MCS-406 SIX STATION CONTROL PACKAGE

Transcription

1 MCS-406 SIX STATION CONTROL PACKAGE MCS VAC MCS VDC I/O NOVATEC, Inc All Rights Reserved MCS-406 IM 9 FEB 2018

2 NOTES: Please record the following information, which is specific to this piece of equipment, in the space provided. Our Parts/Service Department will need these numbers to properly respond to any of your requests. Instruction Manual: MCS-406 IM 9 FEB 2018 Model #: Serial # DISCLAIMER: NOVATEC, Inc. shall not be liable for errors contained in this Instruction Manual nor for misinterpretation of information contained herein. NOVATEC shall not, in any event, be held liable for any special, indirect or consequential damages in connection with performance or use of this information NOVATEC, Inc. All Rights Reserved Page 2

3 Contents 1.0 DRAWING LIST PRINCIPLE OF OPERATION UNPACKING AND INSPECTION INSTALLATION General Vacuum Power Unit Station Valve Cyclone Filter ELECTICAL INSTALLATION Wiring for MCS Volt AC Wiring for MCS Volt DC OPERATION General Proportioning or Purge Control Preset Parameter Values Changing Loading Parameters PARAMETERS EXPLANATION Load Time: Pmp/LT Dump Time: Pmp/DT Seek Time: Pmp/ST SETTING THE TIME RUNNING HOUR COUNTER WARRANTY DRAWING LIST MCS-406 CONTROLLER PART NUMBER DRAWING NUMBER 24 VOLTS DC-115VAC MCS VOLTS AC MCS VOLTS DC-230VAC MCS NOVATEC, Inc. All Rights Reserved Page 3

4 2.0 PRINCIPLE OF OPERATION Novatec MCS-406 CONTROLLERS are designed to operate a single vacuum power unit to convey material to a maximum of six stations. Each vacuum receiver may be turned on individually with its separate ON/OFF switch. It will sequentially load each station that needs material and skip each station that is full. The MCS-406 does not include Blowback nor a NO-LOAD alarm. This controller cannot control proportioning, but an additional control box (PC-1) can be added to each station where proportioning is required. Proportional valves are capable of providing a layering or blending effect to the materials conveyed. In addition, the PC-1 adds Blowback capability to the stations so equipped. 3.0 UNPACKING AND INSPECTION The MCS-406 controller is shipped complete and is fully programmed from the factory. After receipt of the unit, completely inspect it for damage. Although, the units are packaged securely, vibration and mishandling during transit can cause damage. All screws, bolts and other connections should be checked to make sure they have not come loose in transit. Report any damage immediately to the transportation company. 4.0 INSTALLATION 4.1 General The single most important activity performed to ensure satisfactory operation of a pneumatic convey system is the actual installation of the equipment, with personnel safety weighted at every decision point. All components should be located so that material lines and vacuum lines are as short as possible. Elbows or other changes in direction are minimized. The material conveying line should be horizontal and/or vertical and as direct as possible with no slope. Care needs to be taken that all connectors are vacuum tight. All rigid conveying tubing should be properly supported by the user to provide a safe, but secure installation. It's generally acceptable to use flexible hose and clamps to connect material pick up lances, vacuum chambers, etc., to material or vacuum lines. The flexible hose should be only as long as needed since excess hose will reduce the efficiency of the system. The hose should not sag. The conveying lines should be grounded to prevent "shocks" from static electricity that may be generated by some materials as they are conveyed. Rigid tubes and elbows should be connected together with bolted couplers. Each tube end should be square cut, round, and without burrs. The tube ends should butt together when installed, with the bolted coupler centered over the joint. All national and local codes need to be followed. Proper grounding of all equipment is important. Check the electrical wiring schematic for wiring numbers and details. The following describes installation of typical system components NOVATEC, Inc. All Rights Reserved Page 4

