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Manual Sterling Plumbing 882.00252.00

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  • Sterling Plumbing 882.00252.00 - page 1

    SCC 3-Pump 33-Station Controllers Part Number: 882.00252.0 0 Bulletin Number: CV3-635 Effective: 12/05/05 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continui ...

  • Sterling Plumbing 882.00252.00 - page 2

    Please note that our address and phone i nformation has changed. Please reference this page for updated contact information. These manuals are obsolet e and are provided only for their technical inf ormation, data and capacities. Portions of these manuals detailing procedures or precautions in the operation, inspection, main tenanc e and repair of ...

  • Sterling Plumbing 882.00252.00 - page 3

    3–Pump 33-Station Controllers Chapter 1: Safety ii Shipping Information Unpacking and Inspection You should inspect your equipm ent for possible shipping damage. Thoroughl y check the equipment for any damage that m ight have occu rred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc. In the Event ...

  • Sterling Plumbing 882.00252.00 - page 4

    3–Pump 33-Station Controllers Chapter 1: Safety iii Table of Contents CHAPTER 1: SAFETY ............................................................... VI 1-1 How to Use This Manual ............................................................................................ vi Safety Symbols Used in this Manual ................................... ...

  • Sterling Plumbing 882.00252.00 - page 5

    3–Pump 33-Station Controllers Chapter 1: Safety iv Reviewing Pump Status ...................................................................................... 30 Logging On and Logging Off ............................................................................... 31 Enabling and Disabling Stations and Pumps.................................. ...

  • Sterling Plumbing 882.00252.00 - page 6

    3–Pump 33-Station Controllers Chapter 1: Safety v Contract Department ........................................................................................... 51 ...

  • Sterling Plumbing 882.00252.00 - page 7

    3–Pump 33-Station Controllers Chapter 1: Safety vi 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 a pplying efficient, proven techniques that enhance equipment productivity. This manual covers only light corrective mai ...

  • Sterling Plumbing 882.00252.00 - page 8

    3–Pump 33-Station Controllers Chapter 1: Safety vii 1-2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national a nd local safety codes. This may include, but is not limited to OSHA, NEC, CSA, SPI, and any other local, national and inter ...

  • Sterling Plumbing 882.00252.00 - page 9

    3–Pump 33-Station Controllers Chapter 1: Safety viii 1-3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended inst ructions are followed in the maintenance and operation of the machine. All personnel engaged in the use of the machin e should become familiar wi ...

  • Sterling Plumbing 882.00252.00 - page 10

    3–Pump 33-Station Controllers Chapter 1: Safety ix Operator Responsibility The operator’s responsibility does not end with e fficient 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 incent ...

  • Sterling Plumbing 882.00252.00 - page 11

    3 –Pump 33-Station Controllers Chapte r 2: Functional Description 10 of 51 Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, and m aintenance instructions for 3-Pump, 33- Station Conveying Controllers. Model numbers are listed on the serial tag. Make sure you know the model and seria ...

  • Sterling Plumbing 882.00252.00 - page 12

    3–Pump 33-Station Controllers Chapter 2: Functional Description 11 of 51 2-3 Standard Features Mechanical Features Time-fill Capability. The length of time a station’s v acuum valve remains open to allow material to be drawn into its receiver. Volume-fill Capability. The length of time a station’s vacuum valve remains open to allow material t ...

  • Sterling Plumbing 882.00252.00 - page 13

    3–Pump 33-Station Controllers Chapter 2: Functional Description 12 of 51 2-5 Safety Device s and Interlocks This section includes information on safety devices and procedures that are inherent to the Controller. This manual is not intended to s upersede or alter safety standards established by the user of this equipment. Instead, the materi al co ...

  • Sterling Plumbing 882.00252.00 - page 14

    3–Pump 33-Station Controllers Chapter 3: Installation 13 of 51 Chapter 3: Inst allation 3-1 Uncrating 3-Pump, 33-Station Controllers are shipped mounted on a skid, enclosed in a pla stic 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 careful ...

  • Sterling Plumbing 882.00252.00 - page 15

    3–Pump 33-Station Controllers Chapter 3: Installation 14 of 51 Connecting the Control Panel to Vacuum Hoppers Note: Wire size dep ends on contr ol voltage, distance, number of vacuum hoppers, and the number of wires in each raceway. Consult a qualified electrician. 1. On 115 VAC control voltage systems, run a common hot (115 VAC) wire and a commo ...

