Page 2 - here for future reference
Page 2 of 60 Write down your unit serial number(s) Model # Serial # here for future reference ________________ ________________ ________________ ________________ ________________ ________________ ________________ ________________ Performance figures stated in this manual are based on a standard atmo...
Page 4 - Table of Contents
Page 3 of 60 Table of Contents 1 General Information.......................................................................... 9 1-1 Equipment Function......................................................................................9 1-2 Necessary Documents ........................................
Page 6 - Auxiliary Equipment for the Process Industries
Page 5 of 60 11-3 Warranty .....................................................................................................56 12 Safety Tag Information ................................................................... 57 12-1 Controller Safety Tags ...............................................
Page 7 - Charts and Figures
Page 6 of 60 Charts and Figures 1 SCC4/38 Controller with 6" Display ................................................................... 11 2 6” Default “Station Status” Screen Before Setup............................................. 22 3 6” “System Setup” Screen Before Setup .....................
Page 8 - Safety Considerations; Follow all SAFETY CODES.
Page 7 of 60 Safety Considerations Sterling SCC conveying systems are designed to providesafe and reliable operation when installed and operatedwithin design specifications, following national and localsafety codes. To avoid possible personnel injury or equipment damagewhen installing or operating t...
Page 9 - The equipment is distributed in Europe by our European Facility:
Page 8 of 60 Sterling “SCC4-38” Conveying Systems 4-Pump 38-Station Controller This controller is manufactured by Sterling, Inc. at the ACS-Wood Dale facility: ACS, Inc. 800 N. Wood Dale Rd. Wood Dale, IL 60191 Phone: 414.354.0970 Fax: 414.354.6421 The equipment is distributed in Europe by our Europ...
Page 10 - Function; Make sure that the appropriate; This product manual.; Capabilities
Page 9 of 60 1 General Information 1-1 Equipment Function Sterling conveying systems create vacuum for conveyingpelletized or granular material in a central material handlingsystem. A typical use is an in-plant distribution system for plasticprocessing plants. 1-2 Necessary Documents The documents b...
Page 11 - Vacuum leaks occurring anywhere in your system reduce capacity.; Cycle; Programmable Logic Controller.
Page 10 of 60 Use the minimum effective amount of vinyl flex hose tomaximize material line efficiency. Keep material lines asstraight as possible. Refer to the Sterling SPD/SPC ProductManual (Sterling Part No. A0571050) for installationrecommendations. Important! Vacuum leaks occurring anywhere in y...
Page 13 - Safety; Rules; Work only with approved tools and devices.; Tools and Equipment Needed; These tools and equipment are necessary for installation:; Considerations
Page 12 of 60 2 Safety 2-1 Work Rules The installation, operation, and maintenance of thisequipment must be conducted in accordance with all appli-cable work and safety codes for the installation location. Thismay include, but is not limited to OSHA, NEC, CSA, SPI,and any other local, national, and ...
Page 14 - cause personal injury.; Reporting a Safety Defect; Responsibility; Loss of a skilled operator (temporarily or permanently)
Page 13 of 60 DANGER indicates an imminently hazardous situationwhich, if not avoided, will result in death or serious injury.This word will be limited to the most serious situations. The term IMPORTANT emphasizes areas where equipmentdamage could result, or provides additional information tomake a ...
Page 16 - Devices; Identify and locate specific safety devices.; Safety Circuit Standards
Page 15 of 60 2-7 Safety Devices This section includes information on safety devices andprocedures that are inherent to the SCC4/38 Controller. Thismanual is not intended to supersede or alter safetystandards established by the user of this equipment. Instead,the material contained in this section i...
Page 17 - Safety Device Lock-Outs
Page 16 of 60 guarding a motor, and the safety switch fails, the motorshould not be able to run. 2-7-3 Safety Device Lock-Outs Some safety devices disconnect electrical energy from acircuit. The safety devices that are used in the SCC4-38Controller are primarily concerned with electrical powerdiscon...
Page 18 - Unpacking and Inspection; According to the contract terms and conditions of the Carrier, the; Parcel Post Shipment
Page 17 of 60 3 Shipping Information 3-1 Unpacking and Inspection You should inspect your Sterling SCC4-38 controller for anypossible shipping damage. If the container and packingmaterials are in re-usable condition, save them forreshipment if necessary. Thoroughly check the equipment for any damage...
