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Manual Sterling XXX10-80

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  • Sterling XXX10-80 - page 1

    SCC 10-Pump 80-Station Controller Part Number: 882.00585.01 Bulletin Number: CV3-660 Effective: 8/7/07 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing ...

  • Sterling XXX10-80 - page 2

    10-Pump, 80-Station Controller Chapter 1: Safety 2 Shipping Information Unpacking and Inspection You should inspect your equipm ent for possible shipping damage. Thoroughly check the equipment for any damage that m ight have occu rred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc. In the Event of ...

  • Sterling XXX10-80 - page 3

    10-Pump, 80-Station Controller Chapter 1: Safety 3 Table of Contents Shipping Information .............................................................................................................. 2 Unpacking and Inspection ..................................................................................... 2 In the Event of Shipping Damage .. ...

  • Sterling XXX10-80 - page 4

    10-Pump, 80-Station Controller Chapter 1: Safety 4 Setting Up Pumps ............................................................................................... 43 Finishing Setup: Setting Up Passwords .............................................................. 47 Save/Restore Settings ......................................................... ...

  • Sterling XXX10-80 - page 5

    10-Pump, 80-Station Controller Chapter 1: Safety 5 Chapter 1: Safety 1-1 How to Use This Manual Use this manual as a guide and reference for installing, operating, and maintaining your equipment. The purpose is to assist you in a pplying efficient, proven techniques that enhance equipment productivity. This manual covers only light corrective main ...

  • Sterling XXX10-80 - page 6

    10-Pump, 80-Station Controller Chapter 1: Safety 6 1-2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national a nd local safety codes. This may include, but is not limited to OSHA, NEC, CSA, SPI, and any other local, national and internat ...

  • Sterling XXX10-80 - page 7

    10-Pump, 80-Station Controller Chapter 1: Safety 7 1-3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended inst ructions are followed in the maintenance and operation of the machine. All personnel engaged in the use of the machin e should become familiar with i ...

  • Sterling XXX10-80 - page 8

    10-Pump, 80-Station Controller Chapter 1: Safety 8 Maintenance Responsibility 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 access ...

  • Sterling XXX10-80 - page 9

    10-Pump, 80-Station Controller Chap ter 2: Functional Description 9 Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, and m aintenance instructions for 10-Pump, 80- Station Conveying Controllers. Model numbers are listed on the serial tag. Make sure you know the model and serial number ...

  • Sterling XXX10-80 - page 10

    10-Pump, 80-Station Controller Chapter 2: Functional Description 10 Implosion Filter Cleaning. When this feature is enabled, the controller periodically pulls a vacuum on the filter chamber and then release s it to dislodge accumulated dust and debris. Grinder Empty. This feature allows a station to receive material from a grinder bin. The level of ...

  • Sterling XXX10-80 - page 11

    10-Pump, 80-Station Controller Chap ter 2: Functional Description 11 • 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 o perator and maintenance personnel from d ...

  • Sterling XXX10-80 - page 12

    10-Pump, 80-Station Controller Chapter 3: Installation 12 Chapter 3: Inst allation 3-1 Uncrating 10-Pump, 80-Station Controllers are shipped m ounted on a skid, enclosed in a plastic wrapper, and contained in a cardboard box. 1. Pry the crating away from the skid. Note: Remove the nails holding the box to the skid and lift the box off carefully; av ...

  • Sterling XXX10-80 - page 13

    10-Pump, 80-Station Controller Chapter 3: Installation 13 8. Set up and connect vacuum receiver stations to ArmorBlocks installed in Step 3, using yellow patch cords. 9. Set up and connect vacuum pump stations and filter chambers to ArmorBlocks installed in Step 3, using yellow patch cords. 10. Determine location(s) of central alarm(s); set up and ...

  • Sterling XXX10-80 - page 14

    10-Pump, 80-Station Controller Chapter 3: Installation 14 To install KwikLink cables: 1. Cut both black and grey cables to the proper length. 2. Use cable ties to attach KwikLink cables, black cable above grey cable, on the vacuum tubing . Attach cable to the tubing with cable ties at about three-foot (3 ft./ 1 m) intervals. Make sure that cable ti ...

  • Sterling XXX10-80 - page 15

    10-Pump, 80-Station Controller Chapter 3: Installation 15 Figure 3: Side View of a Typical Mounti ng Plate Assembly with ArmorBlock Base Rotate 30º to 45º downward Installing Assembled Mounting Plates After you’ve set up the mounting plates: 1. Install them at each node location by clip ping the tubi ng clamps onto the vacuum tube, just before ...

  • Sterling XXX10-80 - page 16

    10-Pump, 80-Station Controller Chapter 3: Installation 16 Discard the standard resistor cap to eliminate confusion. 5. Mount the mounting plate assembly on the vacuum line at the end of the cable run. See Page 14 for more information. 6. Using the straight-blade cable cutter, carefully trim each flat cable so it sticks out past the final KwikLink c ...

