Sterling SCC 4-38 Conveying System Operation, Installation, and Service Manual

SCC4-38

Conveying Systems

4-Pump 38-Station Controllers

Operation, Installation, and Service Manual

Sterling

5200 W. Clinton Ave.

Milwaukee, WI 53223

Tel. (414) 354-0970

Fax (414) 354-6421 www.sterlco.com

Part No. A0565547 Bulletin No. SM2-615

12/12/03

Write down your unit serial number(s) here for future reference

Model #

________________

________________

________________

________________

Serial #

________________

________________

________________

________________

Performance figures stated in this manual are based on a standard atmosphere of 59°F

(15°C) at 29.92” Hg (1,014 millibars) at sea level, using 60 Hz power. Altitude is an important consideration when specifying vacuum conveying components. Sterling can advise you on proper selection and sizing of systems for your operating environment.

Sterling is committed to a continuing program of product improvement. Specifications, appearance, and dimensions described in this manualare subject to change without notice.

© Copyright

Sterling

2003

All rights reserved. Effective 12/12/2003 Part No.

A0560966 Bulletin No. SM2-615

Page 2 of 60

Please note that our address and phone information has changed.

Please reference this page for updated contact information.

These manuals are obsolete and are provided only for their technical information, data and capacities.

Portions of these manuals detailing procedures or precautions in the operation, inspection, maintenance and repair of the products may be inadequate, inaccurate, and/or incomplete and shouldn’t be relied upon. Please contact the ACS Group for more current information about these manuals and their warnings and precautions.

Parts and Service Department

The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications, which will maximize your equipment’s performance and efficiency. To assist in expediting your phone or fax order, please have the model and serial number of your unit when you contact us. A customer replacement parts list is included in this manual for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service.

For immediate assistance, please contact:

•

North, Central and South America, 8am – 5pm CST +1 (800) 483-3919 for drying, conveying, heating and cooling and automation. For size reduction: +1 (800) 229-2919.

North America, emergencies after 5pm CST (847) 439-5855

North America email: [email protected]

•

Mexico, Central & South America

Email: [email protected]

•

Europe, Middle East & Africa +48 22 390 9720

Email: [email protected]

•

India +91 21 35329112

Email: [email protected]

• Asia/Australia +86 512 8717 1919

Email: [email protected]

Sales and Contracting Department

Our products are sold by a worldwide network of independent sales representatives. Contact our Sales Department for the name of the sales representative nearest you.

Let us install your system. The Contract Department offers any or all of these services: project planning; system packages including drawings; equipment, labor, and construction materials; and union or non-union installations.

For assistance with your sales or system contracting needs please Call:

North, Central and South America +1 (262) 641-8600 or +1 (847) 273-7700 Monday–Friday, 8am–5pm CST

Europe/Middle East/Africa +48 22 390 9720

India +91 21 35329112

Asia/Australia +86 512 8717 1919

Facilities:

ACS offers facilities around the world to service you no matter where you are located. For more information, please visit us at www.acscorporate.com

United States:

ACS Schaumburg – Corporate Offices

1100 E. Woodfield Road

Suite 588

Schaumburg, IL 60173

Phone: + 1 847 273 7700

Fax: + 1 847 273 7804

ACS New Berlin – Manufacturing Facility

2900 S. 160 th

Street

New Berlin, WI 53151

Phone : +1 262 641 8600

Fax: + 1 262 641 8653

Asia/Australia:

ACS Suzhou

109 Xingpu Road SIP

Suzhou, China 215126

Phone: + 86 8717 1919

Fax: +86 512 8717 1916

Europe/Middle East/Africa:

ACS Warsaw

Ul. Dzia

ł

kowa 115

02-234 Warszawa

Phone: + 48 22 390 9720

Fax: +48 22 390 9724

India

ACS India

Gat No. 191/1, Sandbhor Complex

Mhalunge, Chakan, Tal Khed,

Dist. Pune 410501, India

Phone: +91 21 35329112

Fax: + 91 20 40147576

Table of Contents

1 General Information.......................................................................... 9

1-1 Equipment Function......................................................................................9

1-2 Necessary Documents .................................................................................9

1-3 System Capabilities ......................................................................................9

1-4 Equipment Cycle ........................................................................................10

1-5 Models Covered by this Manual .................................................................10

2 Safety ............................................................................................... 12

2-1 Work Rules .................................................................................................12

2-2 Tools and Equipment Needed ....................................................................12

2-3 Safety Considerations ................................................................................12

2-3-1 Reporting a Safety Defect ..............................................................13

2-4 General Responsibility................................................................................13

2-5 Operator Responsibility ..............................................................................14

2-6 Maintenance Responsibility........................................................................14

2-7 Safety Devices............................................................................................15

2-7-1 Safety Circuit Standards.................................................................15

2-7-2 Fail Safe Operation ........................................................................15

2-7-3 Safety Device Lock-Outs................................................................16

3 Shipping Information...................................................................... 17

3-1 Unpacking and Inspection ..........................................................................17

3-2 In the Event of Shipping Damages .............................................................17

3-3 Parcel Post Shipment .................................................................................17

3-4 United Parcel Service Shipment.................................................................18

3-5 If the Shipment is Not Complete.................................................................18

3-6 If the Shipment is Not Correct ....................................................................18

3-7 Returns .......................................................................................................18

4 Installation....................................................................................... 19

4-1 Installing the Sterling Control Panel ...........................................................19

4-2 Making Electrical Connections ...................................................................19

4-3 Making Sterling Control Panel Power Drop Wiring Connections................19

4-4 Connecting the Control Panel to Vacuum Hoppers....................................19

4-5 Connecting the Control Panel to the Pump Package .................................20

5 Using the Standard 6” Touch Screen ........................................... 21

5-1 Introduction.................................................................................................21

5-2 Setup ..........................................................................................................21

5-2-1 Setting Up the System....................................................................21

5-2-1-1 Setting the Number of Stations and the Number of Pumps ...... 21

5-2-1-2 Setting Up Alarm Silences ........................................................ 23

5-2-1-3 Setting Up Pump Staging.......................................................... 24

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5-2-2 Setting Up Stations.........................................................................24

5-2-2-1 Setting Up a Single Station ....................................................... 25

5-2-3 Setting Up Pumps ..........................................................................27

5-2-3-1 Setting Up a Single Pump......................................................... 27

5-2-4 Finishing Setup: Setting Up Passwords .........................................29

5-2-4-1 Setup Password........................................................................ 29

5-2-4-2 Operator Password ................................................................... 29

5-2-5 Starting the System for the First Time............................................31

5-3 General Operation ......................................................................................32

5-3-1 Overview ........................................................................................32

5-3-2 Basic Tasks ....................................................................................32

5-3-2-1 Reviewing Station Status .......................................................... 32

5-3-2-2 Reviewing Pump Status............................................................ 34

5-3-2-3 Logging On and Logging Off..................................................... 35

5-3-2-4 Enabling and Disabling Stations and Pumps ............................ 36

5-3-2-5 Starting and Stopping the System ............................................ 37

