VacTrac™ Series Conveying Systems 8 • 18 • 36

VacTrac™ Series Conveying Systems 8 • 18 • 36
$3000
Operation and Installation Manual
VacTrac™ Series
Conveying Systems
8 • 18 • 36-Station Controllers
Important! Read Carefully Before Attempting to Install or Operate Equipment
8-Station Controller
18- and 36-Station Controller
SET THE VACTRAC DATE
AND TIME?
<YES/NO>
PUMP
ON/OFF
LINE
PRIORITY
CONVEY
HPR CONVEY
TIME
SYSTEM
STATUS
HOPPER
STATUS
BLOWBACK/
DUMP-DELAY
HPR
1
HPR
2
HPR
3
HPR
4
ON/OFF
LINE
ON/OFF
LINE
ON/OFF
LINE
ON/OFF
LINE
HPR
5
HPR
6
HPR
7
ON/OFF
LINE
ON/OFF
LINE
ON/OFF
LINE
Yes
1
2
3
SET THE VACTRAC DATE
AND TIME?
<YES/NO>
Start
PUMP
No
4
5
6
Stop
Help
7
8
9
Alarm
Silence
Special
Escape
0
Clear
Shift
PUMP
1
ON/OFF
LINE
HPR
8
ON/OFF
LINE
PRIORITY
CONVEY
DUMP-DELAY
PUMP
2
ON/OFF
LINE
PUMP
3
ON/OFF
LINE
SYSTEM
STATUS
BLOWBACK/
Yes
1
2
3
No
4
5
6
Stop
Help
7
8
9
Alarm
Silence
Special
Escape
0
Clear
Shift
Start
SPARE
HPR
ON/OFF
LINE
HPR
ASSIGN
PUMP
STATUS
HPR
HPR
CONVEY
TIME
STATUS
VacTrac Series
Conveying Systems
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
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27
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Part No. A0536583
Revision B
Conveying
No Convey Alarm
Material Demand
Bulletin No. WH2-605D.2
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: acsuscanadacustserv@corpemail.com
•
Mexico, Central & South America
Email: acslatinamericacustserv@corpemail.com
•
Europe, Middle East & Africa +48 22 390 9720
Email: acseuropecustserv@corpemail.com
•
India +91 21 35329112
Email: acsindiacustserv@corpemail.com
•
Asia/Australia +86 512 8717 1919
Email: acsasiacustserv@corpemail.com
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
th
2900 S. 160 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. Działkowa 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
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. AEC/Whitlock
can advise you on proper selection and sizing of systems for your operating
environment.
AEC/Whitlock is committed to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual
are subject to change without notice.
Copyright AEC/Whitlock and AEC, Inc. 2000
All rights reserved.
Effective 3/22/2000
Part No. A0536583
Revision B
Bulletin No. WH2-605D.2
Page 2
8 • 18 • 36-Station Controllers
VacTrac™ Conveying Systems
Safety Considerations
AEC/Whitlock VacTrac™ 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 VacTrac™ system properly before applying power.
; Use extreme caution when working with your AEC/Whitlock VacTrac™ 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.
VacTrac™ Conveying Systems
8 • 18 • 36-Station Controllers
Page 3
Table of Contents
1
General Information ................................................. 7
1-1
1-2
1-3
1-4
1-5
2
Shipping Information.............................................. 11
2-1
2-2
2-3
2-4
2-5
3
Unpacking and Inspection
In the Event of Shipping Damages
If the Shipment is Not Complete
If the Shipment is Not Correct
Returns
Installation............................................................... 13
3-1
3-2
3-3
3-4
3-5
3-6
3-7
Page 4
Equipment Function
Necessary Documents
System Capabilities
Equipment Cycle
Models Covered by this Manual
Work Rules
Tools and Equipment Needed
Installing the VacTrac™ Control Panel
Making Electrical Connections
Making VacTrac Control Panel Power Drop Wiring Connections
Connecting the Control Panel to Vacuum Hoppers
Connecting the Control Panel to the Pump Package
8 • 18 • 36-Station Controllers
VacTrac™ Conveying Systems
Table of Contents
4
Controller Operation .............................................. 19
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-11
4-12
4-13
4-14
4-15
4-16
4-17
5
Maintenance ............................................................ 47
5-1
5-2
6
Starting the Control for the First Time
Activating 8-Station Vacuum Hoppers
Assigning 18- and 36-Station Vacuum Hoppers to Pumps
Setting Dump Delay Times
Enabling or Disabling Pump Blowback Sequences
Setting Hopper Convey Times
Placing Installed Vacuum Hoppers On-Line
Starting the System
Shutting Down the System
Making On-the-Fly Adjustments
Using Password Protection
Setting the Time and Date
Using the System Configuration Menu
Using the System Variables Menu
Checking System Status
Enabling or Disabling Spare Pumps
Keypad Descriptions
Replacing the PLC Battery
Restoring a Lost Program
Troubleshooting ..................................................... 51
VacTrac™ Conveying Systems
8 • 18 • 36-Station Controllers
Page 5
Charts and Figures
1
2
3
4
5
Page 6
VacTrac™ 8-Station VTC8L1 Control Panel
9
VacTrac™ 18- and 36-Station Control Panel with Light Panel
10
Typical 24-Volt Junction Box Wiring Diagram
16
Typical 115-Volt Junction Box Wiring Diagram
17
VacTrac™ Control Panel Factory Presets
38
8 • 18 • 36-Station Controllers
VacTrac™ Conveying Systems
1
1-1
General Information
Equipment Function
AEC/Whitlock VacTrac™ ™ 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.
1-2
Necessary Documents
The documents below are necessary for proper installation, operation and maintenance of
VacTrac™ conveying systems. You can obtain additional copies from the AEC/Whitlock
Service Department at AEC, Inc. Make sure that the appropriate personnel are familiar with
these documents:
•
This Operation and Installation Manual.
•
The VacTrac™ Mechanical Components Operation and Installation Manual.
•
Electrical schematic and connection diagrams.
•
Blower and electric motor information sheets.
•
Operation and Installation manuals for installed options and accessories.
1-3
System Capabilities
VacTrac™ central vacuum systems are as varied as the applications they service. The tubing and
equipment furnished in an AEC/Whitlock system are designed to convey the material(s) specified at the time of purchase at specific rates and distances.
AEC/Whitlock 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, footage of pipe, Y-tubes, T-tubes, etc.
VacTrac™ Conveying Systems
8 • 18 • 36-Station Controllers
Page 7
Use the minimum effective amount of vinyl flex hose to maximize material line efficiency. Keep
material lines as straight as possible. Refer to the VacTrac™ Mechanical Components Operation
and Installation Manual (AEC Part No. A0536580) for installation recommendations.
Important!
Vacuum leaks occurring anywhere in your system reduce capacity.
1-4
Equipment Cycle
VacTrac™ material conveying systems are used for automatic pneumatic handling of most freeflowing, dry, pelletized, or granular materials. Material characteristics determine the type of
equipment needed to convey the material.
PLC Controller
The brain of the VacTrac™ system is the programmable logic controller (PLC) inside the control
enclosure. The PLC interprets inputs from vacuum hopper sensors and the vacuum switch. It
responds to these inputs and operates the atmospheric or sequence T-valves to convey material
based on set parameters in the software program.
Alarms and Alarm Screens
If installed, the optional Volume-Fill system audible alarm is triggered by the No-Convey, HighVacuum, and Low-Battery messages displayed on the vacuum fluorescent display. The operator
can silence the alarm by pressing the optional audible alarm package alarm acknowledge button,
or by disabling the alarm using the VacTrac™ control keypad.
Vacuum gauge(s) on the pump packages indicate system vacuum during the conveying
sequence. A normally open, non-adjustable vacuum switch trips if the vacuum exceeds 12” Hg
(406.80 millibars).
Note: This indicates a blocked material line, a blocked vacuum line, or a dirty filter condition.
