Page 3 - Shipping Information; Unpacking and Inspection; Do not; If the Shipment is Not Complete; contact the shipping department immediately; Hold the items until you receive shipping instructions
24-Pump, 128-Station Controller 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 ha...
Page 4 - Table of Contents
24-Pump, 128-Station Controller Chapter 1: Safety 3 Table of Contents CHAPTER 1: SAFETY ................................................................ 5 1-1 How to Use This Manual ............................................................................................. 5 Safety Symbols Used in...
Page 6 - -1 How to Use This Manual; Safety Symbols Used in this Manual
24-Pump, 128-Station Controller Chapter 1: Safety 5 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 productivi...
Page 7 - -2 Warnings and Precautions
24-Pump, 128-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, CS...
Page 10 - Chapter 2: Functional Description; -1 Models Covered in This Manual; Mechanical Components Product; Features; Mechanical Features; Local Blowback Filter Cleaning.
24-Pump, 128-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 24-Pump, 128-Station Conveying Controllers. Model numbers are listed on the serial ta...
Page 11 - Implosion Filter Cleaning.; Electrical Features; Additional audible/visual alarm with silence button.; Devices and Interlocks
24-Pump, 128-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...
Page 13 - Chapter 3: Installation; -2 Mounting the Control Panel; consult factory
24-Pump, 128-Station Controller Chapter 3: Installation 12 Chapter 3: Installation 3-1 Uncrating 24-Pump, 128-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 ...
Page 14 - Connections; Making Control Panel Power Drop Wiring Connections; About KwikLink Flat Cables; Cross Section; Installing KwikLink Cable; and run these cables to each possible location in the plant. Use a
24-Pump, 128-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. Det...
Page 17 - Making sure that the cable is completely straight
24-Pump, 128-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 fl...
Page 18 - Addressing and Installing ArmorBlocksTM; Addressing ArmorBlocks
24-Pump, 128-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 ...
Page 20 - Figure 5: ArmorBlock Address Node Rotary Switches; to the flat cables. If not, reinstall it with its proper alignment.; Figure 6: Using seal block to pierce cable; Gently press it; Figure 7: Securing the Seal Block to the Cable Base
24-Pump, 128-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 alig...
Page 21 - Installing KwikLinkTM Connectors; hinge side; Make sure that the cable is properly seated
24-Pump, 128-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, ri...
Page 22 - carefully; The latch has two catches; the first loosely holds the connector on the cable, the; Connecting the Remote Interface to the Main Controller
24-Pump, 128-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! T...
Page 24 - Figure 8: Proper Controller and Remote Interface Connections; Connecting the Power Supply Enclosure to the Network
24-Pump, 128-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. Lo...
Page 25 - bottom; upper; KwikLink; 4 VDC POWER SUPPLY; . Tighten the cord grip ring until; not; remove any jumpers on power
24-Pump, 128-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 gre...
Page 26 - Figure 9: Proper Power Supply Enclosure Connections; Connecting Vacuum Receivers to the Network
24-Pump, 128-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. Att...
Page 28 - Figure 11: Proper Vacuum Receiver Connections
24-Pump, 128-Station Controller Chapter 3: Installation 27 Figure 11: Proper Vacuum Receiver Connections
Page 29 - Connecting Vacuum Pumps; To connect a vacuum pump to the network:; Figure 12: 4-Vacuum Pump ArmorBlock Connections
24-Pump, 128-Station Controller Chapter 3: Installation 28 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 vacuum pump to the network: 1. Attach patchcords ...
Page 30 - Figure 13: Proper Vacuum Pump Connections, Standard XPD/XPC Pumps
24-Pump, 128-Station Controller Chapter 3: Installation 29 Figure 13: Proper Vacuum Pump Connections, Standard XPD/XPC Pumps
Page 31 - Figure 14: Proper Vacuum Pump Connections, XPDB Pump
24-Pump, 128-Station Controller Chapter 3: Installation 30 Figure 14: Proper Vacuum Pump Connections, XPDB Pump
Page 32 - Connecting Filter Chambers; To connect a filter chamber to the network:
24-Pump, 128-Station Controller Chapter 3: Installation 31 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 from vacuum pump filter chamber to the appropriate co...