5-3-2-6 Reviewing and Adjusting Basic Station Settings....................... 38

5-3-2-7 Navigating among the “Station Operator” Screens ................... 39

5-3-2-8 Adjusting Convey Time and Dump Delay ................................. 39

5-3-2-9 Activating and Stopping Priority Convey for a Station .............. 40

5-3-3 Advanced Tasks.............................................................................41

5-3-3-1 Reviewing and Resetting a Pump Hour Meter.......................... 41

5-3-3-2 Transferring Stations to a Standby Pump ................................. 42

5-3-4 Alarms ............................................................................................45

5-3-4-1 Reviewing Alarms ..................................................................... 45

5-3-4-2 Silencing Alarms ....................................................................... 45

6 Maintenance .................................................................................... 46

7 Configurable Settings..................................................................... 47

7-1 Options for Station Setup ...........................................................................47

7-2 Options for Pump Setup .............................................................................49

8 Troubleshooting ............................................................................. 50

8-1 General Troubleshooting ............................................................................50

8-2 Alarms ........................................................................................................51

8-2-1 Station Alarms ................................................................................51

8-2-2 Pump Alarms..................................................................................51

8-2-3 System Alarms ...............................................................................51

9 Options ............................................................................................ 52

10 Spare Parts List .............................................................................. 53

10-1 Recommended Spare Parts List.................................................................53

11 Technical Assistance ..................................................................... 54

11-1 Contact Information for Technical Assistance ............................................54

11-2 Returned Material Policy ............................................................................55

11-2-1Credit Returns ................................................................................55

11-2-2Warranty Returns ...........................................................................55

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11-3 Warranty .....................................................................................................56

12 Safety Tag Information ................................................................... 57

12-1 Controller Safety Tags................................................................................57

12-2 Controller Identification (Serial Number) Tag .............................................57

13 Appendix ......................................................................................... 58

Auxiliary Equipment for the Process Industries ...................................................60

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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 .......................................................... 22

4 6” System Setup Screen ..................................................................................... 23

5 6” “Station Status” Screen ................................................................................. 25

6 6” “Station Operator” Screen Before Setup...................................................... 26

7 6” “Station Setup” Screen .................................................................................. 26

8 6” “Pump Status” Screen.................................................................................... 27

9 6” Pump Setup Screen Before Setup................................................................. 28

10 6” “Station Status” Screen During Operation................................................... 33

11 6” “Pump Status” Screen During Operation..................................................... 34

12 6” “Password Entry” Screen .............................................................................. 36

13 6” “Station Operator” Screen ............................................................................. 38

14 6” Pump Setup Screen ........................................................................................ 41

15 6” “Transfer To Standby Pump” Screen............................................................ 43

16 6” Transfer To Standby Pump Button................................................................ 43

17 6” Alarm Log Screen ........................................................................................... 45

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Safety Considerations

Sterling SCC conveying systems are designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes.

To avoid possible personnel injury or equipment damage when installing or operating this equipment, always use good judgment and follow these safe practices:

;

Follow all SAFETY CODES.

;

Wear SAFETY GLASSES and WORK GLOVES.

;

Use care when LOADING, UNLOADING, RIGGING, or MOVING this equipment.

;

OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment. It is a good idea to remove the fuses and carry them with you.

;

GROUND your SCC4-38 system properly before applying power.

;

Use extreme caution when working with your Sterling

SCC4-38 system. HIGH VACUUM can be dangerous.

Keep body parts, tools, clothing, and debris away from vacuum inlets.

;

Do not jump or bypass any electrical safety control.

;

Do not restore power until you remove all tools, test equipment, etc.

;

Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment.

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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 European Facility:

ACS-EUROPE

Daniels Industrial Estate

BATH ROAD

Stroud, Gloucestershire, England

GL5 3TJ

Phone: (44) 1453 768980

Fax: (44) 1453 768990

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Sterling conveying systems create vacuum for conveying pelletized or granular material in a central material handling system.

A typical use is an in-plant distribution system for plastic processing plants.

The documents below are necessary for proper installation, operation and maintenance of Sterling conveying systems.

You can obtain additional copies from the Service

Department at Sterling. Make sure that the appropriate

personnel are familiar with these documents:

• This product manual.

• The Sterling SPD/SPC product manual.

• Electrical schematic and connection diagrams.

• Blower and electric motor information sheets.

• Operation and Installation manuals for all electrical components.

Sterling central vacuum systems are as varied as the applications they service. The tubing and equipment furnished in a Sterling system are designed to convey the material(s) specified at the time of purchase at specific rates and distances.

Sterling can advise you on your system capabilities based on system makeup, distance, material, and conveying rates you want.

System capacity is directly affected by the pressure drop in the overall system, such as number of material line bends, pipe length, Y-tubes, T-tubes, etc.

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Use the minimum effective amount of vinyl flex hose to maximize material line efficiency. Keep material lines as straight as possible. Refer to the Sterling SPD/SPC Product

Manual (Sterling Part No. A0571050) for installation recommendations.

Important!

Vacuum leaks occurring anywhere in your system reduce capacity.

Sterling material conveying systems are used for automatic pneumatic handling of most free-flowing, dry, pelletized, or granular materials. Material characteristics determine the type of equipment needed to convey the material.

1-5 Models Covered by this Manual

Sterling SCC4-38 38-Station Controller

• Programmable Logic Controller.

• 24 VDC control circuits.

• Easy-to-use touch screen operator interface terminal.

• Optional audible/visual alarm.

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30”

Figure 1: SCC4/38 Controller with 6" Display

24”

6”

* Depth dimension is 10”

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2 Safety

The installation, operation, and maintenance of this equipment must be conducted in accordance with all applicable work and safety codes for the installation location. This may include, but is not limited to OSHA, NEC, CSA, SPI, and any other local, national, and international regulations.

;

Read and follow these operating instructions when installing, operating, and maintaining this equipment. If the instructions become damaged or unreadable, additional copies are available from Sterling.

;

Only qualified personnel familiar with this equipment should work with this system.

;

Work only with approved tools and devices.

;

Disconnect and lock out power while working on this equipment.

2-2 Tools and Equipment Needed

These tools and equipment are necessary for installation:

;

Hand tools.

;

Wire, conduit, and fittings for wiring runs.

;

Anchor bolts with nuts and washers or red head-type anchors.

The terms NOTICE, CAUTION, WARNING, and DANGER have specific meanings in this manual.

NOTICE is used to indicate a statement of company policy directly or indirectly related to the safety of personnel or protection of property.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

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2-3-1

DANGER indicates an imminently hazardous situation which, 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 equipment damage could result, or provides additional information to make a step or procedure easier to understand. Disregarding information marked IMPORTANT would not be likely to cause personal injury.

Reporting a Safety Defect

If you believe that your equipment has a defect that could cause injury, you should immediately discontinue its use and inform Sterling.

The principle factors that can result in injury are failure to follow proper operating procedures (i.e. lockout/tagout), or failure to maintain a clean and safe working environment.

No mater who you are, safety is important. Owners, operators and maintenance personnel must realize that every day, safety is a vital part of their jobs.

