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Manual Sterling Plumbing 882.00253.00

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  • Sterling Plumbing 882.00253.00 - page 1

    SCC 4-Pump 38-Station Controllers Part Number: 882.00253.0 0 Bulletin Number: CV3-640 Effective: 11/27/05 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continui ...

  • Sterling Plumbing 882.00253.00 - 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 882.00253.00 - page 3

    4 –Pump 38-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 Even ...

  • Sterling Plumbing 882.00253.00 - page 4

    4 –Pump 38-Station Controllers Chapter 1: Safety iii Table of Contents CHAPTER 1: SAFETY ................................................................ V 1-1 How to Use This Manual ............................................................................................. v Safety Symbols Used in this Manual .................................. ...

  • Sterling Plumbing 882.00253.00 - page 5

    4 –Pump 38-Station Controllers Chapter 1: Safety iv Reviewing Station Status .................................................................................... 23 Reviewing Pump Status ...................................................................................... 25 Logging On and Logging Off ............................................ ...

  • Sterling Plumbing 882.00253.00 - page 6

    4 –Pump 38-Station Controllers Chapter 1: Safety v 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 882.00253.00 - page 7

    4 –Pump 38-Station Controllers Chapter 1: Safety vi 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 882.00253.00 - page 8

    4 –Pump 38-Station Controllers Chapter 1: Safety vii 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 882.00253.00 - page 9

    4 –Pump 38-Station Controllers Chapter 1: Safety viii 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 inc ...

  • Sterling Plumbing 882.00253.00 - page 10

    4 –Pump 38-Station Controllers Chapter 2: Functional Description 9 of 44 Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, and m aintenance instructions for 4-Pump, 38- Station Conveying Controllers. Model numbers are listed on the serial tag. Make sure you know the model and serial ...

  • Sterling Plumbing 882.00253.00 - page 11

    4 –Pump 38-Station Controllers Chapte r 2: Functional Description 10 of 44 2-3 Standard Features Mechanical Features Time-fill Capability. The length of time allowed for material to drain from the station to its receiver. During this time, the controller does not attempt to deliver any m ore material to the station. Volume-fill Capability. The le ...

  • Sterling Plumbing 882.00253.00 - page 12

    4 –Pump 38-Station Controllers Chapte r 2: Functional Description 11 of 44 2-4 Optional Features Options marked with “*” indicate options that can be factory installed or retrofitted in the field. 230/1/50 Operation. Required to operate with a 230/1/50 suppl y voltage. Audible/visual alarm. Alarm light and horn assembly that can be remote mou ...

  • Sterling Plumbing 882.00253.00 - page 13

    4 –Pump 38-Station Controllers Chapte r 2: Functional Description 12 of 44 Safety Device Lock-Outs Some safety devices disconnect electrical energy from a circuit. T he safety devices that are used in this Controller are primarily con cerned with electrical power disconnection. WARNING! Always disconnect and lockout all electrical power and pneum ...

  • Sterling Plumbing 882.00253.00 - page 14

    4 –Pump 38-Station Controllers Ch apter 3: Installation 13 of 44 Chapter 3: Inst allation 3-1 Uncrating 4-Pump, 38-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 caref ...

  • Sterling Plumbing 882.00253.00 - page 15

    4 –Pump 38-Station Controllers Ch apter 3: Installation 14 of 44 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 24 VDC control voltage systems, run a common +24 VDC wire and a common 0 ( ...

  • Sterling Plumbing 882.00253.00 - page 16

    4 –Pump 38-Station Controllers Ch apter 3: Installation 15 of 44 Setting the Number of Stations and the Number of Pumps Figure 1: Default “Station Status” Screen Before Setup 1. At the “Station Status” screen (Figure 1) or at the “Pump Status” screen, touch the SYSTEM SETUP button. The “Menu” screen opens. Figure 2: “System Setu ...

