter controller parameters. With the exception of the SET key, each key has at least two functions. The status of the controller determines what functio...
Page 41 - Label Description
2–Pump 12-Station Controllers Chapter 4: Operation 40 4-3 Operation Your 12 station controller electrically controls valves and solenoids to convey material from a central location to individual stations as needed. The controller works within this process by sensing a material demand and responds in...
Page 44 - Chapter 5: Maintenance
2–Pump 12-Station Controllers Chapter 5: Maintenance 43 Chapter 5: Maintenance Updating BIOS Software Occasionally, BIOS software updates are available to enhance the operation of the controller. These updates are available through the Service Deptartment or for download from the internet. To find o...
Page 46 - Figure
2–Pump 12-Station Controllers Chapter 5: Maintenance 45 Figure 6 : BIOS Connection, Electrical Diagram; Drawing 2 A0560970 LEGEND FIELD WIRING OPTION/SERVICE WIRING NOTE: ALL WIRES ARE #18 AWG UNLESS OTHERWISE NOTED +0 VDC 2 STATION 1 SENSORS STATION 2 SENSORS 2 2 STATION 3 SENSORS 2 STATION 4 SENSO...
Page 47 - Chapter 6: Troubleshooting; Troubleshooting
2–Pump 12-Station Controllers Chapter 6: Troubleshooting 46 Chapter 6: Troubleshooting 6-1 General Troubleshooting Problem Possible cause Solution The controller panel is not plugged in. Plug in the controller panel. The external disconnect (recommended) in the dedicated circuit is open (off). Close...
Page 49 - WRITING PARAMETERS
2–Pump 12-Station Controllers Chapter 6: Troubleshooting 48 WRITING PARAMETERS TO FLASH-PLEASE WAIT SAVING BACKUP TO FLASH-PLEASE WAIT Controller Recovery using Flash Memory Technology It is possible for a write error to occur while information is being saved in the controller’s memory. If this occu...
Page 50 - Chapter 7: Appendix
2–Pump 12-Station Controllers Chapter 7: Appendix 49 Chapter 7: Appendix 7-1 Warranty Unless otherwise specified, this product includes a Standard ONE YEAR PARTS AND LABOR WARRANTY. Warranty Specifications The manufacturer hereby expressly warrants all equipment manufactured by it to be free from de...
Page 52 - -2 Drawings and Diagrams; Figure 7: 2 pump 12 station Controller Control Panel
2–Pump 12-Station Controllers Chapter 7: Appendix 51 7-2 Drawings and Diagrams Figure 7: 2 pump 12 station Controller Control Panel Depth dimension of subpanel: 8.0” D (20.3 cm). Also, review electrical drawings supplied in the packet with this manual. SECTION 1 SECTION 2 SECTION 3 SECTION 4
Page 53 - -3 Spare Parts List; Power cord
2–Pump 12-Station Controllers Chapter 7: Appendix 52 7-3 Spare Parts List Figure 8 : Typical 12-Station Controller Exterior Components, Exploded View A0560974 Power cord A0560954 13 1210 1110 14 2 4 places 9 16 8 7 6 5 5 15 2 4 places 4 places 4 places 4 3 2 1 1
Page 56 - Figure 11: Interior Components Parts List
2–Pump 12-Station Controllers Chapter 7: Appendix 55 Figure 11: Interior Components Parts List Refer to Figure 10 on Page 53 when identifying parts. Item Qty. Part no. Description 1. 4 W00001055 WASH, #6 SAE FLAT, PLD 2. 1 A0560961 PNL, SUB, CARLON, JP1210, 10 X 8 3. 4 A0530780 STND, OFF (M/F) #6-32...
Page 58 - Chapter 8: Service Only Information; Settings; defaults to 1.5 seconds
2–Pump 12-Station Controllers Chapter 8: Service Only Information 57 SET RAMP UP TIME? NO/YES SELECT PUMP 1 OR 2 USE KEYPAD TO ENTER RAMP UP DLY: 1.500s SETTING FOR PUMP n Chapter 8: Service Only Information Note: Hidden, programmable features and hidden menu pages should not be made available to fl...