If your main concern is loss of productivity, remember that production is always affected in a negative way following an accident. The following are some of the ways that accidents can affect your production:

• Loss of a skilled operator (temporarily or permanently)

• Breakdown of shop morale

• Costly damage to equipment

• Downtime

An effective safety program is responsible and economically sound.

Organize a safety committee or group, and hold regular meetings. Promote this group from the management level.

Through this group, the safety program can be continually reviewed, maintained, and improved. Keep minutes or a record of the meetings.

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Hold daily equipment inspections in addition to regular maintenance checks. You will keep your equipment safe for production and exhibit your commitment to safety.

Please read and use this manual as a guide to equipment safety. This manual contains safety warnings throughout, specific to each function and point of operation.

The operator’s responsibility does not end with efficient 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 incentive rates, or through a casual attitude toward machinery formed over a period of months or years.

Your employer probably has established a set of safety rules in your workplace. Those rules, this manual, or any other safety information will not keep you from being injured while operating your equipment.

Learn and always use safe operation. Cooperate with coworkers to promote safe practices. Immediately report any potentially dangerous situation to your supervisor or appropriate person.

Proper maintenance is essential to safety. If you are a maintenance worker, you must make safety a priority to effectively repair and maintain equipment.

Before removing, adjusting, or replacing parts on a machine, remember to turn off all electric supplies and all accessory equipment at the machine, and disconnect and lockout electrical power. Attach warning tags to the disconnect switch.

Be sure that all non-current carrying parts are correctly connected to earth ground with an electrical conductor that complies with current codes. Install in accordance with national and local codes.

When you have completed the repair or maintenance procedure, check your work, remove your tools. Rigging, and handling equipment.

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2-7-1

2-7-2

This section includes information on safety devices and procedures that are inherent to the SCC4/38 Controller. This manual is not intended to supersede or alter safety standards established by the user of this equipment. Instead, the material contained in this section is recommended to supplement these procedures in order to proved a safer working environment.

At the completion of this section, the operator and maintenance personnel will be able to do the following:

• Identify and locate specific safety devices.

• Understand the proper use of the safety devices provided.

• Describe the function of the safety device.

Safety Circuit Standards

Safety circuits used in industrial systems protect the operator and maintenance personnel from dangerous energy. They also provide a means of locking out or isolating the energy for servicing equipment.

Various agencies have contributed to the establishment of safety standards that apply to the design and manufacture of automated equipment. The Occupational Safety and Health

Administration (OSHA) and the Joint Industrial council (JIC) are just a few of the organizations that have joined with the plastics industry to develop safety standards.

Every effort has been made to incorporate these standards into the design of the conveying system; however, it is the responsibility of the personnel operating and maintaining the equipment to familiarize themselves with the safety procedures and the proper use of any safety devices.

Fail Safe Operation

If a safety device or circuit should fail, the design must be such that the failure causes a “Safe” condition. As an example, a safety switch must be a normally open switch.

The switch must be held closed with the device it is to protect. If the switch fails, it will go to the open condition, tripping out the safety circuit.

At no time should the safety device fail and allow the operation to continue for example, if a safety switch is

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guarding a motor, and the safety switch fails, the motor should not be able to run.

2-7-3 Safety Device Lock-Outs

Some safety devices disconnect electrical energy from a circuit. The safety devices that are used in the SCC4-38

Controller are primarily concerned with electrical power disconnection.

WARNING!

Always disconnect and lockout all electrical power and pneumatic

(i.e. compressed air) sources prior to servicing the SCC4-38

Controller. Failure to do so may result in serious injury. No one but the person who installed the lockout may remove it.

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3-1 Unpacking and Inspection

You should inspect your Sterling SCC4-38 controller for any possible shipping damage. If the container and packing materials are in re-usable condition, save them for reshipment if necessary.

Thoroughly check the equipment for any damage that might have occurred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc. In case of breakage, damage, shortage, or incorrect shipment, refer to the following sections.

3-2 In the Event of Shipping Damages

Important!

According to the contract terms and conditions of the Carrier, the responsibility of the Shipper ends at the time and place of shipment.

;

Notify the transportation company’s local agent if you discover damage.

;

Hold the damaged goods and packing material for the examining agent’s inspection. Do not return any goods to Sterling before the transportation company inspection and authorization.

;

File a claim against the transportation company.

Substantiate the claim by referring to the agent’s report. A certified copy of our invoice is available upon request. The original Bill of Lading is attached to our original invoice. If the shipment was prepaid, write us for a receipted transportation bill.

;

Advise Sterling regarding your wish for assistance and to obtain an RMA (return material authorization) number.

3-3 Parcel Post Shipment

Notify Sterling at once in writing, giving details of the loss or damage. This information is required for filing a claim with our insurance company.

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Hold the damaged goods with the container and packing materials for possible inspection by postal authorities.

3-4 United Parcel Service Shipment

;

Contact your local UPS office regarding damage and insurance claims.

;

Retain the container and packing.

;

Notify Sterling at once.

3-5 If the Shipment is Not Complete

Check the packing list. The apparent shortage may be intentional. Back-ordered items are noted on the packing list. You should have:

;

Sterling SCC4-38; 38-station controller

;

Bill of Lading

;

Packing list

;

Operating and Installation packet

;

Electrical schematic and panel layout drawings

;

Component instruction manuals

Re-inspect the container and packing material to see if you missed any smaller items during unpacking. Determine that the item was not inadvertently taken from the area before you checked in the shipment. Notify Sterling immediately of the shortage.

3-6 If the Shipment is Not Correct

If the shipment is not what you ordered, contact Sterling

immediately. For shipments in the United States and

Canada, call 1 (414) 354-0970; for all other countries, call

001 (414) 354-0970. Include the order number and item.

Hold the items until you receive shipping instructions.

3-7 Returns

Important!

Do not return any damaged or incorrect items until you receive shipping instructions from Sterling

.

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4 Installation

4-1 Installing the Sterling Control Panel

Note: Before you mount the panel, consider how you run wiring to the vacuum hoppers, the filter chamber atmospheric valve (if so equipped) and the pump motor starter(s), vacuum switch(es), and vent valve(s).

Mount the panel on a flat, vertical area. It should be a visible area that gives your operator access to the control. The panel requires a low voltage power drop as listed on the serial tag.

4-2 Making Electrical Connections

Refer to local electrical codes, the schematic and connection diagrams supplied with this unit and the serial tag for wiring considerations. Run all wiring in conduit if codes require it.

4-3 Making Sterling Control Panel Power Drop Wiring

Connections

Hardwire the input power at 110/1/50-60 VAC or 230V/1/50-

60 VAC, depending on the specifications, which are located on the Sterling Control Panel Serial Tag. The main power switch is located on the front of the enclosure.

Important!

Sterling recommends that you protect PLC memory by providing the control panel with a dedicated circuit, a true earth ground, and a spike/surge protector.

4-4 Connecting the Control Panel to Vacuum Hoppers

1. On 24 VDC control voltage systems, run a common +24

VDC wire and a common 0 (zero) VDC wire from the controller to each vacuum hopper in the SCC system.