Page 19 - contact Sterling; Hold the items until you receive shipping instructions; Do not return any damaged or incorrect items until you receive
Page 18 of 60 Hold the damaged goods with the container and packingmaterials for possible inspection by postal authorities. 3-4 United Parcel Service Shipment ; Contact your local UPS office regarding damage andinsurance claims. ; Retain the container and packing. ; Notify Sterling at once. 3-5 If t...
Page 20 - Installation; Installing the Sterling Control Panel; Sterling recommends that you protect PLC memory by providing; Connecting the Control Panel to Vacuum Hoppers
Page 19 of 60 4 Installation 4-1 Installing the Sterling Control Panel Note: Before you mount the panel, consider how you run wiring tothe vacuum hoppers, the filter chamber atmospheric valve (ifso equipped) and the pump motor starter(s), vacuumswitch(es), and vent valve(s). Mount the panel on a fla...
Page 21 - Consult a qualified electrician.; Connecting the Control Panel to the Pump Package; SOL
Page 20 of 60 3. Make sure that the solenoid and the proximity switch (if supplied) on vacuum hoppers are the same voltage (24VDC) as the SCC control panel voltage. Consult thecontrol panel serial tag and the solenoid valvenameplates. 4. Wire size depends on control voltage, distance, number of vacu...
Page 22 - Using the Standard 6” Touch Screen; Before carrying out these procedures, install all equipment as; Setting Up the System; Setting the Number of Stations and the Number of Pumps
Page 21 of 60 5 Using the Standard 6” Touch Screen 5-1 Introduction This chapter gives the procedures for configuring your SCC4-38 controller. Configuration of your SCC4-38 controller includes setting thenumber of stations and pumps, setting variables such asconvey time and blow-back interval, and s...
Page 23 - Figure 2: 6” Default “Station Status” Screen Before Setup; At the “Station Status” screen (Figure 2) or at the “Pump; SYSTEM SETUP
Page 22 of 60 Figure 2: 6” Default “Station Status” Screen Before Setup 1. At the “Station Status” screen (Figure 2) or at the “Pump Status” screen, touch the SYSTEM SETUP button. The “Menu” screen opens. Figure 3: 6” “System Setup” Screen Before Setup 2. At the “System Setup” screen, (Figure 3), to...
Page 24 - Setting Up Alarm Silences; button are on the banner. Touching this button
Page 23 of 60 4. Touch PUMPS ACTIVE . A keypad pops up. 5. Enter the total number of pumps (1-4) to be controlled by the system. Use CLR to erase any mistakes. Use ENTto enter the value. The keypad disappears, and the newsetting appears under PUMPS ACTIVE . 5-2-1-2 Setting Up Alarm Silences When an ...
Page 25 - Setting Up Pump Staging; Go to the “System Setup” screen by touching the
Page 24 of 60 mistakes. Use ENT to enter the value. The keypaddisappears and the new setting appears under STROBE SUPPRESS . 4. On the “System Setup” screen (Figure 4), touch the HORN SILENCE button. A keypad pops up. 5. Enter the number of minutes (between 0 and 99) that you want the horn to stay o...
Page 26 - Setting Up a Single Station; Go to the “Station Status” screen if needed. To reach this; Figure 5: 6” “Station Status” Screen
Page 25 of 60 5-2-2-1 Setting Up a Single Station 1. Go to the “Station Status” screen if needed. To reach this screen press station status button on any screen. Figure 5: 6” “Station Status” Screen 2. On the “Station Status” screen (Figure 5), touch the icon for the station you want to setup, and h...
Page 27 - button. The “Station Setup” screen; Figure 7: 6” “Station Setup” Screen; Keypad entry works as with many ATM machines
Page 26 of 60 Figure 6: 6” “Station Operator” Screen Before Setup 3. On the “Station Operator” screen (Figure 6), touch the STATION SETUP button. The “Station Setup” screen opens. Figure 7: 6” “Station Setup” Screen 4. On the “Station Setup” screen (Figure 7), adjust settings as required. Touching a...
Page 28 - Setting Up a Single Pump
Page 27 of 60 Touching RESET TO DEFAULTS in the lower right of the screen changes all the settings for this station back totheir factory defaults.See pp. 46–49 for details on the options and their defaultsettings. 5. As appropriate, setup the rest of the stations using either of the following method...
Page 30 - Finishing Setup: Setting Up Passwords; Password; any
Page 29 of 60 5-2-4 Finishing Setup: Setting Up Passwords You can set up passwords for two levels of security: foroperators and for setup personnel. The controller comesfrom the factory with neither password set. This allows everyuser access to all functions. 5-2-4-1 Setup Password If you define a p...