The vacuum fluorescent display indicates which pump is experiencing a high vacuum condition,
and the control skips to the next on-line hopper. This protects the motor from high amp draw and
the pump from dead heading. It also limits the maximum system vacuum, because the vent valve
on the pump package shifts and relieves pressure even if the vacuum switch fails.
If the controller senses that all stations are full, the system goes into Auto Shutdown mode.
Pump motor(s) stop after a non-adjustable 30-second period. The VacTrac™ restarts normal
operation when a vacuum hopper sends a material demand signal.
Page 8
8 • 18 • 36-Station Controllers
VacTrac™ Conveying Systems
1-5
Models Covered by this Manual
VacTrac™ VTC8L1, VTC18L3, VTC36L3 Control Panel
•
Modular PLC control.
•
24 VDC or 115 VAC control output available on most models.
•
Easy-to-use 32-key operator interface keypad.
•
Bright 2-line 40-character vacuum fluorescent display.
•
Optional light board shows system status at a glance.
•
Optional audible/visual alarm.
Figure 1
VacTrac™ 8-Station VTC8L1 Control Panel
SET THE VACTRAC DATE
AND TIME?
<YES/NO>
PUMP
ON/OFF
LINE
PRIORITY
CONVEY
BLOWBACK/
DUMP-DELAY
HPR CONVEY
TIME
SYSTEM
STATUS
HOPPER
STATUS
HPR
1
HPR
2
HPR
3
HPR
4
ON/OFF
LINE
ON/OFF
LINE
ON/OFF
LINE
ON/OFF
LINE
HPR
5
HPR
6
HPR
7
ON/OFF
LINE
ON/OFF
LINE
ON/OFF
LINE
Yes
1
2
3
Start
No
4
5
6
Stop
Help
7
8
9
Silence
Special
Escape
0
Clear
Shift
Alarm
HPR
8
ON/OFF
LINE
VacTrac™ Conveying Systems
8 • 18 • 36-Station Controllers
Page 9
Figure 2
VacTrac™ 18- and 36-Station Control Panel with Light Panel
SET THE VACTRAC DATE
AND TIME?
<YES/NO>
PUMP
PRIORITY
CONVEY
SYSTEM
STATUS
BLOWBACK/
DUMP-DELAY
Yes
1
2
3
Start
No
4
5
6
Stop
Help
7
8
9
Silence
Special
Escape
0
Clear
Shift
SPARE
PUMP
1
ON/OFF
LINE
HPR
ON/OFF
LINE
PUMP
2
ON/OFF
LINE
HPR
ASSIGN
PUMP
3
ON/OFF
LINE
PUMP
STATUS
HPR
Alarm
HPR
CONVEY
TIME
STATUS
VacTrac Series
Conveying Systems
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
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Page 10
8 • 18 • 36-Station Controllers
Conveying
No Convey Alarm
Material Demand
VacTrac™ Conveying Systems
2
2-1
Shipping Information
Unpacking and Inspection
You should inspect your AEC/Whitlock VacTrac™ for 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.
2-2
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.
The Carrier then assumes full responsibility of the 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 AEC, Inc. 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 AEC, Inc. regarding your wish for replacement and to obtain an RMA (return
material authorization) number.
Parcel Post Shipment
; Notify AEC, Inc. at once in writing, giving details of the loss or damage. This information is
required for filing a claim with our insurance company.
; Hold the damaged goods with the container and packing materials for possible inspection by
postal authorities.
VacTrac™ Conveying Systems
8 • 18 • 36-Station Controllers
Page 11
United Parcel Service
; Contact your local UPS office regarding damage and insurance claims.
; Retain the container and packing.
; Notify AEC, Inc. at once.
2-3
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:
; Whitlock VacTrac™ 8, 18, or 36-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 AEC, Inc. immediately of the shortage.
2-4
If the Shipment is Not Correct
If the shipment is not what you ordered, contact AEC, Inc. immediately. Include the order
number and item. Hold the items until you receive shipping instructions.
2-5
Returns
Important!
Do not return any damaged or incorrect items
until you receive shipping instructions from AEC, Inc.
Page 12
8 • 18 • 36-Station Controllers
VacTrac™ Conveying Systems
3
3-1
Installation
Work Rules
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 AEC, Inc.
; 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.
3-2
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.
3-3
Installing the VacTrac 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.
VacTrac™ Conveying Systems
8 • 18 • 36-Station Controllers
Page 13
3-4
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.
3-5
Making VacTrac Control Panel Power Drop
Wiring Connections
Plug the power cord supplied into a properly grounded, 3-slot, 115/1/60 VAC or 230/1/60 VAC
receptacle specified on the VacTrac™ control panel serial tag. The control enclosure draws less
than five (5) amps during normal operation at 115/1/60 VAC.
Important!
AEC/Whitlock recommends that you protect PLC memory
by providing the control panel with a dedicated circuit,
a true earth ground, and a spike/surge protector.
3-6
Connecting the Control Panel to Vacuum
Hoppers
Figures 3 and 4
Refer to wiring connection drawings on Pages 16 or 17 that apply to your application.
•
On 115 VAC control voltage systems, run a common hot (115 VAC) wire and a common
neutral wire from the controller to each vacuum hopper in the VacTrac™ system.
•
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 VacTrac™ system.
Note: The VacTrac™ control panel features a terminal strip at the upper right corner for these
connections.
•
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.
Page 14
8 • 18 • 36-Station Controllers
VacTrac™ Conveying Systems
Notes:
3-7
•
Make sure that the solenoid and the proximity switch (if supplied) on vacuum
hoppers are the same voltage (24 VDC or 115 VAC) as the VacTrac™ control
panel control voltage. Consult the control panel serial tag and the solenoid valve
nameplates.
•
Wire size depends on control voltage, distance, number of vacuum hoppers, and the
number of wires in each raceway. Consult a qualified electrician.
•
Properly ground each hopper to reduce static build-up generated by material
conveying.
Connecting the Control Panel to the Pump
Package
1. Wire the pump package motor starter coil (M) to the terminal provided in the VacTrac™
control panel enclosure.
2. Wire the pump package vacuum relief valve solenoid (SOL A) to the terminal provided
in the VacTrac™ control panel enclosure.
3. Wire the pump package vacuum switch (VS) to the terminal located in the VacTrac™
control panel enclosure.
4. On VTPB pumps, wire the pump package blowback solenoid (SOL B) to the terminal
located in the VacTrac™ control panel enclosure.
5. On 115 VAC control voltage systems, run a common hot (115 VAC) wire and a
common neutral wire from the controller to each vacuum hopper in the VacTrac™
system.
6. 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 VacTrac™ system.
VacTrac™ Conveying Systems
8 • 18 • 36-Station Controllers
Page 15
Figure 3
Typical 24-Volt Junction Box Wiring Diagram
Located on
pump
Vacuum
Vacuum
Common
Blowback
+24 VDC common to all PLC outputs
Kay
valve
To
junction
Blowback
box
Common
Terminate
w/wire nut
1SOL
Vacuum
(yellow)
A1 A2 13
Blowback
(blue)
1M
To upper valve
process
air connection
From PLC output for pump
vacuum solenoid
From PLC output for pump
blowback solenoid
From PLC output for
vacuum pump motor
14
10L
95
Auxiliary contacts in
field-supplied disconnect
96
Wiring Diagram
VS
To PLC input for high-vacuum switch
1VS, 2VS, 3VS...as appropriate
Schematic
Typical Control Wiring Junction Box
FU-L1 FU-L2 FU-L3
L1
L2
L1
L3
L2
L3
1M
Disconnect & fuses
to be provided
by customer.
3 phase, 3 wire
service w/overcurrent
protection & auxiliary
contacts for control
circuit
NOTES:
1. Reference VacTrac connection diagram and operations
and instruction manual for proper terminal
connections and additional wiring information.
2. Remove all power before attempting to make any
field connections.
3. This drawing is intended for reference purposes
only and may not apply to units with special
voltages or requirements.
4. This drawing applies only to units using
GE-Series programmable controls.