2. On all systems, run two wires to each vacuum hopper: one each from the controller to the Bin-Full switch (LS) and to the Atmospheric/Sequence-T solenoid (SOL) valve.

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3. Make sure that the solenoid and the proximity switch (if supplied) on vacuum hoppers are the same voltage (24

VDC) as the SCC control panel voltage. Consult the control panel serial tag and the solenoid valve nameplates.

4. Wire size depends on control voltage, distance, number of vacuum hoppers, and the number of wires in each raceway. Consult a qualified electrician.

5. Properly ground each hopper to reduce static build up generated by material conveying.

4-5 Connecting the Control Panel to the Pump Package

1. Wire the pump package motor starter coil (M) to the terminal provided in the SCC control panel enclosure.

2. Wire the pump package vacuum relief valve solenoid

(SOL A) to the terminal provided in the SCC control panel enclosure.

3. Wire the pump package vacuum switch (VS) to the terminal located in the SCC control panel enclosure.

4. On 24 VDC control voltage systems, run a common +24

VDC wire and a common 0 (zero) VDC wire from the controller to each pump package in the SCC system.

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5 Using the Standard 6” Touch Screen

5-1 Introduction

This chapter gives the procedures for configuring your SCC

4-38 controller.

Configuration of your SCC4-38 controller includes setting the number of stations and pumps, setting variables such as convey time and blow-back interval, and setting up passwords. Sterling recommends that you carry out these procedures in the order given here.

5-2 Setup

Important!

Before carrying out these procedures, install all equipment as described in Chapter 4: “Installation”, and in the manual Sterling

SPD/SPC Series Conveying Systems.

5-2-1 Setting Up the System

5-2-1-1 Setting the Number of Stations and the Number of Pumps

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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), touch

STATIONS ACTIVE A keypad pops up.

3. Enter the total number of stations (1-38) to be controlled by the system. Use CLR to erase any mistakes. Use

ENT to enter the value. The keypad disappears, and the new setting appears under STATIONS ACTIVE.

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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 ENT to enter the value. The keypad disappears, and the new setting appears under PUMPS ACTIVE.

5-2-1-2 Setting Up Alarm Silences

When an alarm occurs, a horn sounds and a strobe light flashes at each installed central alarm. An alarm banner appears in the center of the screen. An alarm message and

Silence button are on the banner. Touching this button

silences the horn and turns off the lights for configurable periods of time and causes the alarm banner to disappear.

You can set different lengths of time for keeping the horn silent and keeping the light turned off. If a new alarm occurs, the horn sounds and the light turns on again.

To set the lengths of time for suppressing the alarm strobe and horn, complete the following steps:

1. Go to the “System Setup” screen by touching the

SYSTEM SETUP button on any screen.

2. On the “System Setup” screen (Figure 4), touch the

STROBE SUPPRESS button. A keypad pops up.

Figure 4: 6” System Setup Screen

3. Enter the number of minutes (between 0 and 99) that you want the strobe lights to stay off. If you want the light to stay on as long as the alarm persists, change the setting to 0. If you want the light to stay off until a new alarm occurs, enter 99 in the keypad. Use CLR to erase any

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mistakes. Use ENT to enter the value. The keypad disappears 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 off. If you want the horn to stay on as long as the alarm persists, change the setting to 0. If you want the horn to stay off until a new alarm occurs, enter 99 in the keypad. Use CLR to erase any mistakes.

Use ENT to enter the value. The keypad disappears and the new setting appears under HORN SILENCE.

5-2-1-3 Setting Up Pump Staging

To avoid an excessive power demand at your facility when the conveying system starts up, you can stagger the times at which pumps start. Whenever a demand would cause two pumps to start simultaneously, your choice for pump staging sets the delay between the start of one pump and the start of the next. The factory default is a delay of three seconds. You need to change this setting only if this delay is too long or too short for your facility.

To set the delay between the start of one pump and the next, complete the following steps:

5-2-2

1. Go to the “System Setup” screen by touching the

SYSTEM SETUP button on any screen.

2. Touch the PUMP STAGING button. A keypad pops up.

3. Enter the number of seconds (between 0 and 99) for the length of the delay between the start of one pump and the next. Use CLR to erase any mistakes. Use ENT to enter the value. The keypad disappears, and the new setting appears under PUMP STAGING.

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 pages 47–48 discusses the individual choices.

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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 hold it for several seconds. The “Station Operator” screen opens.

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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 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 new value.

Keypad entry works as with many ATM machines

the first digit you enter initially appears to the right of the decimal point and moves to the left as you enter more digits. You do not need to use the decimal point. Use

CLR to erase any mistakes. Use ENT to enter the value.

The keypad disappears, and the “Station Setup” screen shows the new value in the selected white box.

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Touching RESET TO DEFAULTS in the lower right of the screen changes all the settings for this station back to their factory defaults.

See pp. 46–49 for details on the options and their default settings.

5. As appropriate, setup the rest of the stations using either of the following methods:

• 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.

5-2-3 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 49 discusses the individual choices.

5-2-3-1 Setting Up a Single Pump

1. Go to the “Pump Status“ screen if needed. To reach this screen from any other screen, touch PUMP STATUS button. The “Pump Status” screen appears:

Figure 8: 6” “Pump Status” Screen

2. Touch the icon for the pump you want to set up, and hold it for several seconds. The “Pump Setup” screen opens.

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Figure 9: 6” 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 works as with many ATM machines: the first digit you enter initially appears in the rightmost column and moves to the left as you enter more digits.

You do not need to use the decimal point. Use CLR to erase any mistakes. Use ENT to enter the value. The keypad disappears and the “Pump Setup” screen shows the new value in the selected white box.

See page 49 for details on the options and their default settings.

4. As appropriate, setup the rest of the pumps using the following method:

• Use the PREVIOUS or NEXT buttons to navigate to other pumps. Touch PREVIOUS to go to the previous “Pump Setup” screen, or touch NEXT to go to the next “Pump Setup” screen.

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5-2-4 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.

If you define a password for setup personnel, then all settings can be changed only after entering the password.

The password will be required to display the following screens:

• System Setup (to review and change system-wide settings).

• Station Setup (to review and change settings for all station options).

• Pump Setup (to review and change settings for all pump options).

If you define a password for operators, then a password will be required to carry out any function (other than reviewing station and pump status, silencing alarms, reviewing the alarm log, and looking at help screens). Entering the operator’s password will give the user access to the functions at the following screens:

• Station Status (to enable or disable a station, and start or stop system)

• Pump Status (to enable or disable a pump, and start or stop system)

• Station Operator (to adjust a station’s convey time and dump delay, activate priority convey, and review the station’s last convey time and pump assignment; depending on the options installed, the screen may also enable the operator to adjust the purge time.

Entering the setup password will give the user access to all functions.

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Note: If you want to protect the operator’s functions with a password, you must also define a setup password. If you leave the setup password undefined, then all users will have access to all functions.

If you want two different levels of password protection, you must make the passwords different from each other. If the two passwords are the same. Then any user who enters the password will have access to all functions.

To set (or remove) password protections, complete the following steps:

1. Go to the “System Setup” screen by touching the

SYSTEM button on any screen.