Page 33 - Figure 15: Proper Filter Chamber Connections, Blowback
24-Pump, 128-Station Controller Chapter 3: Installation 32 Figure 15: Proper Filter Chamber Connections, Blowback
Page 34 - Figure 16: Proper Filter Chamber Connections, Implosion Type
24-Pump, 128-Station Controller Chapter 3: Installation 33 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 giv...
Page 35 - determine where the best location for central alarms should be; To connect an alarm module to the network:; upper right; terminal of the ArmorBlock. Tighten
24-Pump, 128-Station Controller Chapter 3: Installation 34 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) t...
Page 36 - Figure 17: Proper Central Alarm Connections; Attach the other connector to the; upper left; terminal of the ArmorBlock. Tighten the
24-Pump, 128-Station Controller Chapter 3: Installation 35 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...
Page 37 - Figure 18: 4-Connector ArmorBlock Connections for Central Alarms; ArmorBlock for; Mechanical Components manual; Figure 19: Basic Menu Flow for Setup
24-Pump, 128-Station Controller Chapter 3: Installation 36 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 Pushbut...
Page 38 - Setting Up the System; Setting the Number of Stations and the Number of Pumps; Touching; Stations Present
24-Pump, 128-Station Controller Chapter 3: Installation 37 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 yo...
Page 40 - Setting Up Alarm Silences
24-Pump, 128-Station Controller Chapter 3: Installation 39 2. Check that the expected components are shown as present (green) and not present (grey). (Disregard any error messages.) For example, if you have 18 stations, boxes 01 through 18 in the Stations section should be green and boxes 19 through...
Page 41 - Setting Up Pump Staging
24-Pump, 128-Station Controller Chapter 3: Installation 40 The current settings are displayed under Alarm Strobe Suppression and Alarm Horn Silence . 2. Touch Alarm Strobe Suppression or Alarm Horn Silence, as appropriate. A keypad pops up, with the current setting. 3. Enter the number of minutes yo...
Page 42 - Setting Up Stations; Setting Up a Single Station
24-Pump, 128-Station Controller Chapter 3: Installation 41 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 m...
Page 43 - Naming Stations
24-Pump, 128-Station Controller Chapter 3: Installation 42 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 settings as required. Touching any box that appears in red (for “disabled”) toggles it to green (for “enabled”). Man...
Page 44 - Copying Settings from One Station to Others; from; To copy the selected station’s settings to one other station
24-Pump, 128-Station Controller Chapter 3: Installation 43 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 ent...
Page 45 - To copy the selected station’s settings to a; range; of other stations; Copy; To copy the current station’s settings to; all; other stations; Setting Up Pumps; Setting Up a Single Pump
24-Pump, 128-Station Controller Chapter 3: Installation 44 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 gre...
Page 46 - Help; Back; —or—
24-Pump, 128-Station Controller Chapter 3: Installation 45 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...
Page 47 - Naming Pumps; Note: Make sure to choose different names, as the system does not; Copying Settings from One Pump to Others
24-Pump, 128-Station Controller Chapter 3: Installation 46 c. Touch Next ► to go to the Pump n +1 Setup screen —or— d. Touch Goto and enter a pump number to go to that pump’s setup screen 5. To save or restore settings, go to the System Setup screen and touch Save/Restore on the right side of the sc...
Page 49 - System Setup
24-Pump, 128-Station Controller Chapter 3: Installation 48 Finishing Setup: Setting Up Passwords You can set up passwords for two levels of security: for operators and for setup personnel. The controller comes from the factory with neither password set. This allows every user access to all functions...
Page 50 - Save/Restore Settings
24-Pump, 128-Station Controller Chapter 3: Installation 49 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 ...