  • Sterling Plumbing 882.00252.00 - page 16

    3–Pump 33-Station Controllers Chapter 3: Installation 15 of 51 3-4 Setup This section provides the procedures for confi guring your 3-pum p, 33-station controller. Configuration of your controller includes setting the number of stations and pum ps, setting variables such as convey time and blow-back interval, and setting up passwords. We recommen ...

  • Sterling Plumbing 882.00252.00 - page 17

    3–Pump 33-Station Controllers Chapter 3: Installation 16 of 51 Figure 3: “System Setup” Screen Before Setup 3. At the “System Setup” screen, (Figure 3), touch Stations Present . A keypad pops up. 4. Enter the total number of stations (1-33) to be controlled b y the system. Use (Backspace Key) to erase any mistakes. Use (Enter Key) to ente ...

  • Sterling Plumbing 882.00252.00 - page 18

    3–Pump 33-Station Controllers Chapter 3: Installation 17 of 51 Setting Up Alarm Silences When an alarm occurs, a horn sounds and a st robe light flashes at each installed central alarm. An alarm banner screen appears. An alar m message and Alarm Silence button are on the banner. Touching this button silences the horn and turns off the lights for ...

  • Sterling Plumbing 882.00252.00 - page 19

    3–Pump 33-Station Controllers Chapter 3: Installation 18 of 51 Setting Up Pump Staging To avoid an excessive power demand at your fac ility when the conveying system starts up, you can stagger the times at which pumps start. Whenever a demand would cause two pum ps to start simultaneously, your choice for pump staging sets the delay between the s ...

  • Sterling Plumbing 882.00252.00 - page 20

    3–Pump 33-Station Controllers Chapter 3: Installation 19 of 51 Setting Up Stations Before starting the system, you must define several settings for each station, such as which pump conveys material to it. This section first discusses how to use the controller’s menu system to configure stations. The table on pa ges 42–43 discusses the individ ...

  • Sterling Plumbing 882.00252.00 - page 21

    3–Pump 33-Station Controllers Chapter 3: Installation 20 of 51 Figure 7: “Station Setup” Screen 4. On the “Station Setup” screen (Figure 7), adjust settings as required. Touching any box that appears in red (for “disabled”) toggles it to green (for “enabled”), and vice versa. Touching any white box gives you a keypad to enter a ne ...

  • Sterling Plumbing 882.00252.00 - page 22

    3–Pump 33-Station Controllers Chapter 3: Installation 21 of 51 Copying Settings from One Station to Others If other stations at your facility will use the same settings as a station you have already set up, you can copy the settings from this station to the other s. To copy settings from one station to others, complete the steps below. • At the ...

  • Sterling Plumbing 882.00252.00 - page 23

    3–Pump 33-Station Controllers Chapter 3: Installation 22 of 51 2. Enter the station number for the lower e nd of the range you are copying to. Use (Backspace Key) to erase any mistakes. Use (Enter Key) to enter the value. The keypad disappears, and the “Station Copy” screen shows the station number you entered under First Station . 3. On the ...

  • Sterling Plumbing 882.00252.00 - page 24

    3–Pump 33-Station Controllers Chapter 3: Installation 23 of 51 Setting Up Pumps Before starting the system, you must define several settings for each pump, such as how quickly to shut it down when it is not in use. This section first discusses how to use the controller’s menu system to configure pumps . The table on page 44 discusses the indivi ...

  • Sterling Plumbing 882.00252.00 - page 25

    3–Pump 33-Station Controllers Chapter 3: Installation 24 of 51 4. As appropriate, setup the rest of the pumps using eithe r of the following me thods: • Copy this pump’s settings to one or more other pumps, as described below • Use the Back or Next buttons to navigate to other pumps. Touch Back to go to the previous “Pump Setup” screen, ...

  • Sterling Plumbing 882.00252.00 - page 26

    3–Pump 33-Station Controllers Chapter 3: Installation 25 of 51 4. As appropriate, either continue co pying to other pumps, or touch Return to go back to the “Pump Setup” screen. • Copying to a Range of Other Pumps: 1. On the “Pump Copy” screen (Figure 10) touch the gray First Pump button. The keypad pops up. 2. Enter the pump number for ...