2. On the “System Setup” screen (Figure 4), touch the

Operator Password button or the Setup Password

button, depending on which password you want to set up.

A keypad pops up, with an entry of 0.

3. Enter up to four digits. If you want to remove password protection, enter 0 as the password. Use CLR to erase any mistakes. Use ENT to enter the value. The keypad disappears, and the “System Setup” screen shows the password you entered.

Note: When entering a password, all four digits must be supplied.

For example, if you enter a password of 2 here, you will need to enter 0002 when the controller prompts for the password.

If desired, you can also change the duration for which a password remains effective. During operation, the passwordprotected screens are available either until the user logs off or until this time elapses, whichever comes first. This feature prevents the password from remaining active if a user forgets to log off.

Note: The password timer starts when the user logs on. It expires even if the user is actively using the screens when the chosen time is up. If the timer expires, the system goes to the “Station Status” screen. Your password duration should be long enough to allow authorized users to complete their tasks but short enough to provide adequate protection against tampering.

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5-2-5

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 change. A keypad pops up.

2. Enter the number of minutes (between 1 and 99) that you want to set as the password duration. Use CLR to erase any mistakes. Use ENT to enter the value. The keypad disappears, and the “System Setup” screen shows the new setting.

Starting the System for the First Time

Once you have finished all the setup described above, you are ready to start the system. To start your system, complete the following steps.

1. At any screen, touch STATION STATUS or PUMP

STATUS on the bottom left side of the station status or

pump status screen.

2. For each station that you want to use, briefly touch its icon. The icon turns green, indicating that the station is full, or the icon turns yellow, indicating that the station needs material.

3. Touch PUMPS STATUS. The “Pump Status “screen opens (Figure 8)

4. For each pump that you want to use, briefly touch its icon. The icon turns green, indicating that the pump is ready.

5. Touch START SYSTEM in the lower left-hand corner of the screen.

6. The system starts. If any alarm messages appear on the screen, see p. 50.

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5-3-1 Overview

Your SCC4-38 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 responds to the demands in a timely fashion.

This section gives the procedures for using your controller, and it covers tasks that can be carried out with no password or with an operator’s password. The section is divided into three sub-sections:

• Basic tasks: tasks normally carried out by a station operator

• Advanced tasks: tasks normally carried out by setup personnel

• Alarms: silencing and clearing alarms

Important!

Before you carry out any of the procedures in this chapter, the system must be set up as described earlier in this chapter.

The starting point for all operations is the “Station Status” screen. To reach this screen from any other screen, touch

STATION STATUS on any screen. The “Station Status”

screen appears.

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Figure 10: 6” “Station Status” Screen During Operation

Color

Gray outline

Green

Yellow

Blue

Light blue

Purple

Blue, blinking

Red

Red outline

White

Label

Offline

Full

Demand

Convey

Dry Air

Convey

Unload

Priority

Alarm

Critical

Purge

The status of each station is color-coded. You can see an explanation of each status by using the online help. To do so from this screen, complete the following steps:

1. Touch HELP. The “HELP Menu” screen opens.

2. Touch Station States. The “Station Symbols Help” screen opens, explaining the status represented by each color.

3. When you are finished reviewing the information, touch

HELP MENU. The “Help Menu” screen opens.

The following table explains the status represented by each color at the “Station Status” screen.

Description

Station is not enabled. The controller ignores any demands or alarms.

Station is enabled and idle (full).

Station requires material.

Station is being loaded with material.

Air to convey material is coming from dry air source, rather than ambient air.

Station is dumping material into its receiver.

Station is in priority convey mode. Its pump will be temporarily dedicated to filling it as soon as possible.

Station is in alarm.

Station is in critical alarm. The controller has disabled the station until the alarm is cleared.

Air is being drawn through material lines.

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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 available at the “Station Setup” screen. See page 47 for details about each of these settings.

5-3-2-2 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 11: 6” “Pump Status” Screen During Operation

The status of each pump is color-coded. You can see an explanation of each status by using the online help. To do so from this screen, complete the following steps:

1. Touch HELP button. The “HELP Menu” screen appears.

2. Touch PUMP STATES. The “Pump Symbols Help” screen appears, explaining the status represented by each color.

3. When you are finished reviewing the information, touch

HELP MENU.

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Color

Gray outline

Green

Light Blue

Blue

Red,

Red outline

Yellow

Label

Offline

Ready

Idle

Convey

Alarm

Critical

Ramping

Up/Down

The following table explains the status represented by each color at the Station Status screen.

Description

Pump is not enabled. The controller ignores any alarms.

Pump is off, waiting for demand from a station.

Pump is on, waiting for demand from a station. If there is no demand before the end of the auto shutdown delay, the pump will turn off.

Pump is conveying material to a station.

Pump is in alarm.

Pump is in critical alarm. The controller has disabled the pump until the alarm is cleared.

Pump is in process of starting or stopping.

Additional basic information about each pump, including configuration settings and the number of hours the pump has been running, is available at the “Pump Setup” screen. For details on configuration settings, see page 49. For details on the hour meter, see page 41.

5-3-2-3 Logging On and Logging Off

Your controller may be set up to require a password for any operation (other than reviewing station and pump status, silencing alarms, reviewing the alarm log, and looking at help screens). If so, touching a button will open the “Password

Entry” keypad screen.

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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 enables or disables the requested pump or station, or it goes to the “Station Operator” screen. If you did not enter the correct password, the controller erases the entry. You can then try again. To give up, touch Return.

Note: If you have lost the password(s), contact Sterling for assistance.

Once you have logged on, the password remains active until the password expires. (Setup personnel at your facility control the number of minutes before the password expires.)

While the password is active, you can continue to carry out password-protected tasks without reentering the password. If the timer expires, the controller goes to the “Station Status” screen and you must reenter the password to continue working.

5-3-2-4 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 station or pump makes it available for use.

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Note: For a station to be available for the system, it must be

enabled at the controller’s screen and its bypass switch must

be in the “Convey” position.

To enable or disable a station (or pump), complete the following steps:

1. Go to the “Station Status” (or “Pump Status”) screen, if needed. To reach this screen from any other screen, touch STATION STATUS or PUMP STATUS button.

Each disabled station (or pump) has an icon with a status of “offline” (black with a white outline). All other statuses are enabled statuses.

2. Touch the icon for the station (or pump) briefly. The station (or pump) switches to the new state, as indicated by the color of its icon.

Note: If the “Station Operator” (or “Pump Setup”) screen appears when you touch the icon, then you have kept your finger on the screen too long. Touch STATION STATUS (or PUMP

STATUS) to return to the “Status” screen and try again.

5-3-2-5 Starting and Stopping the System

Important!

In an emergency, you can use the power switch on the front of the controller cabinet if a password is required to stop the system and you do not know the password.

Note: Normally, all the stations and pumps you want to use should be enabled before you start the system. When the system is stopped, icons for enabled stations are green or yellow and icons for enabled pumps are green. Enabling stations and pumps is described on p. 36.

A button to start and stop the system is located in the lower left of the “Station Status” and “Pump Status” screens. When the system is off, the button is red and reads START

SYSTEM. When the system is on, the button is green and

reads STOP SYSTEM. Depending on the setup at your facility, the system may prompt for a password when you touch this button.