1 O.L.
1
MTR
Schematic
Page 16
8 • 18 • 36-Station Controllers
VacTrac™ Conveying Systems
Figure 4
Typical 115-Volt Junction Box Wiring Diagram
Located on
pump
Vacuum
Vacuum
Common
Blowback
115 VAC Common to all PLC outputs
Kay
valve
To
junction
box
Blowback
Common
A1
A2
Terminate w/wire nut
1SOL
Vacuum
(yellow)
13
Blowback
(blue)
1M
To upper valve
process
air connection
From PLC output for pump
vacuum solenoid
From PLC output for pump
blowback solenoid
From PLC output for
vacuum pump motor
14
1OL
95
Wiring Diagram
Auxiliary contacts in
field-supplied disconnect
96
VS
To PLC input for high-vacuum switch
1VS, 2VS, 3VS...as appropriate
Schematic
Typical Control Wiring Junction Box
FU-L1 FU-L2 FU-L3
L1
L2
L1
Disconnect & fuses
to be provided
by customer.
3 phase, 3 wire
service w/overcurrent
protection & auxiliary
contacts for control
circuit
L3
L2
L3
1M
NOTES:
1. Reference VacTrac connection diagram and operations
and instruction manual for proper terminal
connections and additional wiring information.
2. Remove all power before attempting to make any
field connections.
3. This drawing is intended for reference purposes
only and may not apply to units with special
voltages or requirements.
4. This drawing applies only to units using
GE-Series programmable controls.
1 O.L.
1
MTR
Schematic
VacTrac™ Conveying Systems
8 • 18 • 36-Station Controllers
Page 17
- Notes -
Page 18
8 • 18 • 36-Station Controllers
VacTrac™ Conveying Systems
4
4-1
Controller Operation
Starting the Control for the First Time
Important!
Mechanical installation must be complete
and ready for operation before startup.
When you apply power to the system, the VacTrac™ panel performs a self-test and powers up
off- line. You can set up the system on-line or off-line, but for the initial start up, it is off-line.
„ Turn on control power to the VacTrac™ panel.
LINKING TO PLC
The screen on the right displays.
„ Wait five (5) seconds for the self-test.
When the screen on the right displays, the system is ready
for setup.
SYSTEM OFFLINE
11:34:56
12/26/95
Note: Initially, the system is off-line and the system uses factory default settings for operation.
4-2
Activating 8-Station Vacuum Hoppers
8-Station Controllers Only
HPR
1
„ Press the
ON/OFF
LINE
HPR
8
through
ON/OFF
LINE
key(s) as needed to activate the hopper(s) you want.
When a hopper LED is lit, the hopper is on-line and included in the conveying sequence. If
the LED is off, the hopper is off-line and skipped.
„ Press
Start
.
PUMP:OFF
The screen on the right displays. The Demand section displays 12:35:43
the on-line hoppers that have a material demand.
VacTrac™ Conveying Systems
8 • 18 • 36-Station Controllers
DEMAND:1
2/4/93
Page 19
PUMP
„ Press
ON/OFF
LINE
once to activate the pump.
The screen on the right displays.
The red LED on the button lights when the pump is on-line.
PUMP:HPR1
12:35:55
DEMAND:1
2/ 4/93
The pump conveys to the hoppers displayed in the Demand section.
The message next to PUMP can display the following messages:
•
HPRn means the pump is on, and the hopper being conveyed to is the one displayed.
•
OFF means the pump is off-line, the pump motor is off, and the vacuum is off.
•
IDLE means the pump is on-line, but it’s off and the vacuum is off because of a lack of
material demand from any of the on-line hoppers.
•
[ blank screen ] means the pump is on-line, the pump motor is running, but the vacuum is
off. A blank screen displays during a dump delay or the automatic shutdown sequence.
•
The number next to DEMAND shows which hoppers need material.
The pump automatically conveys to the on-line hoppers until shutdown or until all on-line
hopper sensors indicate that receivers are full (no material demand).
4-3
Assigning 18- and 36-Station Vacuum Hoppers to
Pumps
18-Station and 36-Station Controllers Only
To assign all installed vacuum hoppers to the pumps for which they are wired and piped:
HPR
„ Press
ASSIGN
.
HOPPER
PUMP 1
The screen on the right displays.
No
„ Press
Yes
if Hopper 1 is piped to Pump 1. Press
„ Press
Yes
when the correct pump number is shown.
1 ASSIGNMT:
<YES/NO>
to move to Pumps 2 and 3.
Continue to assign hoppers to pumps until all installed hoppers are assigned to the proper pump.
Page 20
8 • 18 • 36-Station Controllers
VacTrac™ Conveying Systems
When you have assigned the last installed hopper, or to exit from the hopper assignment menu:
„ Press
Escape
.
The SYSTEM OFFLINE screen displays.
After you have made the last possible assignment (Hopper 18 or Hopper 36), the SYSTEM
OFFLINE screen displays.
To go directly to a selected hopper:
Clear
HOPPER
„ Press
when the screen on the right displays. Then
PUMP 1
enter the desired hopper number (1 through 18 or 1 through
36).
1 ASSIGNMT:
<YES/NO>
When the number you want flashes:
„ Press
Yes
or
No
to assign the proper pump.
To check your work and view each hopper assignment:
HPR
„ Press
and
Yes
repeatedly to view all assignments, then press
SYSTEM OFFLINE screen.
ASSIGN
Escape
to exit to the
To check a selected hopper assignment:
HPR
„ Press
ASSIGN
, then
Clear
. Enter the hopper number (1 through 18 or 1 through 36) you want.
When the number you want flashes:
„ Press
Yes
„ Press
Escape
4-4
to view the hopper pump assignment.
to return to the SYSTEM OFFLINE display.
Setting Dump Delay Times
Dump delay is the time between conveying sequences to allow the vacuum hoppers to dump and
to allow the filter chamber (where installed) to discharge the dust it has collected. Each pump
can have a separate dump delay time.
VacTrac™ Conveying Systems
8 • 18 • 36-Station Controllers
Page 21
The dump delay should be a bit longer than the time it takes the largest hopper in the system to
dump. Typical dump times are listed below.
Largest vacuum hopper size
Volume
Capacity
cu. ft.
liters
lb.
0.3
8.5
10
0.7
19.8
25
1.5
42.4
50
3.0
84.9
100
6.0
169.9
200
Typical
dump time
seconds
3
6
10
15
25
kg
4.5
11.3
22.7
45.4
90.8
To set Pump 1 dump delay time:
BLOWBACK/
DUMP-DELAY
„ For 8-station controllers, press
Shift
HPR CONVEY
TIME
.
- or BLOWBACK/
„ For 18- and 36-station controllers, press
DUMP-DELAY
.
The current dump delay setting displays.
PMP 1 DUMP DELAY:
15 SEC
<YES/NO>
To accept this time:
„ Press
Yes
.
- or For a longer or shorter time:
„ Enter a new one- to three-digit dump delay time, then press
want flashes, or press
Clear
Yes
when the number you
to restart if you make a mistake.
Then:
„ Re-enter the time, or press
No
to move on to the next pump.
- or „ Press
Page 22
Escape
to exit to the off-line screen.
8 • 18 • 36-Station Controllers
VacTrac™ Conveying Systems
4-5
Enabling or Disabling Pump Blowback
Sequences
After you set the dump delay on a pump, you can set up blowback sequence (if your system is so
equipped). Blowback is designed to pulse-clean the VacTrac™ system in-line filter chamber.
Blowback occurs after a conveying attempt.
If the pump does not have blowback:
„ Press
Yes
PUMP 1 B/B: DISABLED
<YES/NO>
when the screen to the right displays.
The next pump dump delay screen then displays.
If the pump has blowback:
„ Press
Yes
No
to change the display to ENABLED, then press
to enter the blowback setup menus.
PUMP 1 B/B: ENABLED
<YES/NO>
First, set the number of loading cycles between blowback pulses. To accept the displayed
number of loads between blowback pulses:
PUMP 1 B/B FREQ:
Yes
<YES/NO>
.
„ Press
4
- or For more or fewer loads between pulses:
„ Enter a new one- to three-digit number, and press
or press
Clear
Yes
when the correct number flashes,
to restart if you make a mistake.