Page 51 - -6 Initial Startup; Stations
24-Pump, 128-Station Controller Chapter 3: Installation 50 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 stat...
Page 52 - Chapter 4: Operation; -2 Starting and Stopping the System; Push to
24-Pump, 128-Station Controller Chapter 4: Operation 51 Chapter 4: Operation 4-1 Overview Your 24/128 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 resp...
Page 53 - Tasks; Reviewing Station Status
24-Pump, 128-Station Controller Chapter 4: Operation 52 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 ...
Page 54 - Pumps; The Pump Status screen appears:
24-Pump, 128-Station Controller Chapter 4: Operation 53 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 ...
Page 56 - Log Off; Enabling and Disabling Stations and Pumps
24-Pump, 128-Station Controller Chapter 4: Operation 55 • 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 ...
Page 57 - Reviewing and Adjusting Basic Station Settings; Reaching and Reading the Station Operator Screens
24-Pump, 128-Station Controller Chapter 4: Operation 56 Reviewing and Adjusting Basic Station Settings Reaching and Reading the Station Operator Screens The 24/128 Controller has a Station Operator Settings screen for each station, as shown below. This screen enables you to review and adjust all bas...
Page 60 - Reviewing and Resetting a Pump Hour Meter; Transferring Stations to a Standby Pump
24-Pump, 128-Station Controller Chapter 4: Operation 59 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 loggi...
Page 63 - Reviewing Alarms; Alarms; Silencing Alarms; Push To Silence
24-Pump, 128-Station Controller Chapter 4: Operation 62 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. Sile...
Page 64 - Chapter 5: Maintenance; Maintenance; Maintenance; Network Scanner Module Considerations
24-Pump, 128-Station Controller Chapter 5: Maintenance 63 Chapter 5: Maintenance 5-1 Preventative Maintenance No preventative maintenance is required on this unit. 5-2 Corrective Maintenance Network Scanner Module Considerations The manufacturer includes a network scanner software diskette with your...
Page 65 - Chapter 6: Configurable Settings; Module; Keep in mind that this condition is extremely rare.; for Station Setup; Name Description
24-Pump, 128-Station Controller Chapter 6: Configurable Settings 64 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 initi...
Page 70 - -3 Options for Pump Setup
24-Pump, 128-Station Controller Chapter 6: Configurable Settings 69 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,...
Page 72 - Chapter 7: Troubleshooting; Troubleshooting; Problem Possible
24-Pump, 128-Station Controller Chapter 7: Troubleshooting 71 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...
Page 73 - Station Alarms
24-Pump, 128-Station Controller Chapter 7: Troubleshooting 72 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 s...
Page 76 - Chapter 8: Appendix; Components; Alarm light and horn assembly that
24-Pump, 128-Station Controller Chapter 8: Appendix 75 Chapter 8: Appendix 8-1 Warranty The manufacturer warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions. The company’s obligation is limited to repair or replace FOB ...
Page 77 - -3 Drawings and Diagrams
24-Pump, 128-Station Controller Chapter 8: Appendix 76 8-3 Drawings and Diagrams Figure 20: 24-Pump, 128-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 c...
Page 78 - Figure 21: Typical System Installation Layout; -4 Spare Parts List; Quantity Part
24-Pump, 128-Station Controller Chapter 8: Appendix 77 Figure 21: Typical System Installation Layout 8-4 Spare Parts List Quantity Part Number Description 1 A0569859 Fan grill with filter 1 739.00017.00 4A Power supply 1 A0542203 2A MDL fuse 1 A0568903 10A FNQ fuse 1 A0542205 2.5A MDL fuse 1 A054220...
Page 79 - Credit Returns; Warranty Returns; authorization
24-Pump, 128-Station Controller Chapter 8: Appendix 78 8-5 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...
Page 80 - Tag; Controller Safety Tags
24-Pump, 128-Station Controller Chapter 8: Appendix 79 8-6 Safety Tag Information Controller Safety Tags 8-7 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. XXX24-12...