  • Sterling XXX10-80 - page 17

    10-Pump, 80-Station Controller Chapter 3: Installation 17 The latch has two catches; the first loosely holds the connector on the cable, the second requires more pressure to close the connector tightly. The cable must be in the correct position for the connector to close properly. 3. Drive the two screws at the center points a bout halfway down; fi ...

  • Sterling XXX10-80 - page 18

    10-Pump, 80-Station Controller Chapter 3: Installation 18 • 61 to 63 — Alarm stations Setting ArmorBlock Addresses Locate the rotary switches underneath th e ArmorBlock. The two switches are: • MSD (most significant digit) for tens • LSD (least significant digit) for units/ones For example, if you wanted to set an address at 36 , you set th ...

  • Sterling XXX10-80 - page 19

    10-Pump, 80-Station Controller Chapter 3: Installation 19 Figure 5: ArmorBlock Address Node Rotary Switches Installing ArmorBlocks The ArmorBlock cable base should already be att ached to the mounting plate, aligned so it is perpendicular to the flat cables. If not, reinstall it with its proper alignment. To install the flat cables in the ArmorBloc ...

  • Sterling XXX10-80 - page 20

    10-Pump, 80-Station Controller Chapter 3: Installation 20 To secure the seal block: 1. Start the threads of each of the four cap tive screws into the cable base receptacle holes. 2. Drive each of the screws about halfway down, using the proper torque sequence: Bottom screw, top screw, left screw, right scr ew. Doing so insures that the cables are p ...

  • Sterling XXX10-80 - page 21

    10-Pump, 80-Station Controller Chapter 3: Installation 21 2. Making sure that the cable is completely straight , carefully close the hinged assembly, and apply firm, even pressure until the first latch locks into place. Note: Make sure that the flat cable is co mpletely straight before continuing! The latch has two catches; the first loosely holds ...

  • Sterling XXX10-80 - page 22

    10-Pump, 80-Station Controller Chapter 3: Installation 22 3. Run the cables from the remote interface(s) to the switch and the main controller, neatly dressing the cable with ties so that it does not interfere with system operation and it gives a neat appearance. 4. Attach RJ45 connectors at each cable e nd following the connector manufacturers ins ...

  • Sterling XXX10-80 - page 23

    10-Pump, 80-Station Controller Chapter 3: Installation 23 Figure 8: Proper Controller and Remote Interface Connections Connecting the Power Supply Enclosure to the Network The power supply provides electrical power to make the system work. Some network layouts require more than one power supply. Location is also an important consideration when loca ...

  • Sterling XXX10-80 - page 24

    10-Pump, 80-Station Controller Chapter 3: Installation 24 1. Attach a KwikLink connector included in the bag with power cables to the flat cables. One connector is used for the network gre y cable and one connector is used for the auxiliary power black cable. 2. Align the square connector of the grey drop cable so the cable leads down from the conn ...

  • Sterling XXX10-80 - page 25

    10-Pump, 80-Station Controller Chapter 3: Installation 25 Figure 9: Proper Power Supply Enclosure Connections Connecting Vacuum Receivers to the Network Make sure that all previous installation steps have been done first before starting this task. To connect a vacuum receiver to the network: 1. Attach patch cord from vacuum hopper junc tion box (st ...

  • Sterling XXX10-80 - page 26

    10-Pump, 80-Station Controller Chapter 3: Installation 26 Figure 10: 10/80 4-Connector ArmorBlock Connections Note 1: The block shown is addressed 01 for the first (2) two hoppers. The block addressed 02 would have the connections for 3-4, etc. Note 2: If a hopper does not have an optional input or optional output, the T-connector is not required. ...

  • Sterling XXX10-80 - page 27

    10-Pump, 80-Station Controller Chapter 3: Installation 27 Figure 11: Proper Vacuum Receiver Connections Connecting Vacuum Pumps and Filter Chambers to the Network Connecting Vacuum Pumps Make sure that all previous installation steps have been done first before starting this task. To connect a vacuum pump to the network: 1. Attach patchcords from v ...

  • Sterling XXX10-80 - page 28

    10-Pump, 80-Station Controller Chapter 3: Installation 28 Note 1: The block shown is addressed 41, for the first pumps. The block addressed 42 would have connectors for pumps etc. Note 2: If a pump does not have “Pump Fault #2” or a local pump alarm light, the T connector is not required. Connect the pat chcord directly to the connector on the ...

  • Sterling XXX10-80 - page 29

    10-Pump, 80-Station Controller Chapter 3: Installation 29 Figure 13: Proper Vacuum Pump Connections, Standard XPD/XPC Pumps ...

  • Sterling XXX10-80 - page 30

    10-Pump, 80-Station Controller Chapter 3: Installation 30 Figure 14: Proper Vacuum Pump Connections, XPDB Pump Connecting Filter Chambers Make sure that all previous installation steps ha ve been done first before starting this task. To connect a filter chamber to the network: 1. Attach patch cords from vacuum pump filter cham ber to the appropriat ...