Then:
„ Re-enter the number of loads, or press
time.
No
to continue without changing the original
- or „ Press
Escape
to exit to the off-line screen.
VacTrac™ Conveying Systems
8 • 18 • 36-Station Controllers
Page 23
Second, set the total blowback cycle length. To accept the
current total cycle time:
„ Press
Yes
PUMP 1 B/B CYCL LGTH:
15 SEC
<YES/NO>
.
- or For a shorter or longer cycle:
„ Enter a new one- to three-digit number, and press
or press
Clear
Yes
when the number you want flashes,
to start over if you make a mistake.
Then:
No
„ Re-enter the cycle time you want, or press
cycle length.
to continue without changing the original
- or „ Press
Escape
to exit to the off-line screen.
Third, set the on-pulse time. The on-pulse time is the blow part PUMP 1 B/B ON-PULSE:
00.2 SEC
<YES/NO>
of the blowback cycle, and can be set to one decimal place.
To accept the current on-pulse time:
„ Press
Yes
.
- or For a shorter or longer on-pulse time:
„ Enter a new one- to three-digit number, and press
or press
Clear
Yes
when the number you want flashes,
to restart if you make a mistake.
Then:
„ Re-enter the desired cycle time, or press
on-pulse time.
No
to continue without changing the original
- or „ Press
Page 24
Escape
to exit to the off-line screen.
8 • 18 • 36-Station Controllers
VacTrac™ Conveying Systems
Fourth, set the off-pulse time. The off-pulse time is the between PUMP 1 B/B OFF-PULSE:
00.2 SEC
<YES/NO>
blows part of the blowback cycle, and can be set to one decimal
place.
To accept the current off-pulse time:
„ Press
Yes
.
- or For a shorter or longer off-pulse time:
„ Enter a new one- to three-digit number, and press
or press
Clear
Yes
when the number you want flashes,
to restart if you make a mistake.
Then:
„ Re-enter the cycle time you want, or press
on-pulse time.
No
to continue without changing the original
- or „ Press
Escape
to exit to the off-line screen.
Proceed through the menus until all the pumps installed in the system have dump delay and
blowback settings. When you have set up all the installed pumps:
„ Press
4-6
Escape
to exit to the off-line screen.
Setting Hopper Convey Times
You can set the hopper convey time for actual conveying time on Time Fill systems.
Note: A reasonable conveying time on such a system increases material handling efficiency.
You can also set the hopper convey time for the maximum time that the system conveys material
to the selected hopper (if the proximity switch doesn’t activate) before the next on-line hopper
fills.
Note: A reasonable conveying time can alert the operator to material supply problems sooner.
VacTrac™ Conveying Systems
8 • 18 • 36-Station Controllers
Page 25
To set conveying times:
HPR 1 CONVEY TIME:
15 SEC
<YES>
BLOWBACK/
DUMP-DELAY
„ For 8-station controllers, press
HPR CONVEY
TIME
.
- or HPR
„ For 18- and 36-station controllers, press
CONVEY
TIME
.
To accept this time:
„ Press
Yes
.
The screen displays information on the next hopper.
- or For a longer or shorter time:
„ Enter a new one- to three-digit conveying time, and press
flashes, or press
Clear
Yes
when the number you want
to restart if you make a mistake.
Then:
„ Re-enter the time, or press
No
to continue without changing the original time.
- or „ Press
Escape
twice to exit to the off-line screen.
To directly access a specific hopper on 18- and 36-station controllers:
„ At the hopper convey time screen, press
screen on the right.
„ Enter the hopper number (
1
through
Escape
3
to display the
6
HOPPER NUMBER:XX
<YES/NO>
as needed) you want.
When the hopper number you want flashes:
„ Press
Yes
to immediately display the hopper screen you selected.
Note: You don’t need to reset the convey times to zero on uninstalled hoppers. If you don’t put
them on-line, they’ll be skipped during the loading sequence.
First-time setup is complete. Install the mechanical components to your VacTrac™ system, and
proceed to the following section for startup.
Page 26
8 • 18 • 36-Station Controllers
VacTrac™ Conveying Systems
4-7
Placing Installed Vacuum Hoppers On Line
A vacuum hopper must be on line so the system can convey material to it during loading
sequences. To place installed hoppers on line:
HPR
1
HPR
8
„ For 8-station controllers, press
to
as needed to place the hopper(s) you want
on-line.
The hopper is included in the next loading sequence.
ON/OFF
LINE
ON/OFF
LINE
- or HPR
„ For 18- and 36-station controllers, press
.
A screen similar to the one on the right should display (18and 36-station controllers only).
ON/OFF
LINE
HOPPER 1: OFFLINE
<YES/NO>
Then, for 18- and 36-station controllers: If Hopper 1 is installed, assigned to a pump, and you
want to include it in the next loading sequence:
No
.
„ Press
A screen similar to the one on the right should display (18and 36-station controllers only).
HOPPER 1: ONLINE
<YES/NO>
Yes
„ Press
.
The hopper is now on line.
On all controllers:
„ Press
Escape
to return to the operating screen.
Continue placing installed vacuum hoppers on line or off line until you set up all the hoppers in
your system.
To place a specific hopper directly on line or off line:
HOPPER XX: OFFLINE
„ Enter the one- or two-digit hopper number when the screen on
<YES/NO>
the right displays.
When the hopper number you want flashes on the screen:
Yes
„ Press
to go directly to the hopper screen, then press
on- or off-line.
Yes
or
No
to put the hopper
System setup is now complete.
VacTrac™ Conveying Systems
8 • 18 • 36-Station Controllers
Page 27
4-8
Starting the System
18- and 36-Station Systems Only
Important!
You must complete the mechanical installation of your VacTrac™ system
and verify that the system is ready for operation before startup.
The entire conveying system must be installed
and ready to operate before performing these steps.
To begin routine startup:
„ Turn on PLC control power if it is not already on.
LINKING TO PLC
Wait five (5) seconds for the system to activate.
„ Press
Start
.
P1:OFF P2:OFF P3:OFF
DMD: 2 DMD: 12 DMD: 6
The screen on the right displays.
P1, P2 and P3 are the (up to) three (3) pumps that can be on the system. DMD indicates which
on-line vacuum hoppers assigned to that pump have a material demand.
To start the pump(s):
PUMP
„ For 8-station controllers, press
ON/OFF
LINE
.
- or „ For 18- and 36-station controllers, press
PUMP
1
ON/OFF
LINE
,
PUMP
2
ON/OFF
LINE
, or
PUMP
3
ON/OFF
LINE
.
The pump(s) start conveying to the on-line hopper(s) showing a material demand.
The screen on the right displays.
P1: 6 P2:OFF P3:IDL
DMD: 6 DMD: 12 DMD:
This screen displays Pump 1 conveying to Hopper 6, Pump
2 is off-line, and Pump 3 is idle, because all material receivers below the hoppers are full.
The top line displays the hopper that the pump is conveying to at the moment. The bottom line
shows which of the on-line vacuum hoppers for the selected pump have a material demand
(DMD).
The pump(s) automatically convey to on-line hoppers until you shut down the system, or when
sensors transmit a Bin Full signal to the controller.
Page 28
8 • 18 • 36-Station Controllers
VacTrac™ Conveying Systems
4-9
Shutting Down the System
To stop all pumps immediately:
„ Press
Stop
.
For a controlled stop of a specific pump:
PUMP
„ For 8-station controllers, press
ON/OFF
LINE
.
- or „ For 18- and 36-station controllers, press
PUMP
1
ON/OFF
LINE
PUMP
2
ON/OFF
LINE
,
, or
PUMP
3
ON/OFF
LINE
.
To turn off PLC control power immediately:
„ Move the control power rocker switch to OFF.
- or „ Disconnect power to the control panel.
To take individual vacuum hoppers off-line one at a time:
HPR
1
„ For 8-station controllers, press
on- or off-line.