5 4.2 Vacuum Power Unit Locate so that access to the secondary filter element mounted to the vacuum power unit is available. Secure to floor or platform as necessary. Attach high voltage (check nameplate) to the motor starter (located in the motor starter junction box mounted to the vacuum power unit) from a field supplied disconnect switch or to the optional combination starter with fused disconnect switch. An electrical ground wire is also required. A clean, dry supply of PSIG compressed air is connected to the vacuum breaker valve solenoid. When the vacuum breaker valve is energized it allows ambient air to pass through the vacuum blower. This is done instead of simply shutting the pump down to prevent premature wearing of the pump and belt drive caused by constantly starting and stopping the pump. Eventually the pump will shut down completely if not needed when the search timer expires. 4.3 Station Valve Some vacuum receivers have a built-in station valve. Otherwise, locate a separate station-t conveniently to each vacuum receiver. Typically the station-t valve is rigidly attached with bolted couplers to vacuum lines running to the vacuum power unit or to the optional cyclone filter while flex hose is used to connect the vacuum inlet to the top of the vacuum chamber. The station valve solenoid is wired to the main control panel. Ground the system as necessary. A clean, dry supply of PSIG compressed air is connected to the station tee valve solenoid. 4.4 Cyclone Filter Locate the cyclone filter as close as possible to the vacuum power unit. Provide access for the material with catch pan or fines drum as necessary. Secure the cyclone filter to the floor or platform. Attach vacuum lines from the conveying system to the cyclone inlet (Tangential inlet on the side of the cyclone body). Attach the cyclone outlet (top duct) to the vacuum breaker valve inlet on the vacuum power unit NOVATEC, Inc. All Rights Reserved Page 5

6 5.0 ELECTICAL INSTALLATION WARNING: IMPORTANT INFORMATION Danger! Disconnect all voltage before inspecting or servicing the equipment. Only properly trained, qualified technicians should operate or service the equipment. All national and local electrical, building, and safety codes need to be followed. Proper grounding of all equipment is important. Check the electrical wiring schematic for wiring numbers and details. Pre-punched holes have been provided to accept an appropriate strain relief for field wiring. 5.1 Wiring for MCS Volt AC Dangerous Voltage! Do not put your finger or any object in the program module/card slot. If the power supply is not connected properly, the plug for the module/card may carry voltage. The module/card or cover must be in place at all times. NOTE: the module/card accessory is optional and is not needed for normal operation. 1. Mount the MCS-406 control box in a secure location. 2. Refer to drawings MCS D Remove screw (item number 3 in drawing) allowing the cover plate to be opened. 4. Open the hinged cover plate. Note: Wire number 2 is the neutral wire. 5. Motor Starter. Connect wire (wire number 28 in drawing) from the normally closed contact of overload for the vacuum power unit to the output terminal Q8 on the PLC (Typical Novatec motor starters are shown on drawing SK-836A). Connect the motor starter coil to terminal number 2 on the terminal block (wire number 2 in drawing). 6. VBV (vacuum breaker valve). Connect wire (wire number 27 in drawing) from the VBV solenoid to the output terminal Q7 on the PLC. Connect the VBV solenoid to terminal number 2 on the terminal block (wire number 2 in drawing). 7. Level switch. Connect wire (wire number 11,12,13,14,15,16 in drawing) from the ON/OFF switch to the level switch (green screw of twist-lock plug) on the respective station. Connect the level switch (copper screw of twist-lock plug) to terminal number 3 on the terminal block (wire number 3 in drawing). If using photoelectric switch, connect wire (wire number 2 in drawing) from terminal 2 on the terminal block to silver screw on twist-lock plug. Note: If using a capacitance type proximity switch, install resistor kit part number 10467, as shown on drawing. 8. Station valve solenoid. Connect wire (wire number 21,22,23,24,24,26 in drawing) from the output terminal on the PLC (Q1, Q2, Q3, Q4, Q5, Q6) to the respective station valve solenoid. Connect the station valve solenoid to (wire number 2 in drawing) to terminal number 2 on the terminal block. 9. Connect power to the terminal block (L1, L2) and ground NOVATEC, Inc. All Rights Reserved Page 6