  • Sterling Plumbing 882.00253.00 - page 17

    4 –Pump 38-Station Controllers Ch apter 3: Installation 16 of 44 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 appears in the cen ter of the screen. An alarm message a nd Silence button are on the banner. Touching this butto n silences the horn and turns ...

  • Sterling Plumbing 882.00253.00 - page 18

    4 –Pump 38-Station Controllers Ch apter 3: Installation 17 of 44 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 ...

  • Sterling Plumbing 882.00253.00 - page 19

    4 –Pump 38-Station Controllers Ch apter 3: Installation 18 of 44 Figure 5: “Station Operator” Screen Before Setup 3. On the “Station Operator” screen (Figure 5), touch the STATION SETUP button. The “Station Setup” screen opens. Figure 6: “Station Setup” Screen 4. On the “Station Setup” screen (Figure 6), adjust settings as req ...

  • Sterling Plumbing 882.00253.00 - page 20

    4 –Pump 38-Station Controllers Ch apter 3: Installation 19 of 44 5. As appropriate, setup the rest of the stati ons using either of the following m ethods: • Use the PREVIOUS or NEXT buttons to navigate to other stations. Touch PREVIOUS to go to the previous “Station Setup” screen, or touch NEXT to go to the next “Station Setup” screen. ...

  • Sterling Plumbing 882.00253.00 - page 21

    4 –Pump 38-Station Controllers Ch apter 3: Installation 20 of 44 Figure 8: Pump Setup Screen Before Setup 3. Adjust settings as required. Touching any box that appears in red (for “disabled”) toggles it to green (for “enabled”), and vice versa. Touching any box that appears in white gives you a keypad to enter a new value. Keypad entry wo ...

  • Sterling Plumbing 882.00253.00 - page 22

    4 –Pump 38-Station Controllers Ch apter 3: Installation 21 of 44 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 ...

  • Sterling Plumbing 882.00253.00 - page 23

    4 –Pump 38-Station Controllers Ch apter 3: Installation 22 of 44 To change the duration of the password, complete the following steps: 1. On the “System Setup” screen, touch the Operator Password Duration button or the Setup Password Duration button, depending on wh ich password duration you want to change. A keypad pops up. 2. Enter the numb ...

  • Sterling Plumbing 882.00253.00 - page 24

    4 –Pump 38-Station Controllers Ch apter 4: Operation 23 of 44 Chapter 4: Operation 4-1 Overview Your 4-pump, 38-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 tim ...

  • Sterling Plumbing 882.00253.00 - page 25

    4 –Pump 38-Station Controllers Ch apter 4: Operation 24 of 44 The following table explains the status re presented by each color at the “Station Status” screen. Color Label Description Gray outline Offline Station is not enabled. The controller ignore s any demands or alarms. Green Full Station is enabled and idle (full). Yellow Demand Statio ...

  • Sterling Plumbing 882.00253.00 - page 26

    4 –Pump 38-Station Controllers Ch apter 4: Operation 25 of 44 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 PUMP STATUS on any screen. The “Pump Status” screen appears. Figure 10: “Pump Status” Screen During Opera ...

  • Sterling Plumbing 882.00253.00 - page 27

    4 –Pump 38-Station Controllers Ch apter 4: Operation 26 of 44 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 ...

  • Sterling Plumbing 882.00253.00 - page 28

    4 –Pump 38-Station Controllers Ch apter 4: Operation 27 of 44 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 ...

  • Sterling Plumbing 882.00253.00 - page 29

    4 –Pump 38-Station Controllers Ch apter 4: Operation 28 of 44 Reviewing and Adjusting Basic Station Settings The 4-pump, 38-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 ...

  • Sterling Plumbing 882.00253.00 - page 30

    4 –Pump 38-Station Controllers Ch apter 4: Operation 29 of 44 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, whiche ...

  • Sterling Plumbing 882.00253.00 - page 31

    4 –Pump 38-Station Controllers Ch apter 4: Operation 30 of 44 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 w ...