ON/OFF
LINE
HPR
8
to
ON/OFF
LINE
as needed to place the hopper(s) you want
- or HPR
„ For 18- and 36-station controllers, press
number.
„ Press
No
„ Press
Escape
ON/OFF
LINE
and enter the one- or two-digit hopper
to take the vacuum hopper off-line.
when you are done.
The operating screen displays again.
VacTrac™ Conveying Systems
8 • 18 • 36-Station Controllers
Page 29
4-10 Making On-the-Fly Adjustments
Taking a Hopper Off-Line
To take individual vacuum hoppers off-line one at a time:
HPR
1
„ For 8-station controllers, press
ON/OFF
LINE
HPR
8
to
ON/OFF
LINE
to place the hopper you want off-line.
- or HPR
„ For 18- and 36-station controllers, press
number.
ON/OFF
LINE
and enter the one- or two-digit hopper
When the correct hopper number flashes on the screen:
Yes
„ Press
off-line.
to go directly to the hopper screen, then press
Yes
or
No
to put the hopper
The hopper is removed from the next loading sequence (8-station controller systems only).
On 18- and 36-station controllers:
„ Press
No
„ Press
Escape
to take the vacuum hopper off-line.
when you are done.
The operating screen displays again.
Note: If the hopper is being conveyed to at the time you take it off-line, the convey cycle stops
conveying to the hopper immediately and the hopper is bypassed in subsequent cycles as
long as it is off-line. The No-Convey alarm is canceled when you take a hopper off-line.
Placing a Hopper On-Line
To place individual vacuum hoppers on-line, one at a time:
HPR
1
„ For 8-station controllers, press
ON/OFF
LINE
HPR
8
to
ON/OFF
LINE
to place the hopper you want on-line.
The hopper is included in the next loading sequence (8-station controller systems only).
- or HPR
„ For 18- and 36-station controllers, press
number.
Page 30
8 • 18 • 36-Station Controllers
ON/OFF
LINE
and enter the one- or two-digit hopper
VacTrac™ Conveying Systems
On 18- and 36-station controllers:
„ Press
Yes
„ Press
Escape
to place the vacuum hopper on-line.
when you are done.
The operating screen displays again. The hopper loads in subsequent cycles.
Start Conveying to a Selected Hopper Immediately
To convey material to a selected hopper immediately:
„ Press
PRIORITY
CONVEY
.
CONVEY: HOPPER XX
<YES>
The screen on the right displays.
„ Enter the number of an on-line hopper; for example, press
Priority Convey status.
8
to place Hopper 8 in
When the correct hopper number flashes:
„ Press
Yes
.
CONVEYING TO
HOPPER 8
The screen on the right displays.
If the display on the right appears momentarily, the hopper wasn’t
on-line.
„ Put the hopper on-line before you press
PRIORITY
CONVEY
HOPPER 8
OFFLINE
.
If the screen on the right display appears momentarily, the hopper
pump wasn’t on-line.
„ Put the hopper pump on-line before you press
PRIORITY
CONVEY
PUMP 1
OFFLINE
.
The pump conveys material to the priority hopper until hopper sensors indicate that the
receiver below the hopper is full.
PRIORITY
CONVEY
When the priority hopper receiver is full, the
light goes out and the normal conveying
sequence resumes where it left off, conveying to on-line hoppers.
To stop priority conveying before the hopper receiver becomes full:
„ Press
Escape
.
VacTrac™ Conveying Systems
8 • 18 • 36-Station Controllers
Page 31
Adjusting Hopper Conveying Times
To adjust hopper conveying times at any time during a loading cycle:
HPR
„ Press
CONVEY
TIME
.
- or BLOWBACK/
DUMP-DELAY
„ If you have an 8-station controller, press
HPR CONVEY
TIME
.
HPR 1 CONVEY TIME:
15 SEC
<YES>
The screen on the right displays.
If the hopper convey time is acceptable:
„ Press
Yes
.
- or To adjust the hopper conveying time:
„ Press
Clear
to reset the current convey time to zero, then enter the new time.
When the time value you want flashes:
„ Press
Yes
„ Press
Escape
to save the time value.
until the regular on-line screen displays again.
To quickly select a hopper:
„ Press
Escape
when the screen on the right displays.
„ Enter the hopper number you want, and press
flashes.
Page 32
8 • 18 • 36-Station Controllers
Yes
HPR 1 CONVEY TIME:
15 SEC
<YES>
when the hopper number you want
VacTrac™ Conveying Systems
4-11 Using Password Protection
You can protect keys on the VacTrac™ control panel with passwords to prevent any
unauthorized tampering. You can assign or change passwords while the system is on-line or offline.
To set up a password:
„ Press
Shift
Special
.
DO YOU WANT TO SET UP
A PASSWORD? <YES/NO>
The screen on the right displays.
„ Press
Yes
.
PRESS THE KEY YOU
WANT TO PROTECT
The screen on the right displays.
„ Press the key to which you select to assign a password.
Special
key can
Note: Only the 12 yellow function keys and the
have passwords. If you attempt to give a password to
other keys, the message on the right displays, and the
previous screen displays.
„ Enter the password you want, up to four (4) numerical
digits. If the key already has a password, enter the current
password.
When the new password flashes:
„ Press
Yes
SORRY,THAT KEY CANNOT
HAVE A PASSWORD
THE OLD PASSWORD WAS:
XXXX
<YES>
THE NEW PASSWORD IS:
XXXX
<YES>
.
Note: If the key is already password-protected, the screen on
the right displays. You cannot change a password unless
you know the current password for that key.
SORRY, THAT IS NOT
THAT KEY’S PASSWORD
The screen on the right prompts you to assign or change another
password.
PRESS THE KEY YOU
WANT TO PROTECT
„ Press the key to which you select to assign the password.
When you finish assigning/changing passwords:
„ Press
Escape
twice to exit to the on-line or off-line screen.
VacTrac™ Conveying Systems
8 • 18 • 36-Station Controllers
Page 33
4-12 Setting the Time and Date
The control has a clock and calendar (with battery backup) that is used with the inventory
management features of your VacTrac™ system.
To set the date and time, start from the on- or off-line screen and:
„ Press
Shift
Special
,
, then
No
.
The screen on the right displays. This screen also displays
after you set up a password.
„ Press
Yes
SET THE VACTRAC DATE
AND TIME?
<YES/NO>
.
TIME AND DATE SETUP
08HR
<YES/NO>
The time and date setup menu with the Hour prompt
displays.
„ Enter the current hour of the day in 24-hour military time format.
„ Press
Yes
when the correct hour number displays.
No
if the hour displayed is already correct.
- or „ Press
TIME AND DATE SETUP
15 MIN
<YES>
The Minutes prompt displays.
„ Enter minutes past the hour (1-59), and press
Yes
.
- or „ Press
No
if the minutes displayed is already correct.
TIME AND DATE SETUP
45 SEC
<YES>
The Seconds prompt displays.
„ Enter the seconds past the minute (1-59), then press
Yes
.
- or „ Press
No
if the seconds displayed is already correct.
The Month prompt displays.
Page 34
8 • 18 • 36-Station Controllers
TIME AND DATE SETUP
12 MONTH
<YES>
VacTrac™ Conveying Systems
Yes
„ Enter the month of the year (1-12), then press
.
- or „ Press
No
if the month shown is already correct.
The Day prompt displays.
„ Enter the day of the month, then press
Yes
TIME AND DATE SETUP
12 DAY
<YES>
.
- or „ Press
No
if the day shown is already correct.
The Year prompt displays.
„ Enter the year (two digits), then press
Yes
TIME AND DATE SETUP
95 YEAR
<YES>
.
- or „ Press
No
„ Press
Escape
if the year shown is correct.
twice to return to the on-line or off-line screen.
4-13 Using the System Configuration Menu
The System Configuration Menu screens contain options to set Standard or Special displays,
select Standard or High-Vacuum modes, and Standard Hopper or Special Hopper operation.
To display the initial System Configuration menu:
„ Press
Special
.
The screen on the right displays.