  • Sterling Plumbing 882.00252.00 - page 27

    3–Pump 33-Station Controllers Chapter 3: Installation 26 of 51 Operator Password If you define a password for operators, then a password will be required to carry out any function (other than reviewing station and pum p status, silencing alarms, reviewing the alarm log, and looking at help screens). Entering th e operator’s password will give t ...

  • Sterling Plumbing 882.00252.00 - page 28

    3–Pump 33-Station Controllers Chapter 3: Installation 27 of 51 To change the duration of the password, complete the following steps: 1. On the “System Setup” screen (Figure 4), touch the Operator Password Duration button or the Setup Password Duration button, depending on which password duration you want to ch ange. A keypad pops up. 2. Enter ...

  • Sterling Plumbing 882.00252.00 - page 29

    3–Pump 33-Station Controllers Chapter 4: Operation 28 of 51 Chapter 4: Operation 4-1 Overview Your 3-pump, 33-station controller electrically contro ls 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 r esponds to the demands in a timel ...

  • Sterling Plumbing 882.00252.00 - page 30

    3–Pump 33-Station Controllers Chapter 4: Operation 29 of 51 4. When you are finished review ing the information, touch Return . The “Help Menu” screen opens. 5. Touch Menu to return to the “Menu” screen. The following table explains the status re presented by each color at the “Station Status” screen. Color Label Description Gray outl ...

  • Sterling Plumbing 882.00252.00 - page 31

    3–Pump 33-Station Controllers Chapter 4: Operation 30 of 51 Reviewing Pump Status The “Pump Status” screen is the counterpart of the “Station Status” screen. To reach the “Pump Status” screen from any other screen, touch Menu on the right-hand side of the screen, and then touch Pumps . The “Pump Status” screen appears. Figure 12: ...

  • Sterling Plumbing 882.00252.00 - page 32

    3–Pump 33-Station Controllers Chapter 4: Operation 31 of 51 Logging On and Logging Off Your controller may be set up to require a p assword for any operation (other than reviewing station and pump status, silencing alarms, re viewing the alarm log, and looking a t help screens). If so, touching a button will open the “Password Entry” keypad s ...

  • Sterling Plumbing 882.00252.00 - page 33

    3–Pump 33-Station Controllers Chapter 4: Operation 32 of 51 Enabling and Disabling Stations and Pumps When a station or pump is disabled, the controller makes no attempt to use it and ignores any alarms that occur for it. Disabling a station or pump at the controller’s screen is similar to bypassing a station with its bypass switch. Enabling a ...

  • Sterling Plumbing 882.00252.00 - page 34

    3–Pump 33-Station Controllers Chapter 4: Operation 33 of 51 Reviewing and Adjusting Basic Station Settings The 3-pump, 33-station controller has a “Station Operator” screen for each station, as shown below. This screen enables you to review a nd adjust all basic settings for the station. To reach the “Station Operator” screen, complete th ...

  • Sterling Plumbing 882.00252.00 - page 35

    3–Pump 33-Station Controllers Chapter 4: Operation 34 of 51 Adjusting Convey Time and Dump Delay 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, whicheve ...

  • Sterling Plumbing 882.00252.00 - page 36

    3–Pump 33-Station Controllers Chapter 4: Operation 35 of 51 Activating and Stopping Priority Convey for a Station Note: Before activating priority convey, make sure that all other stations using the same pump have adequate material in reserve to c ontinue operation. No material will be conveyed to these stations during priority convey. If you wan ...

  • Sterling Plumbing 882.00252.00 - page 37

    3–Pump 33-Station Controllers Chapter 4: Operation 36 of 51 4-3 Adjusting Advanced Settings 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 logging on and o ff with the setup p ...

  • Sterling Plumbing 882.00252.00 - page 38

    3–Pump 33-Station Controllers Chapter 4: Operation 37 of 51 Transferring Stations to a Standby Pump If a pump fails, you can transfer all of the controller’s station assignments for that pump to a standby pump. To do this, you must disable (take offline) both t he source pump and the standby pump, and the standby pump must have no stations al r ...

  • Sterling Plumbing 882.00252.00 - page 39

    3–Pump 33-Station Controllers Chapter 4: Operation 38 of 51 9. Enter the number of the standby pump. Use (Backsp ace Key) to erase any mistakes. Use (Enter Key) to enter the value. The number appears under Standby Pump , and a button labeled Transfer to Standby Pump appears on the screen. Figure 17: Transfer To Standby Pump Button Note: When you ...