Note: If conveying does not begin when you start the system, check to make sure that all needed pumps are enabled. If they are, check that all needed stations are enabled.

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5-3-2-6 Reviewing and Adjusting Basic Station Settings

The Sterling controller has a “Station Operator” screen for each station, as shown below. This screen enables you to review and adjust all basic settings for the station.

To reach the “Station Operator” screen, complete the following steps:

1. Go to the “Station Status” screen, if needed. To reach this screen from any other screen, touch STATION

STATUS button.

2. Touch and hold the icon for the station, until the controller either prompts for the password or displays the “Station

Operator” screen. Once you have entered the password

(if needed), the “Station Operator” screen appears.

Figure 13: 6” “Station Operator” Screen

Buttons in white are settings that you can adjust at this screen. Boxes in black are for display only. If a pump assignment or purge time can be changed from operator screen, this must be done at the “Station Setup” screen.

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5-3-2-7 Navigating among the “Station Operator” Screens

The controls at the top of the screen enable you to move among 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 the screen for Station 14), touch PREVIOUS.

• To display the screen for the next higher-numbered station

(for example, to move from the screen for Station 15 to the screen for Station 16), touch Next.

• To exit to the “Station Status” (or “Pump Status”) screen, touch STATION STATUS (or PUMP STATUS).

5-3-2-8 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, whichever comes first.)

Unload time is the length of time allowed for material to drain from the station into its receiver. During this time, the controller does not attempt to deliver any more material to the station.

The settings for convey time and unload time should match the times actually required to fill and empty the station. The following problems may occur if these settings are incorrect:

• Material is backing up and causing “high vacuum” alarms

(for time-fill stations only): Convey time is too long.

• System is not keeping up with the demand for material:

Convey time is too short, or dump delay is too long.

For your reference, the “Station Operator” screen shows the length of time the controller actually spent conveying material during the most recent delivery under Last Convey.

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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 convey time or unload time. Use CLR to erase any mistakes. Use ENT to enter the value. The new setting appears under

CONVEY TIME (or UNLOAD TIME).

5-3-2-9 Activating and Stopping Priority Convey for a Station

Important!

Before activating priority convey, make sure that all other stations using the same pump have adequate material in reserve to continue operation. No material will be conveyed to these stations during priority convey.

If you want the controller to fill a specific station with material immediately, you can activate “priority convey” for that station. When you do so, the controller temporarily dedicates the station’s pump to it, ignoring demands from other stations assigned to that pump. Once the chosen station is full, normal operation resumes.

You can also use this feature to give one station a “head start” by conveying a few loads to it and then stopping the priority convey.

No more than one station for a given pump can be in “priority convey” at once. To activate priority convey, complete the following steps:

1. Go to the “Station Operator” by touching and holding a station icon, or go to the “Station Setup” screen.

2. Touch PRIORITY CONVEY ACTIVATE. The button changes to PRIORITY CONVEY ACTIVE until the station’s demand has been satisfied (or you stop the priority convey). The controller begins filling the chosen station only (after finishing any conveying already in progress).

3. To stop a priority convey before the station is completely full, Touch the PRIORITY CONVEY ACTIVE button. The button changes to PRIORITY CONVEY ACTIVATE. The

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controller finishes the current convey, if any, and resumes normal operation.

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 off with the setup password is the same as for logging on with the operator password; see p. 35 for step-by-step instructions for logging on and off.

5-3-3-1 Reviewing and Resetting a Pump Hour Meter

The controller keeps two meters for the length of time a pump has run. One, like a car’s odometer, keeps a running total and cannot be reset. The other, like a car’s trip odometer, counts the running time since the last reset.

To review and reset the hour meter, complete the following steps:

1. At any screen, touch the PUMP STATUS button.

2. Touch and hold the icon for the pump. The “Pump Setup” screen opens.

Figure 14: 6” Pump Setup Screen

The box labeled x Hours shows the running time since the last reset. The box labeled total x Hours shows total running time.

To reset the resettable meter, touch Hour Meter Reset. The time above x Hours changes to 0.

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5-3-3-2 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 the source pump and the standby pump, and the standby pump must have no stations already assigned to it.

The transfer operation at the controller’s touch screen merely changes the pump assignment for every station on the failed pump. It does not transfer any pump settings for auto shutdown delay, alarms, or blow-back to the standby pump. Mechanical connections must be changed manually.

To transfer stations from a pump to a standby pump, complete the following steps:

1. At any screen, touch PUMP STATUS button. The “Pump

Status” screen appears.

2. Both the source pump and the standby pump must be offline. If either pump is any other state, disable it by touching its icon briefly. The icon becomes black with a white outline.

3. Move the vacuum hose from the failed pump to the standby pump, and carry out any other mechanical procedures needed to use the standby pump.

4. At the “Pump Status” screen, touch and hold the icon for any pump until the “Pump Setup” screen appears.

5. At the “Pump Setup” screen, touch Transfer Stations To

Standby Pump. The “Transfer to Standby Pump” screen

opens:

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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 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, error messages appear on the screen instead of MOVE button. If you get an error message, first check to make sure that you have entered the correct numbers and reenter if necessary. If another error occurs, see the Standby Pump Errors section on page 44.

7. Touch the MOVE button. When transfer is complete, stations moved will appear on the screen.

8. Touch RETURN, to return to the “Pump Setup” screen.

9. Put the standby pump online by briefly touching its icon.

The icon changes color to show the new status, and the

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system begins using the pump. In addition, all “Station

Operator” and “Station Setup” screens show the new pump assignment.

Standby Pump Errors

If the error message tells you to disable the source pump and/or the standby pump, touch RETURN at this screen, then PUMP STATUS at the “Pump Setup” screen. Take the pumps offline and then return to the “Transfer to Standby

Pump” screen.

If the error message tells you that the standby pump has stations assigned, you must either use a different standby pump or you must remove the pump assignment for all stations assigned to the standby pump. To remove the assignments, complete the following steps:

1. Touch RETURN at the “Standby Pump” screen, and then touch STATION STATUS.

2. Touch and hold a station icon to get to the “Station

Operator” screen.

3. Then touch STATION SETUP to go to the “Station

Setup” screen.

4. Use PREVIOUS and NEXT to review all pump assignments.

5. Where necessary, choose ASSIGNED TO PUMP to set station assignments to 0 (unassigned). Then return to the

“Transfer to Standby Pump” screen.

6. Touch left side pump value and enter the number of the pump whose hoppers are to be transferred.

7. Touch right side pump value and enter destination pump number.

Filter cleaning

Sterling 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 or disable the filter cleaning option altogether.

Note: Each type of filter cleaning requires optional equipment that must be purchased and installed prior to enabling this option.

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5-3-4 Alarms

To review your system’s alarms, touch Alarms on any screen. The “Alarm Log” screen appears, with the newest alarm 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.

Whenever a new alarm occurs, your controller sounds the horn and turns on the strobe light at each central alarm.

Touch SILENCE on the alarm message banner that appears when a new alarm occurs.