SYSTEM CONFIGURATION
<YES/NO>
To enter the System Configuration menu system:
„ Press
Yes
.
The Display prompt screen displays.
DISPLAY: STANDARD
<YES/NO>
Standard and Special Screens
The top line of the standard operating display screen shows which hoppers are being conveyed
to and which hoppers have a material demand.
VacTrac™ Conveying Systems
8 • 18 • 36-Station Controllers
Page 35
To keep the standard display:
„ Press
Yes
.
To switch to the special display prompt:
„ Press
No
.
The Special Display screen prompt displays.
DISPLAY: SPECIAL
<YES/NO>
The top line of the special operating display just shows SYSTEM ONLINE or SYSTEM OFFLINE
messages.
To use the special display:
„ Press
Yes
.
Standard and High Vacuum Operation
VacTrac™ systems can operate in standard sensor-driven mode or in the optional high vacuum
mode.
Standard Volume Fill Mode
In the standard Time Fill or Volume Fill mode, each on-line vacuum hopper is conveyed to until
the proximity sensor in the side of the hopper tells the VacTrac™ control that it is full. The
vacuum hopper re-fills until the Bin Full sensor on the vacuum hopper flapper dump valve is
buried in the material in the bin below it. The optional Volume Fill sensor lets the controller fill
the hopper until the hopper is full or the time allotment elapses. The control then conveys to the
next on-line hopper.
Special High Vacuum Mode
In High Vacuum mode, the system conveys material to each on-line vacuum hopper until the
system vacuum switch senses high vacuum, indicating an overfilled vacuum hopper. The control
remembers the duration to overfill the vacuum hopper, reduces that value by a few seconds, and
refills the vacuum hopper.
The control refills the vacuum hopper a pre-set number of times before again monitoring another
loading to overfilling. The vacuum hopper is re-filled until the bin full sensor on the vacuum
hopper flapper dump valve is buried in the material in the bin below it. The control then conveys
to the next on-line hopper.
Page 36
8 • 18 • 36-Station Controllers
VacTrac™ Conveying Systems
Caution!
High Vacuum mode is hard on pumps, vacuum hopper filters, and screens.
However, you may want to use it if your conveying system
is running very near total capacity, or if conveying conditions
such as distance or material change frequently.
To change the conveying mode, start from the on-line or off-line display, then:
„ Press
Special
press
Yes
„ Press
No
to enter the system configuration menu, then
until the screen on the right displays.
OPERATION: STANDARD
<YES/NO>
OPERATION:HI VACUUM
<YES/NO>
to display the screen on the right.
To start High Vacuum mode:
„ Press
Yes
.
„ Enter the hopper number(s) you want to change.
Repeat the previous steps to return to standard operation.
Configuring Hoppers for Standard or Special Operation
After selecting Standard or Special High Vacuum mode, you can configure individual hoppers
for standard or special operation.
Standard hopper operation is when the hopper operates normally in Time Fill or Volume Fill
modes. If the hopper loses the demand sensor signal while loading, the conveying sequence stops
and the system indexes to the next hopper station.
Special hopper operation is when the hopper operates in a special Time Fill mode only, and fills
to the present time, even when the hopper loses the demand signal.
VacTrac™ Conveying Systems
8 • 18 • 36-Station Controllers
Page 37
Figure 5
VacTrac™ Control Panel Factory Presets
Parameter
Hopper On/Offline
Pump On/Offline
Hopper Convey Time
Dump Delay
Blowback, Enable/Disable
Blowback Frequency
Blowback Cycle Length
Blowback On-Pulse
Blowback Off-Pulse
Display Mode
Operation Mode
Hopper Configuration
Pump Auto-Shutdown
Audible Alarm Delay
Pump High Vacuum Delay
Hopper No-Convey Alarm Delay
Hopper Input Delay
High-Vacuum Mode Delay
High-Vacuum Mode Adjustment Time
Factory-set defaults
Offline
Offline
15 seconds
15 seconds
Disabled
Every 2 cycles
10 seconds
0.2 seconds
2.0 seconds
Standard
Standard
Standard
30 seconds
5 minutes
3 seconds
3 loading attempts
0.5 seconds
10
5 seconds
Range
Online Or Offline
Online Or Offline
Standard or Special
Standard or High-Vacuum
4-14 Using the System Variables Menu
To work in the System Variables menu:
„ Press
Special
, then press
No
.
The screen on the right displays.
SYSTEM VARIABLES
<YES/NO>
To enter into the System Variables menu:
„ Press
Yes
„ Press
No
to step through the parameters that can be adjusted in this menu.
Yes
to select a displayed parameter for adjustment.
.
- or „ Press
Page 38
8 • 18 • 36-Station Controllers
VacTrac™ Conveying Systems
Setting the Pump Auto-Shutdown Time
PUMP 1 AUTO-SHUTDOWN:
Auto-shutdown delay is the number of seconds the pump runs
030 SEC
<YES/NO>
after all material demands to the on-line vacuum hoppers are
satisfied. The system is factory-set to give the pump motor 30 seconds to cool down. This setting
prevents unnecessary on/off pump package cycling in fast-moving operations.
To set pump auto-shutdown time:
„ Press
Clear
to clear auto-shutdown time to zero.
- or „ Enter seconds for pump auto-shutdown from 0 to 999.
When the automatic shutdown delay time you want displays:
„ Press
Yes
to save the time into memory and move to the next pump.
Repeat this procedure for each pump in your VacTrac™ system.
Audible Alarm Delay
Audible alarm delay is the time that the audible NO CONVEY,
HIGH VACUUM, or LOW BATTERY alarm is disabled after you
AUDIBLE ALARM DELAY:
005 MIN
<YES/NO>
Alarm
press Silence . It is set at the factory for five (5) minutes. If another alarm condition occurs during
the silence period, the alarm sounds. If your system does not have this option, ignore the Audible
Alarm menu.
„ Press
Clear
Alarm
to clear the audible alarm delay to zero (the
Silence
key is disabled).
- or „ Enter minutes for alarm delay from 0 to 999.
When the alarm delay time you want displays:
„ Press
Yes
to save the time into memory and move to the next screen.
VacTrac™ Conveying Systems
8 • 18 • 36-Station Controllers
Page 39
Pump High Vacuum Delay
Pump high vacuum delay is the length of time the control ignores PUMP 1 HI-VACUUM DLY:
003 SEC
<YES/NO>
a high vacuum signal from the vacuum switch. This delay
prevents nuisance high vacuum alarms caused by temporary, transient high vacuum conditions
when a pump first draws material from the supply. It is set at the factory for three (3) seconds.
If you have high vacuum alarms and know that the VacTrac™ system is operating properly with
clean filters, you can increase the delay.
„ Press
Clear
to clear the high vacuum alarm delay to zero for no alarm delay.
- or „ Enter minutes for alarm vacuum delay from 0 to 999.
When the alarm vacuum delay time displays:
„ Press
Yes
to save the time to memory and move to the next pump.
Vacuum Hopper No-Convey Alarm Delay
No-Convey alarms occur after a set number of vacuum hopper loading attempts fail. Each
vacuum hopper on a 8-station system can have a separate No-Convey alarm delay setting. The
factory setting is 3 for all hoppers, so the no-convey alarm sounds after three failed loading
attempts.
„ Enter 1 to 99 delay attempts.
- or „ Press
Clear
to clear the high vacuum alarm delay to zero.
When the attempt delay time you want displays:
Yes
HPR 1 NO-CONVEY ALM
DELAY:003
<YES/NO>
„ Press
to save the time to memory and move to the
next hopper.
Repeat for each hopper in your VacTrac™ system.
To set an individual hopper time:
„ Press
Escape
, and enter the hopper number.
„ Set the time as in the previous steps.
Page 40
8 • 18 • 36-Station Controllers
VacTrac™ Conveying Systems
Hopper Input Delay
HOPPER INPUT DELAY:
When the proximity sensor in the side of each vacuum hopper
0.5 SEC
<YES/NO>
senses a full load, the pump skips to the next on-line vacuum
hopper. If the material being conveyed comes in momentary contact with the proximity sensor
before the hopper is full, a less-than-full load can occur.