Page 31 - SYSTEM; button on any screen.; Operator Password; button or the; Setup Password; Enter up to four digits. If you want to remove password
Page 30 of 60 Note: If you want to protect the operator’s functions with apassword, you must also define a setup password. If youleave the setup password undefined, then all users will haveaccess to all functions. If you want two different levels of password protection, youmust make the passwords di...
Page 33 - Operation; Before you carry out any of the procedures in this chapter, the; Station; STATION STATUS
Page 32 of 60 5-3 General Operation 5-3-1 Overview Your SCC4-38 controller electrically controls valves andsolenoids to convey material from a central location toindividual stations as needed. The controller sensesdemands for material at the stations and responds to thedemands in a timely fashion. T...
Page 34 - . The “Station Symbols Help”; HELP MENU
Page 33 of 60 Figure 10: 6” “Station Status” Screen During Operation The status of each station is color-coded. You can see anexplanation of each status by using the online help. To do sofrom this screen, complete the following steps: 1. Touch HELP . The “HELP Menu” screen opens. 2. Touch Station St...
Page 35 - Reviewing Pump Status; PUMP STATUS; “Pump Status” screen appears.; Figure 11: 6” “Pump Status” Screen During Operation; . The “Pump Symbols Help”
Page 34 of 60 Additional basic information about each station (convey time,dump delay, and pump assignment) is available at the“Station Operator” screen. See page 38 for details. Detailed configuration settings for each station are availableat the “Station Setup” screen. See page 47 for details abou...
Page 36 - Logging On and Logging Off
Page 35 of 60 The following table explains the status represented by eachcolor at the Station Status screen. Color Label Description Gray outline Offline Pump is not enabled. The controller ignores any alarms. Green Ready Pump is off, waiting for demand from a station. Light Blue Idle Pump is on, wa...
Page 37 - Figure 12: 6” “Password Entry” Screen; Each digit appears as an “; Return; Enabling and Disabling Stations and Pumps
Page 36 of 60 Figure 12: 6” “Password Entry” Screen Enter the four-digit password (including any leading zeros).For example, if the password is 1, enter 0001 . Each digit appears as an “ * ” as you touch it. When you touch the fourth digit, the controller carries out your request.For example, it ena...
Page 38 - STATION STATUS or PUMP STATUS; Starting and Stopping the System; In an emergency, you can use the power switch on the front of the; . When the system is on, the button is green and; STOP SYSTEM; . Depending on the setup at your
Page 37 of 60 Note: For a station to be available for the system, it must beenabled at the controller’s screen and its bypass switch must be in the “Convey” position. To enable or disable a station (or pump), complete thefollowing steps: 1. Go to the “Station Status” (or “Pump Status”) screen, if ne...
Page 39 - Reviewing and Adjusting Basic Station Settings; this screen from any other screen, touch; STATION; Touch and hold the icon for the station, until the controller; Figure 13: 6” “Station Operator” Screen
Page 38 of 60 5-3-2-6 Reviewing and Adjusting Basic Station Settings The Sterling controller has a “Station Operator” screen foreach station, as shown below. This screen enables you toreview and adjust all basic settings for the station. To reach the “Station Operator” screen, complete thefollowing ...
Page 40 - Navigating among the “Station Operator” Screens; PREVIOUS; Adjusting Convey Time and Dump Delay; Last Convey
Page 39 of 60 5-3-2-7 Navigating among the “Station Operator” Screens The controls at the top of the screen enable you to moveamong the “Station Operator” screens: • To display the screen for the next lower-numbered station (for example, to move from the screen for Station 15 to thescreen for Statio...
Page 41 - Activating and Stopping Priority Convey for a Station
Page 40 of 60 To adjust a station’s convey time (or the unload time),complete the following steps: 1. Go to the “Station Operator” screen by touching and holding a station icon, or go to the “Station Setup”screen. 2. Touch CONVEY TIME . A keypad pops up. 3. Enter the number of seconds desired for co...
Page 42 - Reviewing and Resetting a Pump Hour Meter
Page 41 of 60 controller finishes the current convey, if any, andresumes normal operation. 5-3-3 Advanced Tasks This section describes the procedures carried out duringoperation that are normally reserved for setup personnel.These procedures require use of the setup password (if yourfacility has def...
Page 43 - Transferring Stations to a Standby Pump
Page 42 of 60 5-3-3-2 Transferring Stations to a Standby Pump If a pump fails, you can transfer all of the controller’s stationassignments for that pump to a standby pump. To do this,you must disable (take offline) both the source pump and thestandby pump, and the standby pump must have no stationsa...