  • Sterling XXX10-80 - page 31

    10-Pump, 80-Station Controller Chapter 3: Installation 31 Figure 15: Proper Filter Chamber Connections, Blowback XFC-S ...

  • Sterling XXX10-80 - page 32

    10-Pump, 80-Station Controller Chapter 3: Installation 32 Figure 16: Proper Filter Chamber Connections, Implosion Type Note: Retain the terminal caps from the ArmorBlock. They may be used later. 2. Dress the excess patch cord cables with cab le ties so they do not interfere with operation and to give a pleasing appearance. ...

  • Sterling XXX10-80 - page 33

    10-Pump, 80-Station Controller Chapter 3: Installation 33 Connecting Central Alarms to the Network Make sure that all previous installation steps have been done first before starting this task. First, determine where the best location for central alarms should be , and install the alarm module(s) there. You’ll use two yellow patch cords to connec ...

  • Sterling XXX10-80 - page 34

    10-Pump, 80-Station Controller Chapter 3: Installation 34 Figure 17: Proper Central Alarm Connections 3. Attach one connector of a yellow patch co rd to the terminal on the alarm silence switch module. Tighten the cord grip ring until snug. 4. Attach the other connector to the upper left terminal of the ArmorBlock. Tighten the cord grip ring until ...

  • Sterling XXX10-80 - page 35

    10-Pump, 80-Station Controller Chapter 3: Installation 35 Figure 18: 4-Connector ArmorBlock Connections for Central Alarms Alarm Silence Pushbutton (A-I0) Alarm Silence Pushbutton (A-I1) 4 Input / 4 Output ArmorBlock for Central Alarms Alarm Strobe Light (C- O0) Alarm Horn (C-O1) Alarm Silence Pushbutton (B-I2) Alarm Silence Pushbutton (B-I3) Alarm ...

  • Sterling XXX10-80 - page 36

    10-Pump, 80-Station Controller Chapter 3: Installation 36 Setting Up the System Setting the Number of Stations and the Number of Pumps 1. Touch System Setup at the Station Status (or Pump Status) screen. The System Setup screen appears: Note: Touching Help in the lower right of this screen gives you a menu of online help for the choices in this scr ...

  • Sterling XXX10-80 - page 37

    10-Pump, 80-Station Controller Chapter 3: Installation 37 4. Press System Setup to return to the System Setup screen. 5. Touch Pumps Present in the upper part of the System Setup screen. 6. This will take you to the Pumps Installed screen. The screen shows a list of pumps. The pumps that are not installed are red. The pumps that are installed are g ...

  • Sterling XXX10-80 - page 38

    10-Pump, 80-Station Controller Chapter 3: Installation 38 2. Check that the expected components ar e shown as present (green) and not present (grey). (Disregard any error messages.) For example, if you have 18 stations, boxes 01 through 18 in the Stations section should be green and boxes 19 through 80 should be grey. For central purge valves, you ...

  • Sterling XXX10-80 - page 39

    10-Pump, 80-Station Controller Chapter 3: Installation 39 The current settings are displayed under Alarm Strobe Suppression and Alarm Horn Silence . When a station node is configured for the default 2 stations per block (see Setting up the System on page 37), one option input and one option output per station is available. When a station node is co ...

  • Sterling XXX10-80 - page 40

    10-Pump, 80-Station Controller Chapter 3: Installation 40 Setting Up Stations Before starting the system, you must define several settings for each station, such as which pump conveys material to it and whether the station has a slide gate. This section first discusses how to use the controller’s menu system to configure stations. The table on pp ...

  • Sterling XXX10-80 - page 41

    10-Pump, 80-Station Controller Chapter 3: Installation 41 3. Touching Help in the lower right of t his screen gives you a menu of online help for the choices in this screen. 4. Adjust settings as required. Touching any box that appears in red (for “disabled”) toggles it to green (for “enabled”). Many boxes have m ore than one embedded state ...

  • Sterling XXX10-80 - page 42

    10-Pump, 80-Station Controller Chapter 3: Installation 42 2. You can enter a name of up to four (4) a lpha-numeric characters. If you would like to enter a longer name, you can go back to the Station n Setup screen and press Name Line 2 to repeat the process . Using Name Line 2 will allow you to enter up to four (4) more alpha-numeric characters, f ...

  • Sterling XXX10-80 - page 43

    10-Pump, 80-Station Controller Chapter 3: Installation 43 4. As appropriate, either continue co pying to other stations, or touch S tation Setup to go back to the Station n Setup screen. To copy the selected station’s settings to a range of other stations 1. Touch First Station button next to the green button labeled “Copy to Range of Stations. ...

  • Sterling XXX10-80 - page 44

    10-Pump, 80-Station Controller Chapter 3: Installation 44 2. Touch the icon for the pump you want to set up, and hold it for several seconds. The Pump n Setup screen appears: 3. Touching Help in the lower right of t his screen gives you a menu of online help for the choices in this screen. 4. Adjust settings as required. Touching any box that appea ...