Note: The hopper input delay solves this potential problem by providing a time period that lets
the controller ignore input signals from a proximity sensor before the controller accepts
it. The factory setting is one-half (0.5) second.
„ Enter seconds for hopper input delay from .1 to 9.9.
- or „ Press
Clear
to clear the hopper input delay to zero which means immediate reaction.
When the hopper delay time you want displays:
„
Press
Yes
to save the time to memory and move to the next variable.
Hi-Vacuum Mode Delay
HI-VAC MODE DLY:
Hi-Vacuum mode delay is the number of times a VacTrac™
<YES>
system in Hi-Vacuum mode conveys to an on-line vacuum hopper 010
before it re-tests the conveying time that elapses before a high vacuum signal occurs. This delay
is factory set to ten (10) conveying cycles.
„ Enter cycles for re-test from 1 to 999 conveying cycles.
When the delay mode value you want displays:
„ Press
Yes
to save the time to memory and move to the next variable.
See Standard and High Vacuum Operation on Page 36 for more information.
VacTrac™ Conveying Systems
8 • 18 • 36-Station Controllers
Page 41
High Vacuum Mode Adjustment Time
High Vacuum mode adjustment time is the amount of time in seconds that the control reduces
from the conveying time. See Standard and High Vacuum Operation on Page 36 for more
information.
Hopper Limit
18- and 36-Station Controllers
To limit the number of hoppers on 18- and 36-station systems:
„ Press
Clear
.
„ Enter the number of stations you want (1 to 36) for limiting the system, and press
Yes
.
The CONFIGURATION screen displays.
„ Press
Escape
.
The SYSTEM OFFLINE screen displays.
4-15 Checking System Status
To view system totals:
„ For 8-station controllers, press
Shift
SYSTEM
STATUS
HOPPER
STATUS
.
- or „ For 18- and 36-station controllers, press
The screen on the right displays.
SYSTEM
STATUS
.
SYSTEM TOTALS
VIEW
<YES/NO>
To view the total number of hours that a pump package has operated since it was last re-set:
„ Press
Yes
.
The screen on the right displays.
TOTAL PMP 1 RUN TIME
0801HR
<YES/NO>
Yes
„ Press
repeatedly to page through the total number of
HPR 2 TOTAL FILLS:
times each vacuum hopper has been conveyed to since it was 6641
<YES/NO>
last reset.
This information helps estimate total system throughput to each vacuum hopper.
Page 42
8 • 18 • 36-Station Controllers
VacTrac™ Conveying Systems
Viewing Spare Pump Assignments
18- and 36-Station Controllers Only
To view the current status of the spare pump:
„ Press
Yes
.
SPARE PUMP:DISABLE
<YES>
The screen on the right displays.
This screen tells you if the spare pump is enabled or disabled.
If the spare pump is already enabled, the screen on the right
displays.
SPARE PUMP ASSGNMNT:
PUMP 1
<YES>
To continue to the next section:
„ Press
Yes
.
Resetting System Totals
To re-set system totals to zero:
„
Press
No
when the screen on the right displays.
The bottom line of the display changes to CLEAR.
To clear the totals to zero:
„ Press
Yes
Yes
SYSTEM TOTALS
CLEAR
<YES/NO>
.
The screen prompts you again to verify that you want to
clear the totals.
„ Press
SYSTEM TOTALS
VIEW
<YES/NO>
CLEAR SYSTEM TOTALS?
<YES/NO>
again.
The screen on the right displays when system totals clear to
zero.
SYSTEM TOTALS
CLEARED
After a brief interval, the SYSTEM OFFLINE screen displays.
VacTrac™ Conveying Systems
8 • 18 • 36-Station Controllers
Page 43
4-16 Enabling or Disabling Spare Pumps
18- and 36-Station Controllers Only
Note: Only Pump 3 can be designated as a spare pump for Pump 1 or Pump 2.
To enable or disable the spare pump:
PUMP
„ Press
SPARE
.
SPARE PUMP:ENABLE
<YES/NO>
The screen on the right displays.
To disable the spare pump:
„ If the SPARE PUMP:ENABLE prompt displays, press
No
.
The screen on the right displays.
SPARE PUMP:DISABLE
<YES/NO>
- or „ If the SPARE PUMP:DISABLE prompt displays, press
Yes
.
The spare pump is disabled and the SYSTEM OFFLINE screen displays.
To enable the spare pump:
„ If the SPARE PUMP:DISABLE prompt displays, press
No
.
The screen on the right displays.
SPARE PUMP:ENABLE
<YES/NO>
- or „ If the SPARE PUMP:ENABLE prompt displays, press
The screen on the right displays.
Yes
.
SPARE PUMP ASSGNMNT:
PUMP 1
<YES/NO>
To take a pump off-line, which allows the spare pump to operate in its place:
„ Toggle through the screens by pressing
displayed.
No
until the pump you want to take off-line is
When the pump number you want to take off-line displays:
„ Press
Yes
.
The SYSTEM OFFLINE screen displays.
Page 44
8 • 18 • 36-Station Controllers
VacTrac™ Conveying Systems
4-17 Keypad Descriptions
Start
Allows the pump to be placed on-line.
Stop
Takes the pump off-line.
Alarm
Silence
Silences the alarm horn.
BLOWBACK/
DUMP-DELAY
Shift
8-station: Access the upper level of dual level function keys like
Shift
HPR CONVEY
TIME
and
SYSTEM
STATUS
HOPPER
STATUS
.
Special
All controllers: You can also use
with
to access some of the special
configuration and system setup selections, such as password setup and system time and
date.
Clear
Escape
Erases a number entry.
Moves back one menu level. Use this key to return to the normal operating display.
Yes
Accepts menus and parameters.
No
Toggles through menu choices.
Help
Special
Shift
Alerts user of system setup errors.
Sets up the control time and date; also creates, changes, and assigns passwords.
Special
PUMP
ON/OFF
LINE
or
Allows changes to system configuration or system variables.
PUMP
1
ON/OFF
LINE
,
PUMP
2
ON/OFF
LINE
,
PUMP
3
ON/OFF
LINE
Toggles the pump on-line and off-line.
PUMP
SPARE
PRIORITY
CONVEY
18- and 36-station: Enables or disables the spare pump.
Turns on Priority Convey mode. Enter the hopper number you want, and the system
conveys material to that hopper exclusively until the bin below it is full.
VacTrac™ Conveying Systems
8 • 18 • 36-Station Controllers
Page 45
HPR
1
ON/OFF
LINE
HPR
8
through
ON/OFF
LINE
- or HPR
ON/OFF
LINE
1
and
BLOWBACK/
DUMP-DELAY
HPR CONVEY
TIME
SYSTEM
STATUS
HOPPER
STATUS
Shift
3
6
Toggles the corresponding hopper on-line and off-line.
HPR
or
CONVEY
TIME
BLOWBACK/
DUMP-DELAY
Shift
through
HPR CONVEY
TIME
Sets maximum conveying time to each hopper.
BLOWBACK/
or
DUMP-DELAY
Sets system blowback and dump delay parameters.
HPR
or
STATUS
SYSTEM
STATUS
HOPPER
STATUS
or
Allows you to view the status of each vacuum hopper. You can view statuses
such as on-line or off-line, set conveying time, and actual conveying time.
SYSTEM
STATUS
Allows you to view and/or clear total pump running hours and total number
of conveying sequences to each vacuum hopper.
PUMP
STATUS
18- and 36-station: Allows you to view pump status.
HPR
ASSIGN
18- and 36-station: Allows you to assign a hopper for conveying.
Page 46
8 • 18 • 36-Station Controllers
VacTrac™ Conveying Systems
5
Maintenance
5-1
Replacing the PLC Battery
Replace the PLC battery if the BATT indicator lights or the message BATTERY LOW
REPLACE
to the right displays.
If the battery fails and PLC power is lost or is shut off, the programmed parameters are retained
for about 20 minutes after the power loss. This should provide you enough time to replace the
dead battery without losing the parameters you programmed.