The horns and lights at the central alarms turn off. Your controller has separate, configurable settings for how long the horns should remain silent and how long the light should remain off. If the alarm condition still exists when either of these times elapses, the corresponding device (horn or light) turn on again and the alarm message banner appears. If a new alarm occurs, both horns and lights turn on. See page

50 for a list of alarms and their possible causes.

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6 Maintenance

No Periodic maintenance is required on this unit.

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This section describes the proper setup of the SCC4-38 control system parameters. These parameters are operator changeable; however, these items should require setup only during the initial installation. Only authorized personnel should change them.

Many of the variables and setup parameters have been preset at the factory and do not need to be changed.

However, this section of the manual will address all of the setup parameters that were available at the time of printing.

The purpose of this is to familiarize the reader with all the setup parameters and their usage.

7-1 Options for Station Setup

Name

Conveying Options

Convey time

Description

(Last convey time)

Unload delay

Dry air

Purge

Purge time

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, whichever comes first.)

Adjust this value to match the actual time needed to fill the station.

Display only. Length of time the station’s vacuum valve was open for receiving material during the most recent convey. This information is displayed for your reference when adjusting convey time and dump delay.

Length of time allowed for material to drain from the station into the receiver. The controller will not attempt to deliver more material to the station until this time has elapsed.

Adjust this value to match the actual time needed to drain the station. If it is set too short, the controller may attempt to refill the station before it is empty, causing material to back up and/or underusing the station’s capacity. If it is set too long, the system may be unable to keep up with your equipment’s demand for material.

When this option is enabled, dry air will be used to convey material to station (Requires additional

optional equipment.)

When this option is enabled, source air is used to cleanout the stations material line after every convey. (Requires additional optional

equipment.)

Amount of time allowed to clear material line

Options

1–999 sec.

—

1–99 sec.

disabled, enabled disabled, enabled

0-999

Default

30 sec.

—

10 sec.

disabled disabled

15 sec.

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Name

Assigned to pump n

Special convey

Name

Alarm Options

No convey

# attempts before alarm

Description

Number (address) of the pump to which this station’s vacuum line is connected.

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 there is demand from the station, and it remains open until the convey time has elapsed or material trips the volume-fill proximity switch.

Enable this option if and only if the station has no flapper.

Description

Options

0–4 (0 = not assigned) disabled, enabled

Options

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 controlled by the next setting.)

Usually this option should be enabled. At times, you may wish to disable it during operation as a stopgap measure for dealing with an alarm.

Number of attempts before alarm: the number of times the controller will attempt to convey material to a station before it issues a “no convey” alarm.

The setting for this option depends on (a) how much material your injection mold uses to make each part compared with the capacity of the receiver and (b) how important it is to keep your injection mold from running out of material and shutting down. A higher setting will give you fewer alarms, at the risk of emptying the receiver without warning. A lower setting will give more frequent alarms, at the risk of disrupting operations unnecessarily.

disabled, enabled

1–99

Default

0 disabled

Default

disabled

3

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7-2 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 5, which cover operation procedures.

Name Description

Idle Time Options

1 Idle time

Length of time the pump continues to run unloaded without demand from any station. After this time has elapsed, the pump shuts down to save power and to prevent wear on the pump.

Adjust this setting to fit the needs of your facility in trading off the energy savings against the costs associated with waiting for a pump to start up when there is a demand for material.

Alarm Options

General Pump fault

Cleaning pulses

Pulse On time

(Compressed air cleaning only)

Pulse Off time

(Vacuum Pulse cleaning only)

Vacuum time

Vacuum vent time

The control has one input/pump that you can wire to generate alarms for situations of your choosing. For example, you may have a sensor that turns on when material reaches the top of a filter-chamber waste bin. When this option is enabled, the controller issues an alarm if the sensor wired to the input for Pump

Fault turns on.

Enable this option if and only if your facility has installed a miscellaneous alarm on the input for

Pump Fault for this pump.

Pump Filter Cleaning Options

Vacuum pulsed filter cleaning

(Compressed air filter cleaning)

When this option is enabled, the controller periodically sends compressed air backward through the pump’s air filter to dislodge accumulated dust and debris.

Enable this option if and only if the pump has the equipment for compressed-air filter cleaning.

Conveys before cleaning

Number of conveying cycles to stations between filter cleanings.

Adjust this setting based on experience. The more dust and debris in your material line, the smaller this number needs to be.

Number of pulses of compressed air sent through the pump’s filter during cleaning.

If filter-cleaning is not working as desired, Sterling service may ask you to change this setting.

Number of seconds that the air compressor remains on for each pulse during filter cleaning.

If filter-cleaning is not working as desired, Sterling service may ask you to change this setting.

Number of seconds between air pulses during filter cleaning.

If filter-cleaning is not working as desired, Sterling service may ask you to change this setting.

Amount of time clearing valve is closed and vacuum increases inside filter chamber.

Amount of time clearing valve is open to allow air to reverse flow through filter.

Options

0–999 sec.

disabled, enabled disabled, vacuum pulse enabled comp air enabled

1–99

1–99

0–9.9 sec.

0–9.9 sec.

0-9.9 sec.

0-9.9 sec.

Default

45 sec.

disabled disabled

5

5

3.0 sec.

1.5 sec.

3.0 sec.

1.5 sec.

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8 Troubleshooting

Problem

The control panel doesn’t light up at all

The touch screen display doesn’t come on when the control panel is powered up.

A pump package doesn’t run, even though it is on-line and its indicator is lit.

Possible Cause

The control panel is not turned on.

Fuse/circuit breaker in the power drop is blown/tripped.

Control power switch is broken.

Fuse in display is blown.

Loose wiring to display.

Display is faulty.

The motor overload has tripped.

A vacuum receiver is being bypassed in the loading cycle.

Main fuse in power drop or optional fused disconnect has blown.

Motor contact is faulty.

The vacuum receiver is off-line.

Vacuum receivers are overfilling.

The convey time for the vacuum receiver is set to zero.

The field-installed station bypass switch is simulating a Bin Full condition.

The field-installed station bypass switch is bad or mis-wired.

The vacuum receiver was assigned to the wrong pump during setup.

Conveying times are too long

(Time Fill Mode only).

Maximum conveying times are too long, and the PLC does not recognize the Vacuum Receiver

Full Proximity Switch(es).

Solution

Turn on the control panel.

Replace/reset.

Replace.

Replace.

Repair.

Replace.

Reset the overload and check the motor for the proper amp draw on tag.

Replace the fuse.

Repair or replace as required.

Use the controller to put the vacuum receiver on-line.

Use the controller to enter a longer convey time.

Normal operation. Set the switch so the vacuum receiver is back in the loading sequence.

Repair, replace, or re-wire.

Repeat the setup procedure.

Time the vacuum receiver (s) during loading, and set the conveying times to a few seconds less.

Check proximity sensors for proper operation and proper wiring to the PLC. Repair as needed. Reset the conveying times to a reasonable value, and adjust as needed.

Page 50 of 60

8-2 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 following tables list all alarms alphabetically, together with possible causes. A “critical” alarm is one that causes the affected device to stop.