Page 59 - defaults to 8.0 seconds
2–Pump 12-Station Controllers Chapter 8: Service Only Information 58 SET RAMP DOWN TIME? NO/YES RAMP DN DLY: 8.000s SETTING FOR PUMP n SELECT PUMP 1 OR 2 USE KEYPAD TO ENTER Setting the Ramp Down Time Ramp down time is a delay that allows the pump to come to a full stop when needed. The control cann...
Page 60 - defaults to 3.0 seconds
2–Pump 12-Station Controllers Chapter 8: Service Only Information 59 SET PUMP STAGE TIME? NO/YES STAGE DELAY: 3.000s PRESS ENTER TO SAVE Setting the Pump Stage Time Pump stage time is a delay that prevents both pumps from engaging at the same time. Although rare in a two-pump system, both pumps can ...
Page 61 - defaults to 0.5 seconds
2–Pump 12-Station Controllers Chapter 8: Service Only Information 60 SET LCD BLINK DELAY? NO/YES BLINK DELAY: .500s PRESS ENTER TO SAVE Setting the LCD Blink Delay LCD Blink Delay lets you alter the ON/OFF time that the LCD blinks during an alarm. This delay does not effect the Visual or Audible ala...
Page 63 - defaults to 10.0 seconds
2–Pump 12-Station Controllers Chapter 8: Service Only Information 62 HI VAC VENT DELAY? NO/YES SELECT PUMP 1 OR 2 USE KEYPAD TO ENTER HV VENT DLY: 10.000s SETTING FOR PUMP n Setting the Hi Vacuum Vent Delay Hi vacuum vent delay is the vent time initiated by a high vacuum condition. This delay defaul...
Page 64 - off line
2–Pump 12-Station Controllers Chapter 8: Service Only Information 63 HI VAC LOAD COUNT? NO/YES SELECT PUMP 1 OR 2 USE KEYPAD TO ENTER HV LOAD CNT: 7 SETTING FOR PUMP n Setting the Hi Vacuum Load Count Hi vacuum load count sets the maximum number of loads on a station in a high vacuum condition. If a...
Page 65 - Input Monitor Screen
2–Pump 12-Station Controllers Chapter 8: Service Only Information 64 INPUT MONITOR? NO/YES IN BNK0: 0000000000 IN BNK1: 0000000000 Using the Installation Aids Menus Input Monitor Screen To assist in the installation process or to aid in problem diagnoses, the controller uses two (2) OEM menu functio...
Page 66 - Output Control Menu
2–Pump 12-Station Controllers Chapter 8: Service Only Information 65 OUTPUT CONTROL? NO/YES AUTOMATIC OR MANUAL? N=AUTO Y=MANUAL Output Control Menu The Output Control menu gives you direct access to all 20 outputs of the controller. The menu has two (2) modes: Manual and Automatic. Automatic mode c...
Page 68 - OEM MENU ACCESS; -2 Other Controller Restricted Areas; Access
2–Pump 12-Station Controllers Chapter 8: Service Only Information 67 OEM MENU ACCESS IS NOW AVAILABLE! OEM SETTINGS? NO/YES 8-2 Other Controller Restricted Areas Using the OEM Service Menu The OEM service menu ( O riginal E quipment M anufacturer) lets you set parameters not commonly used. It also c...
Page 70 - PRESS YES TO RESUME; including passwords and OEM Service settings
2–Pump 12-Station Controllers Chapter 8: Service Only Information 69 ROM CHECKSUM: 0x0000 PRESS YES TO RESUME Restoring the Controller to Factory Defaults Although rare, you may experience a condition when you need to perform a total reset of the controller. To do so, perform the following procedure...