Page 44 - Figure 15: 6” “Transfer To Standby Pump” Screen; Use CLR to erase any mistakes. Use ENT to enter the; Figure 16: 6” Transfer To Standby Pump Button; MOVE; stations moved will appear on the screen.; RETURN; Put the standby pump online by briefly touching its icon.
Page 43 of 60 Figure 15: 6” “Transfer To Standby Pump” Screen 6. Use CLR to erase any mistakes. Use ENT to enter the value. Figure 16: 6” Transfer To Standby Pump Button Note: When you enter the second pump number, the controllerchecks to make sure that both pumps are offline and that thestandby pum...
Page 46 - Alarms; Alarms; SILENCE
Page 45 of 60 5-3-4 Alarms 5-3-4-1 Reviewing Alarms To review your system’s alarms, touch Alarms on any screen. The “Alarm Log” screen appears, with the newestalarm listed first. Figure 17: 6” Alarm Log Screen To scroll up and down through the list, touch DOWN or UP at the top of the screen. 5-3-4-2...
Page 47 - Maintenance; No Periodic maintenance is required on this unit.
Page 46 of 60 6 Maintenance No Periodic maintenance is required on this unit.
Page 48 - Options for Station Setup
Page 47 of 60 7 Configurable Settings This section describes the proper setup of the SCC4-38control system parameters. These parameters are operatorchangeable; however, these items should require setup onlyduring the initial installation. Only authorized personnelshould change them. Many of the vari...
Page 50 - Options for Pump Setup
Page 49 of 60 7-2 Options for Pump Setup Several of the items in this screen are not setup options butare instead intended for use during operation. These items(hour meter and transferring stations to a standby pump) aredescribed in Chapter 5, which cover operation procedures. Name Description Optio...
Page 51 - Troubleshooting
Page 50 of 60 8 Troubleshooting 8-1 General Troubleshooting Problem Possible Cause Solution The control panel is not turnedon. Turn on the control panel. Fuse/circuit breaker in the powerdrop is blown/tripped. Replace/reset. The control panel doesn’t light upat all Control power switch is broken. Re...
Page 53 - Options; Ethernet Capability; Enables SCC controller to be connected to ethernet network.; Line Filter/Surge Suppressor
Page 52 of 60 9 Options The following is a list of options that your controller may beequipped with: 230/1/50 Operation Required to operate with a 230/1/50 supply voltage. Audible/visual alarm Alarm light and horn assembly that can be remote mountedand wired into the controller to indicate an alarm ...
Page 54 - Spare Parts List; 0-1 Recommended Spare Parts List
Page 53 of 60 10 Spare Parts List 10-1 Recommended Spare Parts List Quantity Sterling Part Number Description 1 A0569874 AB 20A Power Supply, 24VDC, #1606-XL480EP 1 A0569870 Relay Magnecraft #781XAXML 1 A0569859 Filter/Grill 1 A0540997 Fuse, MDL –1 1 A0542210 Fuse, MDL – 5 1 A0544793 Fuse, MDL – 15 ...
Page 55 - Assistance; Contact Information for Technical Assistance; Parts Department
Page 54 of 60 11 Technical Assistance 11-1 Contact Information for Technical Assistance Parts Department Call toll-free 7am–5pm CST [800] 423-3183 or call [414] 354-0970, Fax [414] 354-6421 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured toSterlin...
Page 56 - 1-2 Returned Material Policy
Page 55 of 60 11-2 Returned Material Policy 11-2-1 Credit Returns 1. Prior to the return of any material, authorization must be given by Sterling. A RMS number will be assigned for the equipment to be returned. 2. Reason for requesting the return must be given.3. All returned material purchased from...
Page 57 - warrants all equipment manufactured by it to be
Page 56 of 60 11-3 Warranty Sterling. warrants all equipment manufactured by it to be free from defects in workmanship and material when usedunder recommended conditions. The Company’s obligationis limited to repair or replace FOB the factory any parts thatare returned prepaid within one year of equ...
Page 58 - Safety Tag Information; 2-1 Controller Safety Tags; (Located on the side of the controller box)
Page 57 of 60 12 Safety Tag Information 12-1 Controller Safety Tags 12-2 Controller Identification (Serial Number) Tag (Located on the side of the controller box) 5200 W. Clinton Ave.Milwaukee, WI 53223Tel. (414) 354-0970Fax (414) 354-6421 SCC CONTROL PANELModel No. SCC4-38 Serial No. 31K0182 115 Vo...