Note: You can also see a list of alarms and their causes in the controller’s online help. To display this information, touch the color key of statuses in the upper right-hand corner of either the “Station Status” or the “Pump Status” screen, or touch

Help at any other screen. When you are finished reviewing the help, touch Return.

Alarm message

High vacuum

No convey

Not assigned (Critical)

Alarm message

Low battery

Possible cause

Material line is blocked.

Vacuum line is blocked.

Convey time is too long (time-fill station only).

Sequence valve has malfunctioned.

Vacuum switch has malfunctioned.

Note: After you have corrected the cause of this alarm, the alarm will be cleared when the controller has conveyed a full load to this station.

Material container is empty.

Material line is disconnected from material source.

Vacuum line is disconnected from station.

Take-off compartment is not adjusted properly.

Convey time is too short.

Note: As a stopgap measure, you can disable the “no convey” alarm for this station until the problem can be remedied. See pp. 48.

Station has not been assigned to a pump

Alarm message

Pump failure

(Critical)

Pump fault

Too many stations assigned to pump

(Critical)

Possible cause

Circuit breaker or overload protector has tripped.

Contactor has malfunctioned.

(Function determined by your facility.)

More than 20 stations are assigned to this pump.

Possible cause

Battery for the controller is defective.

Battery for the controller is old and drained.

Page 51 of 60

9 Options

The following is a list of options that your controller may be equipped 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 mounted and wired into the controller to indicate an alarm condition.

Ethernet Capability

Enables SCC controller to be connected to ethernet network.

Line Filter/Surge Suppressor

Recommended for additional protection of electronic control components.

Page 52 of 60

10 Spare Parts List

10-1 Recommended Spare Parts List

Quantity

1

1

1

1

1

1

5

1

Sterling Part Number

A0569874

A0569870

A0569859

A0540997

A0542210

A0544793

A0542205

A0542209

Description

AB 20A Power Supply, 24VDC, #1606-XL480EP

Relay Magnecraft #781XAXML

Filter/Grill

Fuse, MDL –1

Fuse, MDL – 5

Fuse, MDL – 15

Fuse, MDL – 2.5

Fuse, MDL - 4

Page 53 of 60

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 to

Sterling engineering design specifications, which will maximize your equipment’s performance and efficiency. To assist in expediting your phone or fax order, please have the model and serial number of your unit when you contact us. A customer replacement parts list is included in this manual for your convenience. ACS welcomes inquiries on all your Sterling parts needs and is dedicated to providing excellent customer service.

Service Department

Call toll-free 8am–5pm CST [800] 657-4679 or call [414] 354-0970

Emergencies after 5pm CST, call [847] 439-5655

Sterling has a qualified service department ready to help. Service contracts are available for most Sterling products.

Sales Department

Call [414] 354-0970 Monday–Friday, 8am–5pm CST

Sterling products are sold by a world-wide network of independent sales representatives. Contact our Sales

Department for the name of the sales representative nearest you.

Contract Department

Call [414] 354-0970 Monday–Friday, 8am–5pm CST

Let Sterling install your system. The Contract Department offers any or all of these services: project planning; system packages including drawings; equipment, labor, and construction materials; and union or non-union installations.

Page 54 of 60

Sterling

5200 W. Clinton Ave

Milwaukee, WI 53223

[414] 354-0970 • Fax [414] 354-6421

11-2 Returned Material Policy

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 Sterling is subject to 15% ($75.00 minimum) restocking charge.

4. All returns are to be shipped prepaid.

5. The invoice number and date or purchase order number and date must be supplied.

6. No credit will be issued for material that is not within the manufacturer’s warranty period and/or in new and unused condition, suitable for resale.

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 returns are to be shipped prepaid.

4. The invoice number and date or purchase order number and date must be supplied.

5. After inspecting the material, a replacement or credit will be given, at Sterling’s discretion, if the item is found to be defective in materials or workmanship, and it was manufactured by Sterling. Purchased components are covered under their specific warranty terms.

Page 55 of 60

11-3 Warranty

Sterling. 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 the factory any parts that are returned prepaid within one year of equipment shipment to the original purchaser, and which, in the Company’s opinion, are defective. Any replacement part assumes the unused portion of this warranty.

This parts warranty does not cover any labor charges for replacement of parts, adjustment repairs, or any other work.

This warranty does not apply to any equipment which, in the

Company’s opinion, has been subjected to misuse, negligence, or operation in excess of recommended limits, including freezing or which has been repaired or altered without the Company’s express authorization. If the serial number has been defaced or removed from the component, the warranty on that component is void. Defective parts become the property of the warrantor and are to be returned.

The Company is not liable for any incidental, consequential, or special damages or expense. The Company’s obligation for parts not furnished as components of its manufactured equipment is limited to the warranty of the manufacturers of said parts.

Any sales, use, excise, or other tax incident to the replacement of parts under this warranty is the responsibility of the purchaser.

The company neither assumes nor authorizes any other persons to assume for it any liability in connection with the sale of its equipment not expressed in this warranty.

Page 56 of 60

12 Safety Tag Information

12-1 Controller Safety Tags

High Voltage

Inside Enclosure

Read Operation and

Installation Manual

12-2 Controller Identification (Serial Number) Tag

(Located on the side of the controller box)

5200 W. Clinton Ave.

Milwaukee, WI 53223

Tel. (414) 354-0970

Fax (414) 354-6421

SCC CONTROL PANEL

Model No. SCC4-38 Serial No. 31K0182

115 Volt 60 Hz 1 Ph

Control Voltage 24VDC

Page 57 of 60

13 Appendix

Review electrical drawings supplied in the packet with the manual.

Page 58 of 60

Sterling 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 the factory) any parts for a period of 12 months from initial start-up or 18 months from the date of start-up, whichever is less, which, in the Company’s opinion, are defective.

This parts warranty does not cover any labor charges for replacement of parts, adjustment repairs, or any other work. This warranty does not apply to any equipment which, in the Company’s opinion, has been subjected to misuse, negligence, or operation in excess of recommended limits, including freezing or which has been repaired or altered without the Company’s express authorization. If the serial number has been defaced or removed from the component, the warranty on that component is void. Defective parts become the property of the warrantor and are to be returned.

The Company is not liable for any incidental, consequential, or special damages or expenses. The

Company’s obligation for parts not furnished as components of its manufactured equipment is limited to the warranty of the manufacturers of said parts.

Any sales, use, excise, or other tax incident to the replacement of parts under this warranty is the responsibility of the purchaser.

The company neither assumes nor authorizes any other persons to assume for it any liability in connection with the sale of its equipment not expressed in this warranty.

PO Box 245018 • 5200 West Clinton Avenue • Milwaukee, WI 53224-9518

Phone (414) 354-0970

• Fax (414) 354-6421 http://www.sterlco.com

Auxiliary Equipment for the Process Industries

PO Box 245018

5200 West Clinton Avenue

• Milwaukee, WI 53224-9518

(414) 354-0970 • Fax (414) 354-6421

Scrap

Recovery Systems

Process Heating/

Cooling

Automated Material

Parts Removal Processing