  • Sterling XXX10-80 - page 45

    10-Pump, 80-Station Controller Chapter 3: Installation 45 d. Touch Goto and enter a pump number to go to that pump’s setup screen 5. To save or restore settings, go to the System Setup screen and touch Save/Restore on the right side of the screen. Naming Pumps To name a station, go to the Pum p Status screen. Touch the icon for the pump you want ...

  • Sterling XXX10-80 - page 46

    10-Pump, 80-Station Controller Chapter 3: Installation 46 To copy the selected pump’s settings to one other pump 1. Touch the gray Copy to Pump button next to the gr een Copy To Single Pump button. The keypad pops up. 2. Enter the pump number for the pump you are copying to. Use ← to erase any mistakes. Use ↵ to enter the value. The keypad di ...

  • Sterling XXX10-80 - page 47

    10-Pump, 80-Station Controller Chapter 3: Installation 47 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 ne ither password set. This allows every user access to all functions. Setup Password. If you define a password for set ...

  • Sterling XXX10-80 - page 48

    10-Pump, 80-Station Controller Chapter 3: Installation 48 2. Touch Operator Password or Setup Password, as appropriate. A keypad pops up. 3. Enter up to eight (8) alpha-numeric characters. If you want to remove the password protection, simply leave the entry blank. Use ← to erase any mistakes. Use ↵ to enter the value. The keypad disappears and ...

  • Sterling XXX10-80 - page 49

    10-Pump, 80-Station Controller Chapter 3: Installation 49 3-6 Initial Startup Once you have finished all the setup described a bove, you are ready to start the system. To do so: 1. At any screen, touch Stations on the right-hand side of the screen. The Station Status screen appears. 2. For each station that you want to use, briefly touch its icon. ...

  • Sterling XXX10-80 - page 50

    10-Pump, 80-Station Controller Chapter 4: Operation 50 Chapter 4: Operation 4-1 Overview Your 10/80 controller electrically controls va lves and solenoids to c onvey material from a central location to individual stations as n eeded. The controller senses demands for material at the stations and responds to the demands in a timely fashion. This sec ...

  • Sterling XXX10-80 - page 51

    10-Pump, 80-Station Controller Chapter 4: Operation 51 4-3 Basic Tasks This section covers tasks that can be carried out with no password or with an operator’s password. Reviewing Station Status The starting point for all operations is the Sta tion Status screen. To reach this screen from any other screen: 1. Touch Stations . The Station Status s ...

  • Sterling XXX10-80 - page 52

    10-Pump, 80-Station Controller Chapter 4: Operation 52 The following table explains the status represen ted by each color at the Station Status screen. Color Label Description Silver Offline Station is not enabled. The controller ign ores any demands or alarms. Blue Ready Station is enabled and idle (full). Dark Yellow Demand Station requires mater ...

  • Sterling XXX10-80 - page 53

    10-Pump, 80-Station Controller Chapter 4: Operation 53 2. Touch anywhere in the rectangle in the upper right of the screen or the Help button on the lower right side of the screen. The Help Menu appears. 3. In the section of the Help Menu labeled Screen Symbols/Colors , touch Pump . The Pump Symbols help screen appears, explaining the status repres ...

  • Sterling XXX10-80 - page 54

    10-Pump, 80-Station Controller Chapter 4: Operation 54 • Enter the alphanumeric password. Each digit appears as an “ * ” as you touch it. Press ↵ when complete. If you have lost the password(s), contact the manufacturer for assistance. Once you have logged on, the password rema ins active until you log off or the password expires. (Setup pe ...

  • Sterling XXX10-80 - page 55

    10-Pump, 80-Station Controller Chapter 4: Operation 55 Reviewing and Adjusting Basic Station Settings Reaching and Reading the Station Operator Screens The 10/80 Controller has a Station Operator Settings 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 n ...

  • Sterling XXX10-80 - page 56

    10-Pump, 80-Station Controller Chapter 4: Operation 56 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 ...

  • Sterling XXX10-80 - page 57

    10-Pump, 80-Station Controller Chapter 4: Operation 57 The button changes to Priority Convey Active and blinks until the station’s demand has been satisfied (or you stop the priority convey).The controller begins filling the chosen station only (after fi nishing any convey already in progress). To stop a priority convey before the station is com ...

  • Sterling XXX10-80 - page 58

    10-Pump, 80-Station Controller Chapter 4: Operation 58 4-4 Advanced Tasks 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 with the setup password is the same as for lo ...

  • Sterling XXX10-80 - page 59

    10-Pump, 80-Station Controller Chapter 4: Operation 59 shutdown delay, alarms, or blowback to the st andby pump. Mechanical connections must be changed manually. To transfer stations from a pump to a standby pum p: 1. At any screen, touch Pumps . The Pump Status screen appears. 2. Both the source pump and the standby pump must be offline. If either ...