You can obtain new lithium batteries by contacting the AEC/Whitlock Parts Department toll free
from 7am to 5pm at 1/800/423-3183. Be ready with your controller model number and serial
number. Ask for AEC Part No. A0536917.
Important!
AEC/Whitlock recommends that you keep at least one (1) spare battery
on hand at all times to avoid possible loss of the parameters you programmed.
Battery life expectancy is approximately two to three (2 to 3) years in single-shift operation. The
battery holds the active program in RAM when the controller is OFF, so battery life depends on
the length of time that the controller does not operate.
To replace the battery:
1. Power down the controller.
2. Open the cabinet and locate the battery chamber cover on the PLC housing.
3. Open the battery chamber cover, and leaving the old battery plugged into the terminals,
remove the cover from the battery body.
4. Install the cover onto the body of the new battery.
Caution!
Do not remove the old battery until after you plug in the new battery.
5. Plug in the new battery on the spare set of terminals.
6. Unplug the old battery and properly discard it.
7. Install the battery cover containing the new battery onto the battery chamber.
VacTrac™ Conveying Systems
8 • 18 • 36-Station Controllers
Page 47
5-2
Restoring a Lost Program
If you lose the basic program stored in RAM on the PLC backplane as a result of
electromagnetic or RF radiation, static discharge, or long term battery failure, you must restore
the basic program to RAM. To restore the program, perform these procedures:
Begin Program Restoration
1. Disconnect power to the control panel.
2. Open the control enclosure and remove the three (3) I/O modules next to the PLC power
supply module. Make note of their order so you can put them back in the proper slots.
The UVPROM in the PROGRAM PROM socket on the PLC backplane should now be
accessible.
Caution!
Never remove the system EPROM,
and never remove a module when power is applied!
•
Terminal strips on modules are removable.
•
AEC recommends using PROM removal and insertion tools when removing and
installing program PROMs.
•
Be careful to avoid bending PROM legs when removing and installing. Place
PROMs on a foam sheet to protect from damage before installation.
Note: Some older units feature a chip locking screw located just above the EPROM,
which needs to be unlocked before you remove the EPROM.
3. Use a PROM removal tool to remove the OPERATION UVPROM from the PROGRAM
PROM socket.
4. Using a PROM insertion tool, carefully insert the CONFIGURATION EPROM into the
PROGRAM PROM socket. Align the EPROM notch as shown in the graphic on the
backplane.
Note: The CONFIGURATION EPROM was shipped in a box taped to the inside the VTC
control panel enclosure.
5. Reconnect power to the control panel.
Page 48
8 • 18 • 36-Station Controllers
VacTrac™ Conveying Systems
Continue with Program Restoration
1. Turn the CONTROL POWER toggle switch ON.
The OK indicator on the PLC flashes for a moment. When the RUN indicator lights, the
program has been successfully transferred to RAM.
2. Power down the PLC with the CONTROL POWER switch.
3. Disconnect power to the control.
4. Using a PROM removal tool, carefully remove the CONFIGURATION EPROM from the
socket.
5. Using a PROM removal tool, carefully remove the CONFIGURATION EPROM from the
backplane.
6. Using a PROM insertion tool, carefully insert the OPERATION UVPROM (the one that
was originally there) back into the PROGRAM PROM socket. Align the EPROM notch
as shown in the graphic on the backplane.
7. Reconnect power to the control panel.
Complete Program Restoration
1. Turn the CONTROL POWER toggle switch ON.
The OK indicator on the PLC flashes for a moment. When the RUN indicator lights, the
program has been successfully transferred to RAM.
2. Power down the PLC with the CONTROL POWER switch.
3. Disconnect power to the control.
4. Restore the modules that were removed to gain access.
5. Re-connect power to the control enclosure and prepare the system for operation.
6. Store the CONFIGURATION EPROM in a safe place.
7. Repeat the first-time startup procedures listed in Chapter 4 on Page 19.
8. Record the system configuration if it wasn’t done before.
VacTrac™ Conveying Systems
8 • 18 • 36-Station Controllers
Page 49
- Notes -
Page 50
8 • 18 • 36-Station Controllers
VacTrac™ Conveying Systems
6
Troubleshooting
Problem
The control panel doesn’t
light up at all.
The vacuum fluorescent
display doesn’t come on
when the control panel is
powered up, but other
indicators light.
A pump package doesn’t run,
even though it is on line and
its indicator is lit.
A vacuum hopper is being
by-passed in the loading
cycle.
Possible cause
The control panel is not
plugged in.
The external disconnect
(recommended) in the
dedicated circuit is open (off).
Fuse/circuit breaker in the
power drop is blown/tripped.
Broken control power switch.
Fuse in display is blown.
Loose wiring to display.
Solution
Replace.
Replace.
Repair.
Display failure.
Replace.
The motor overload has
tripped.
Reset the overload and
check the motor for the
proper amp draw on tag.
Plug in the control panel.
Close the switch (on).
Replace/reset.
Main fuse in power drop or
optional fused disconnect has Replace the fuse.
blown.
Repair or replace as
Motor contact is faulty.
required.
Normal operation. When the
The bin below it is full if its
level drops, the hopper is
amber indicator light is off.
conveyed to.
Use the controller to put the
The hopper is off-line.
hopper on-line.
The convey time for the
Use the controller to enter a
hopper is set to zero.
reasonable convey time.
Normal operation. Set the
The field-installed station
bypass switch is simulating a switch so the hopper is back
in the loading sequence.
Bin Full condition.
The field-installed station
bypass switch is bad or misRepair, replace, or rewire.
wired.
Repeat the setup procedure.
The vacuum hopper was
See Chapter 4 on Pages 19
assigned to the wrong pump
to 46 for more information.
during setup.
VacTrac™ Conveying Systems
8 • 18 • 36-Station Controllers
Page 51
Problem
Possible cause
Conveying times are too long
(Time Fill mode only).
Vacuum hoppers are overfilling.
Maximum conveying times
are too long and the PLC
does not recognize the
Hopper Full proximity
switch(es).
Solution
Time the hopper(s) during
loading, and set 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.
Service Notes
Page 52
8 • 18 • 36-Station Controllers
VacTrac™ Conveying Systems
Service Notes
VacTrac™ Conveying Systems
8 • 18 • 36-Station Controllers
Page 53
Parts Department
Call toll-free 7am–5pm CST [800] 423-3183 or call [630] 595-1060
The AEC/Whitlock Parts Department at AEC, Inc. is ready to provide the parts to keep your systems up and running.
Application Engineering replacement parts ensure operation at design specifications. Please have the model and
serial number of your equipment when you call. Consult the Customer Parts List included in your information packet
for replacement part numbers.
Service Department
Call toll-free 8am–5pm CST [800] 233-4819 or call [630] 595-1060
Emergencies after 5pm CST, call [847] 439-5655
AEC/Whitlock has a qualified service department ready to help. Service contracts are available for most AEC/
Whitlock products.
Sales Department
Call [630] 595-1060 Monday–Friday, 8am–5pm CST
AEC/Whitlock 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 [630] 475-7282 Monday–Friday, 8am–5pm CST
Let AEC/Whitlock install your system. The Contract Department offers any or all of these services: project planning;
system packages including as-built drawings; equipment, labor, and construction materials; union or non-union
installations; and field supervision.
AEC, Inc.
801 AEC Drive
Wood Dale IL 60191-1198
[630] 595-1060 • Fax [630] 595-6641
Page 54
8 • 18 • 36-Station Controllers
VacTrac™ Conveying Systems
Warranty
AEC, Inc. 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 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.
Many types of AEC, Inc. equipment carry an additional one-year service policy. Consult your AEC
sales representative for specific details.
801 AEC Drive • Wood Dale, Illinois 60191-1198 USA
Phone (630) 595-1060 • Fax (630) 595-6641
http://www.aecinternet.com
801 AEC Drive • Wood Dale, IL 60191-1198 USA
(630) 595-1060 • Fax (630) 595-6641
http://www.aecinternet.com
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