  • Sterling Plumbing 882.00252.00 - page 40

    3–Pump 33-Station Controllers Chapter 4: Operation 39 of 51 Standby Pump Errors If the error message tells you to disable the s ource pump and/or the standby pump, touch Return at this screen, then Pumps at the “Pump Setup” screen. Take the pumps offline and then return to the “Transfer to Standby Pump” screen. If the error message tells ...

  • Sterling Plumbing 882.00252.00 - page 41

    3–Pump 33-Station Controllers Chapter 4: Operation 40 of 51 Silencing Alarms Whenever a new alarm occurs, your controller sounds the horn and turns on t he strobe light at each central alarm. Touch Alarm Silence on the alarm message banner that appears when a new alarm occurs or press the physical push button included in the central alarm option. ...

  • Sterling Plumbing 882.00252.00 - page 42

    3–Pump 33-Station Controllers Chap ter 5: Maintenance 41 of 51 Chapter 5: Maintenance No Periodic maintenance is required on this unit. ...

  • Sterling Plumbing 882.00252.00 - page 43

    3–Pump 33-Station Controllers Chapter 6: Configurable Settings 42 of 51 Chapter 6: Configurable Settings This section describes the proper setup of the 3 pump, 33-station control s ystem parameters. These parameters are operator changeable; however, these items sh ould require setup only during the initial installation. Only authorized personnel ...

  • Sterling Plumbing 882.00252.00 - page 44

    3–Pump 33-Station Controllers Chapter 6: Configurable Settings 43 of 51 Name Description Options Default Alarm Options No convey When this option is enabled, 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 ...

  • Sterling Plumbing 882.00252.00 - page 45

    3–Pump 33-Station Controllers Chapter 6: Configurable Settings 44 of 51 6-2 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, which cover operation procedures. Name Desc ...

  • Sterling Plumbing 882.00252.00 - page 46

    3–Pump 33-Station Controllers Chap ter 7: Troubleshooting 45 of 51 Chapter 7: T roubleshooting 7-1 General Troubleshooting Problem Possible Cause Solution The control panel is not turne d on. Turn on the control pa nel. The external disconnect (recommende d) in the de dicated circuit is open (off). Close the switch (on) . Fuse/circuit breaker in ...

  • Sterling Plumbing 882.00252.00 - page 47

    3–Pump 33-Station Controllers Chap ter 7: Troubleshooting 46 of 51 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 system alarm. The follow ...

  • Sterling Plumbing 882.00252.00 - page 48

    3–Pump 33-Station Controllers Chapter 8: Appendix 47 of 51 Chapter 8: Appendix 1-1 Warranty The manufacturer warrants all equipment manufactured by it to be free from defects in workmanship and material when used un der recommended conditions. The company’s obligation is limited to repair or replace FOB th e factory any parts that are returned ...

  • Sterling Plumbing 882.00252.00 - page 49

    3–Pump 33-Station Controllers Chapter 8: Appendix 48 of 51 8-3 Drawings and Diagrams Figure 19: 3 pump 33 station Controller with 6" Display Also, review electrical drawings supplied in the packet with this manual. 24 ” 30 ” 6 ” * De p th dimension is 12” ...

  • Sterling Plumbing 882.00252.00 - page 50

    3–Pump 33-Station Controllers Chapter 8: Appendix 49 of 51 8-4 Spare Parts List AC Voltage Quantity Part Number Description 1 A0563932 2.1A Power Supply 1 A0569862 Input Card 1 A0572817 Output Card 2 A0569859 Air Grill with Filter 3 A0541611 Fuse, MDL – .75 4 A0540997 Fuse, MDL – 1 1 A0540993 Fuse, MDL – .5 1 A0505812 Fuse, MDL – 1.25 DC ...

  • Sterling Plumbing 882.00252.00 - page 51

    3–Pump 33-Station Controllers Chapter 8: Appendix 50 of 51 Warranty Returns Prior to the return of any material, authoriz ation 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 returns are to be shipped prepaid . The invoice number and date or pu ...

  • Sterling Plumbing 882.00252.00 - page 52

    3–Pump 33-Station Controllers Chapter 8: Appendix 51 of 51 8-8 Technical Assistance (Contact Information) Parts Department Call toll-free 7am–5pm CST [ 800 ] 423- 3183 or call [ 630 ] 595-1060, Fax [630] 475-700 5 The ACS Customer Service Group w ill provide your compa ny with genuine OEM quality parts manufactured to engi neering design specif ...

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