  • Sterling XXX10-80 - page 60

    10-Pump, 80-Station Controller Chapter 4: Operation 60 10. When you enter the second pump num ber, 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 a Press To Move Stations button. If you get an ...

  • Sterling XXX10-80 - page 61

    10-Pump, 80-Station Controller Chapter 4: Operation 61 3-5 Alarms Reviewing Alarms At the Station Status or Pump Status screen: 1. Touch Alarms . The Alarm Log screen appears, with the newest alarm listed first: To scroll up and down through the list: • Touch ▲ and ▼ at the bottom of the list. Silencing Alarms Whenever a new alarm occurs, you ...

  • Sterling XXX10-80 - page 62

    10-Pump, 80-Station Controller Chapter 5: Maintenance 62 Chapter 5: Maintenance 5-1 Preventative Maintenance To maintain cooling fan, check and clean and/or replace filter. ...

  • Sterling XXX10-80 - page 63

    10-Pump, 80-Station Controller Chapter 6: Configurable Settings 63 Chapter 6: Configurable Settings This section describes the proper setup of the 24-pump 128-station control system parameters. These parameters are operat or cha ngeable; however, these items should require setup only during the initial installation. Only authorized personnel should ...

  • Sterling XXX10-80 - page 64

    10-Pump, 80-Station Controller Chapter 6: Configurable Settings 64 Name Description Options Default Conveying Options Assigned to pump n Name of the pump to which this station’s vacuum line is connected. Special convey Whe n this option is enabled, the station’s vacuum valve remains open for the co nvey time, even if the station is not demandin ...

  • Sterling XXX10-80 - page 65

    10-Pump, 80-Station Controller Chapter 6: Configurable Settings 65 Name Description Options Default Partial convey When this option is enabled, the controll er issues a “partial convey ” al arm if it has repeatedly attempted to convey material to the station, and material has moved from t he station into the receiver, but the volume-fill proxim ...

  • Sterling XXX10-80 - page 66

    10-Pump, 80-Station Controller Chapter 6: Configurable Settings 66 Name Description Options Default Every n loads Number of convey ing cycles between filter cleanings. Adjust this setting based on experi ence. The more dust and debris in your material lin e, the smaller this number needs to be. 1–99 5 # pulses Number of pulses of compressed air s ...

  • Sterling XXX10-80 - page 67

    10-Pump, 80-Station Controller Chapter 6: Configurable Settings 67 Name Description Options Default RPV (Remote Proportioning Valve) This option allows the system to use a remote proportioning valve to mix two different materials, typically virgin and regrind m aterials, during a convey cycle. Touching RPV repeatedly at the Station n Setup screen s ...

  • Sterling XXX10-80 - page 68

    10-Pump, 80-Station Controller Chapter 6: Configurable Settings 68 6-3 Options for Pump Setup Several of the items in this screen are not setup options but are instead intended for use during operation. These items (hour meter and transferring stations to a standby pump) are described in Chapter 4, “Operation.” Name Description Options Default ...

  • Sterling XXX10-80 - page 69

    10-Pump, 80-Station Controller Chapter 6: Configurable Settings 69 Name Description Options Default # pulses Number of pulses of compressed air sen t through the pump’s filter during cleanin g. If blowback is not working as de si red, the service department may ask you to chan ge this setting. 1–99 5 On time Number of seconds that the air comp ...

  • Sterling XXX10-80 - page 70

    10-Pump, 80-Station Controller Chapter 7: Troubleshooting 70 Chapter 7: T roubleshooting 7-1 General Troubleshooting Problem Possible cause Solution The controller panel is not connected to a power source. Plug in the controller panel. Fuse/circuit breaker in the power drop is blown/tripped. Replace/reset. The controller panel doesn’t light up at ...

  • Sterling XXX10-80 - page 71

    10-Pump, 80-Station Controller Chapter 7: Troubleshooting 71 7-2 Alarms The format for all station alarms is “Station n [alarm text],” for example, “Station 12 receiver low level.” The format for all pump alarms is “Pump n [alarm text].” Any alarm that does not start with “Station” or “Pump” is a system alarm. The following tabl ...

  • Sterling XXX10-80 - page 72

    10-Pump, 80-Station Controller Chapter 7: Troubleshooting 72 Alarm message Possible cause Pump X Option Output Conflict An assigned station has closed loop enabled and the pump has either implosion with sealing valve or Local Alarm enabled. Patch cord is cut or disconnected Purge Valve X Failure Solenoid has f ailed. ArmorBlock is not installed pro ...

  • Sterling XXX10-80 - page 73

    10-Pump, 80-Station Controller Chapter 7: Troubleshooting 73 Pump Alarms Alarm message Possible cause Patch cord is cut or disconnected. Blowback Solenoid Failure (Critical) Solenoid has failed. Patch cord is cut or disconnected. Clearing Valve Failure Solenoid has failed. Pump disconnect is off. Patch cord is cut or disconnected. Failure Pump cont ...