  • Sterling Plumbing 882.00253.00 - page 32

    4 –Pump 38-Station Controllers Ch apter 4: Operation 31 of 44 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 ...

  • Sterling Plumbing 882.00253.00 - page 33

    4 –Pump 38-Station Controllers Ch apter 4: Operation 32 of 44 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 ...

  • Sterling Plumbing 882.00253.00 - page 34

    4 –Pump 38-Station Controllers Ch apter 4: Operation 33 of 44 Figure 15: Transfer To Standby Pump Button Note: When you enter the second pump number, th e controller checks to make sure that both pumps are offline and that the standby pump has no stations assigned to it. If these conditions are not all met, erro r messages appear on the screen in ...

  • Sterling Plumbing 882.00253.00 - page 35

    4 –Pump 38-Station Controllers Ch apter 4: Operation 34 of 44 Filter cleaning Our pumps have two options available for filter cleaning; these are vacuum pulse or compressed air filter cleaning. Touching the ENABLE/DISABLE button located in the lower left hand corner of the pump setup screen will allow the operator to turn on/off these two options ...

  • Sterling Plumbing 882.00253.00 - page 36

    4 –Pump 38-Station Controllers Chapter 5: Maintenance 35 of 44 Chapter 5: Maintenance No Periodic maintenance is required on this unit. ...

  • Sterling Plumbing 882.00253.00 - page 37

    4 –Pump 38-Station Controllers Chapter 6: Configurable Settings 36 of 44 Chapter 6: Configurable Settings This section describes the proper setup of the 4 pump, 38-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 882.00253.00 - page 38

    4 –Pump 38-Station Controllers Chapter 6: Configurable Settings 37 of 44 Name Description Options Default Special convey When this option is enabled, the station’s vacuum valve remains open for the convey time, even if the station is not demanding material and is indicating that it is full. When disabled, the station’s vacuum valve opens when ...

  • Sterling Plumbing 882.00253.00 - page 39

    4 –Pump 38-Station Controllers Chapter 6: Configurable Settings 38 of 44 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 Des ...

  • Sterling Plumbing 882.00253.00 - page 40

    4 –Pump 38-Station Controllers Ch apter 7: Troubleshooting 39 of 44 Chapter 7: T roubleshooting 7-1 General Troubleshooting Problem Possible Cause Solution The control panel is not turned on. Turn on the control panel. Fuse/circuit breaker in the power drop is blown/tripped. Replace/reset. The control panel doesn’t light up at all Control power ...

  • Sterling Plumbing 882.00253.00 - page 41

    4 –Pump 38-Station Controllers Ch apter 7: Troubleshooting 40 of 44 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 follo ...

  • Sterling Plumbing 882.00253.00 - page 42

    4 –Pump 38-Station Controllers Chapter 8: Appendix 41 of 44 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 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 882.00253.00 - page 43

    4 –Pump 38-Station Controllers Chapter 8: Appendix 42 of 44 8-3 Drawings and Diagrams Figure 17: 4 pump 38 station Controller with 6" Display Also, review electrical drawings supplied in the packet with this manual. 8-4 Spare Parts List Quantity Part Number Description 1 A0569874 AB 20A Power Supply, 24VDC, #1606-XL480EP 1 A0569870 Relay Mag ...

  • Sterling Plumbing 882.00253.00 - page 44

    4 –Pump 38-Station Controllers Chapter 8: Appendix 43 of 44 8-5 Returned Material Policy Credit 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 returned material purchased from the manu ...

  • Sterling Plumbing 882.00253.00 - page 45

    4 –Pump 38-Station Controllers Chapter 8: Appendix 44 of 44 8-7 Controller Identification (Serial Number) Tag (Located on the side of the controller box) 8-8 Technical Assistance (Contact Information) Parts Department Call toll-free 7am–5pm CST [ 800 ] 423- 3183 or call [414] 354-0970, Fax [414] 354-6 421 The ACS Customer Service Group w ill pr ...

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