  • Sterling XXX10-80 - page 74

    10-Pump, 80-Station Controller Chapter 8: Appendix 74 Chapter 8: Appendix 8-1 Optional Components The following is a list of options that your controller may be equipped with: 230/1/60 Operation. Required to operate with a 230/1/60 suppl y voltage. Additional audible/visual alarm with silence button. Alarm light and horn assembly that can be remote ...

  • Sterling XXX10-80 - page 75

    10-Pump, 80-Station Controller Chapter 8: Appendix 75 8-2 Drawings and Diagrams Figure 20: 10-Pump, 80-Station Controller with 10" Display Also, review electrical drawings supplied in the packet with this manual. Note: Allow 12” of clearance on each side of the controller for ventilation and cables. ...

  • Sterling XXX10-80 - page 76

    10-Pump, 80-Station Controller Chapter 8: Appendix 76 Figure 21: Typical System Installation Layout 8-3 Main Control Panel Spare Parts List Quantity Part Number Description 1 Filter only- Clean as ne eded 1 A0569859 Fan grill with filter 1 739.00017.00 4A Power supply 1 A0542203 2A MDL fuse 1 A0568903 10A FNQ fuse 1 A0542205 2.5A MDL fuse 1 A054220 ...

  • Sterling XXX10-80 - page 77

    10-Pump, 80-Station Controller Chapter 8: Appendix 77 8-4 Returned Material Policy Credit Returns Prior to the return of any material, authoriz ation must be given by the manufacturer. A RMS number will be assigned for the equipment to be returned. Reason for requesting the return must be given. All returned material purchased from the manufacturer ...

  • Sterling XXX10-80 - page 78

    10-Pump, 80-Station Controller Chapter 8: Appendix 78 8-5 Safety Tag Information Controller Safety Tags 8-6 Controller Identification (Serial Number) Tag (Located on the side of the controller box) Street Address Town, State, Zip Code Telephone Number Fax Number XXX CONTROL PA NEL Model No. XXX10 -80 Serial No. 31K0 182 115 Volt 60 Hz 1 Ph Control ...

  • Sterling XXX10-80 - page 79

    10-Pump, 80-Station Controller Chapter 8: Appendix 79 8-7 Technical Assistance (Contact Information) Parts Department Call toll-free 7am–5pm CST [ 800 ] 423- 3183 or call [ 262 ] 641 - 861 0, Fax [262] 641-8653 The ACS Customer Service Group will provide your compan y with genuine OEM qualit y parts manufactured to engi neering desig n specificat ...

  • Sterling XXX10-80 - page 80

    10-Pump, 80-Station Controller Chapter 8: Appendix 80 10 Pump / 80 Station Convey Control Hardware Setup and Upgrade Instructions ...

  • Sterling XXX10-80 - page 81

    10-Pump, 80-Station Controller Chapter 8: Appendix 81 Table of Contents CompactLogix L35E Setup ( Brand New Processor )…………………………… 82 CompactLogix L35E Upgrade …................. ............................ ............................ 86 VersaView CE 1000H Setup …………………… ………………………… …? ...

  • Sterling XXX10-80 - page 82

    10-Pump, 80-Station Controller Chapter 8: Appendix 82 CompactLogix L35E Setup Use this procedure to setup a new CompactLogix PLC for use on a 10 Pump – 80 Station Conve y Control. 1. Verify that the control is powered down and the PLC CPU key switch is in the RUN position. 2. Insert the configuration compact flash card contai ning the new version ...

  • Sterling XXX10-80 - page 83

    10-Pump, 80-Station Controller Chapter 8: Appendix 83 4. Wait for the Run LED on the top front of the CPU to turn solid gre en and for the I/O LED to stop blinking ( Fig 2 ) for 30 seconds. Since a new CPU requi res a firmware upgrade this will take about 2-3 minutes. Do not turn off power until the upgrade completes . Fig 2 5. Turn off power to th ...

  • Sterling XXX10-80 - page 84

    10-Pump, 80-Station Controller Chapter 8: Appendix 84 9. Go to the System Setup Screen ( Fig 3 ) by pressing the System Setup button on any screen. Fig 3 10. Go to the Save / Restore Screen ( Fig 4) by pressing the Save / Restore button on the right side of the screen. Fig 4 11. Restore Settings by pressing the yellow Restore Settings button. 12. W ...

  • Sterling XXX10-80 - page 85

    10-Pump, 80-Station Controller Chapter 8: Appendix 85 15. Save Settings by pressing the yellow Save Settings button. 16. Wait for the “ Save Complete ” message. ( This message is only displayed for 10 seconds ). 17. Go to the System Setup screen by pressing the System Setup button. 18. Verify that the clock has the correct time. If not, set the ...

  • Sterling XXX10-80 - page 86

    10-Pump, 80-Station Controller Chapter 8: Appendix 86 CompactLogix L35E Upgrade Use this procedure to upgrade the software on a CompactLogix PLC for use on a 10 Pump – 80 Station Convey Control. 1. If the control is off, turn it on and wait f or the control to power up. 2. Verify that the key switch on the front of the PLC CPU is in the RUN posit ...

  • Sterling XXX10-80 - page 87

    10-Pump, 80-Station Controller Chapter 8: Appendix 87 5. Go to the System Setup Screen ( Fig 6 ) by pressing the System Setup button on any screen. Fig 6 6. Go to the Save / Restore Screen ( Fig 7) by pressing the Save / Restore button on the right side of the screen. Fig 7 7. Save Settings by pressing the yellow Save Settings button. 8. Wait for t ...

  • Sterling XXX10-80 - page 88

    10-Pump, 80-Station Controller Chapter 8: Appendix 88 about 10 seconds. If a firmware upgrade is re quired, this will take about 2-3 m inutes. Do not turn off power until the upgrade completes . Fig 8 11. Turn off power to the contr ol enclosure. Wait 5 seconds. Turn on power. 12. Go to the System Setup Screen by pressing the System Setup button on ...

  • Sterling XXX10-80 - page 89

    10-Pump, 80-Station Controller Chapter 8: Appendix 89 VersaView CE 1000H Setup Use this procedure to setup a new VersaView display or to upgrade a VersaView display for use on a Sterling 10 Pump – 80 Station Conve y Control. 1. Remove the compact flash card from the VersaView if one is installed by pressing the Eject Button ( Fig 9 ). Fig 9 2. If ...

  • Sterling XXX10-80 - page 90

    10-Pump, 80-Station Controller Chapter 8: Appendix 90 4. If you are upgrading a VersaView that has been configured to work with 10 Pum p – 80 Station control an Error screen ( Fig 10 ) will appear. Press the “ OK [F7] ” button to close the screen. Fig 10 ...

  • Sterling XXX10-80 - page 91

    10-Pump, 80-Station Controller Chapter 8: Appendix 91 5. If VersaView boots to the Windows CE desktop ( Fig 11 ) skip to step 26. Fig 11 ...

  • Sterling XXX10-80 - page 92

    10-Pump, 80-Station Controller Chapter 8: Appendix 92 6. If the VersaView boots to the RSView ME Station screen with an “ Exit [F8] ” button ( Fig 12 ), press the “ Exit [F8] ” button to bring up the Windows CE desktop ( Fig 11 ). Skip to step 26. Fig 12 ...

  • Sterling XXX10-80 - page 93

    10-Pump, 80-Station Controller Chapter 8: Appendix 93 7. If the VersaView boots to the RSView ME Station screen without an “ Exit [F8] ” button ( Fi g 13 ), insert the VersaView Program Compact Flash Card labeled 744.00134.00 10P80S Disp Program. Fig 13 8. Press the “ Load Application [F1] ” button. ...

  • Sterling XXX10-80 - page 94

    10-Pump, 80-Station Controller Chapter 8: Appendix 94 9. The Load Application Screen ( Fig 14 ) will appear. Fig 14 10. Press the “ Source [F1] ” button so the circle next to “ External Storage 1 ” is filled. 11. Use the up and down arrows to select the “ VersaViewCE_LockDown.mer ” application. 12. Press the “ Load [F2] ” button. ...

  • Sterling XXX10-80 - page 95

    10-Pump, 80-Station Controller Chapter 8: Appendix 95 13. The Replace Communications Confirmation Screen ( Fig 15 ) will appear. Fig 15 14. Press the “ Yes [F7] ” button. 15. The RSView ME Station Screen without an “ Exit [F8] ” button ( Fig 13 ) will appear. 16. Press the “ Run Application [F2] ” button when it is no longer grayed out. ...

  • Sterling XXX10-80 - page 96

    10-Pump, 80-Station Controller Chapter 8: Appendix 96 17. The application will start after a short time ( Fig 16 ). Fig 16 18. Press the “ VersaView Enable ” button. 19. “ VersaView Mode Enable ” message will be displayed. 20. Remove the VersaView Program Compact Flash Card from the display. 21. Press the “ Reboot ” button. 22. The disp ...

  • Sterling XXX10-80 - page 97

    10-Pump, 80-Station Controller Chapter 8: Appendix 97 27. The Firmware Upgrade Card Window ( Fig 17 ) will appear. Fig 17 28. When prompted to upgrade firmware, press the “ Upgrade [F7] ” button 29. The firmware upgrade process will begin and after a short time the display will reboot. ...

  • Sterling XXX10-80 - page 98

    10-Pump, 80-Station Controller Chapter 8: Appendix 98 30. When the calibration screen ( Fig 18 ) appears, follow the on-screen instructions ( use a pencil eraser, pen cap or other dull pointing device ). Fig 18 31. When the firmware upgrade complete window appears, remove the VersaView Firmware Upgrade Compact Flash Card from the display by pressin ...

  • Sterling XXX10-80 - page 99

    10-Pump, 80-Station Controller Chapter 8: Appendix 99 39. A window will appear showing the contents of the “ My Computer ” folder ( Fig 19 ). Fig 19 40. Double tap the “ Storage Card2 ” folder. ...

  • Sterling XXX10-80 - page 100

    10-Pump, 80-Station Controller Chapter 8: Appendix 100 41. A window will appear showing the contents of the “ Storage Card2 ” folder ( Fig 20 ). Fig 20 42. Double tap the “ BRutil ” icon. ...

  • Sterling XXX10-80 - page 101

    10-Pump, 80-Station Controller Chapter 8: Appendix 101 43. The System Backup/Recover Window ( Fig 21 ) will appear. Fig 21 44. Press the “ Restore system ” button. DO NOT PRESS THE “BACK UP SYSTEM” BUTTON . ...

  • Sterling XXX10-80 - page 102

    10-Pump, 80-Station Controller Chapter 8: Appendix 102 45. A Warning Window ( Fig 22 ) will appear. Fig 22 46. Press the “ OK ” button in the upper right corner of the Warning Window ( Fig 22 ). 47. After a short delay the VersaView will reboot. 48. If the calibration screen ( Fig 18 ) appears, follow the on-screen instructions ( use a pencil e ...

  • Sterling XXX10-80 - page 103

    10-Pump, 80-Station Controller Chapter 8: Appendix 103 • Remote Display #4 – Select “ 745_00092_00.m er ”. 11. Press the “ Load [F2] ” button. 12. The Replace Communications Confirmation Screen ( Fig 15 ) will appear. 13. Press the “ Yes [F7] ” button. 14. The RSView ME Station Screen will appear ( Fig 12 ). 15. The application will ...

  • Sterling XXX10-80 - page 104

    10-Pump, 80-Station Controller Chapter 8: Appendix 104 20. The Startup Options Screen ( Fig 24 ) will appear. Fig 24 21. Press the enter “  ” button to select “ RSView ME Station Startup ” button. ...

  • Sterling XXX10-80 - page 105

    10-Pump, 80-Station Controller Chapter 8: Appendix 105 22. The RSView ME Station Startup Screen ( Fig 25 ) will appear. Fig 25 23. Verify that the circle next to “ Run Current Application ” is filled. If not, press the “ On Startup [F1] ” button until the “ Run Current Application ” is filled. 24. Press the “ OK [F7] ” button. 25. T ...

  • Sterling XXX10-80 - page 106

    10-Pump, 80-Station Controller Chapter 8: Appendix 106 30. The Networks and Communications Menu ( Fig 26 ) will appear. Fig 26 31. Press the down arrow “ ▼ ” button to highlight “ Network Connections ”. 32. Press the enter “  ” button to select “ Networks Connections ” . ...

  • Sterling XXX10-80 - page 107

    10-Pump, 80-Station Controller Chapter 8: Appendix 107 33. The Network Connections Menu will appear ( Fig 27 ). Fig 27 34. Press the down arrow “ ▼ ” button to highlight “ Network Adaptors ”. 35. Press the enter “  ” button to select “ Networks Adaptors ”. ...

  • Sterling XXX10-80 - page 108

    10-Pump, 80-Station Controller Chapter 8: Appendix 108 36. The Network Adaptors Screen will appear ( Fig 28 ). Fig 28 37. Press the “ IP Address [F2] ” button. ...

  • Sterling XXX10-80 - page 109

    10-Pump, 80-Station Controller Chapter 8: Appendix 109 38. The IP Address screen will appear ( Fig 29 ). Fig 29 39. Press the “ IP Address [F1] ” button. ...

  • Sterling XXX10-80 - page 110

    10-Pump, 80-Station Controller Chapter 8: Appendix 110 40. A keyboard will appear ( Fig 30 ). Fig 30 41. Enter the appropriate IP Address for the display you are setting up: • Remote Display #1 - Enter “ 192.168.10.2 ” via the ke yboard. • Remote Display #2 - Enter “ 192.168.10.3 ” via the ke yboard. • Remote Display #3 - Enter “ 19 ...

  • Sterling XXX10-80 - page 111

    10-Pump, 80-Station Controller Chapter 8: Appendix 111 45. After a short delay the Adapters Screen ( Fig 31 ) will appear. Fig 31 46. Press the “ OK [F7] ” button. 47. The Network Adaptors Screen will appear ( Fig 28 ). 48. Press the “ Close [F8] ” button. 49. The Network Connections Menu will appear ( Fig 27 ). 50. Press the “ Close [F8] ...

  • Sterling XXX10-80 - page 112

    10-Pump, 80-Station Controller Chapter 8: Appendix 112 57. A Reset Confirmation screen will appear ( Fig 32 ). Fig 32 58. Press the “ Yes [F7] ” button. 59. After a short delay the screen will reboot. 60. While the VersaView is rebooting, pl ug the Ethernet cable back in. 61. The Windows CE desktop will appear for a shor t time. The VersaView w ...

Manufacturer Sterling Category Home Theater Server

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