7 5.2 Wiring for MCS Volt DC Dangerous Voltage! Do not put your finger or any object in the program module/card slot. If the power supply is not connected properly, the plug for the module/card may carry voltage. The module/card or cover must be in place at all times. NOTE: the module/card accessory is optional and is not needed for normal operation. Keep low voltage wiring separated from higher voltage wires. 1. Mount the MCS-406 control box with power supply box in a secure location. 2. Refer to drawings MCS-406 D Remove screw (item number 3 in drawing) allowing the cover plate to be opened. 4. Open the hinged cover plate. Note: Wire number 2 is the negative wire. 5. Motor Starter. Connect wire (wire number 28 in drawing) from the normally closed contact of overload for the vacuum power unit to the output terminal Q8 on the PLC (Typical Novatec motor starters are shown on drawing SK-836A). Connect the motor starter coil to terminal number 2 on the terminal block (wire number 2 in drawing). 6. VBV (vacuum breaker valve). Connect wire (wire number 27 in drawing) from the VBV solenoid to the output terminal Q7 on the PLC. Connect the VBV solenoid to terminal number 2 on the terminal block (wire number 2 in drawing). 7. Level switch. Connect wire (wire number 11,12,13,14,15,16 in drawing) from the on/off switch to the level switch (green screw of twist-lock plug) on the respective station. Connect the level switch (copper screw of twist-lock plug) to terminal number 3 on the terminal block (wire number 3 in drawing). If using photoelectric switch, connect wire (wire number 2 in drawing) from terminal 2 on the terminal block to silver screw on twist-lock plug. Note: If using a capacitance type proximity switch, install resistor kit part number 10467, as shown on drawing. 8. Station valve solenoid. Connect wire (wire number 21,22,23,24,24,26 in drawing) from the output terminal on the PLC (Q1, Q2, Q3, Q4, Q5, Q6) to the respective station valve solenoid. Connect the station valve solenoid to (wire number 2 in drawing) to terminal number 2 on the terminal block. Connect supply voltage (240vac models only) wires from the incoming power supply cable to the customer s power supply. (Refer to drawing MCS-406D6). Voltage (or Hot) to the red wire, Neutral to the white wire, and ground to the green wire. 120 VAC versions already have a molded plug with about a 7-foot cable to plug into a dedicated outlet NOVATEC, Inc. All Rights Reserved Page 7

8 6.0 OPERATION 6.1 General Push the SYSTEM switch to the "ON" position. Enable the desired stations by switching the individual ON/OFF STATION switches to the ON position. The vacuum power unit motor will then start and load material to the first empty station for a time that is adjustable by changing the Load Time value in the SETTINGS menu of the controller. The load time may be increased or decreased as necessary. See CHANGING PARAMETERS on page 9 of this manual. NOTE: DO NOT ALLOW RECEIVER TO OVERFILL. When the load time is completed, the controller will select the next station that is enabled and needs material, allowing material in the first loaded vacuum receiver to fall through the dump valve. The dump time begins at the end of the load time and may be adjusted as necessary. The dump value should be set 1 to 2 seconds greater than the time necessary for the chamber to completely empty. The load and dump cycles will continue until all the drying hoppers or surge bins are full, at which time the material will hold the dump valve flapper open, placing the system in a Seek-time mode. If the hoppers remain full until the end of the search time, the pump will shut down. As material is withdrawn from the hopper, the material level will fall, the flapper will close, and the loader will again activate to automatically keep the hopper full. On machine mount units the load and dump cycles will continue if the material level remains below the sensors located on the sight tube. When the material is above this point a capacitance sensor or a pair of photoelectric sensors will continuously detect material and not allow the system to load. As material is withdrawn, the level will fall, and the sensors will no longer detect material. The loader will then continue with the loading cycle NOVATEC, Inc. All Rights Reserved Page 8

9 6.2 Proportioning or Purge Control Although this controller cannot control purge or proportioning, an additional control box can be added for each station, for these functions. Refer to the appropriate manual for detailed instructions. 6.3 Preset Parameter Values The MCS-406 controller is preset at the factory with the following values. FUNCTION TIMER FACTORY SETTING Load Time Sta1/LT through Sta5/LT Seconds Dump Time Sta1/DT through Sta5/DT Seconds Global: Seek-time ST/T 45 These values can be easily changed by the system operator to account for the individual flow properties of the materials being processed. See 6.4 Changing Loading Parameters 6.4 Changing Loading Parameters The control is equipped with a small LCD screen that displays operating and programming prompts, plus pushbuttons to aid in selecting parameters and making changes. Instructions listed below are repeated on the control face for ease of use NOVATEC, Inc. All Rights Reserved Page 9

10 7.0 PARAMETERS EXPLANATION 7.1 Load Time: Pmp/LT Measured in seconds, this is the amount of time the vacuum pump will run to load material into the vacuum receiver. Too little time will result in insufficient loading. Too much time will pack the loader full of material, prematurely blinding the filter and possibly clogging the conveying line. This setting should be adjusted over the course of several normal loading cycles to just fill (but not overfill) the vacuum receiver. NOTE: VRP series powder receivers include an extended body to house the cartridge filter(s). Loaded material should not be allowed to be filled up into this extended hopper area. It is intended only as a housing for the filter cartridges(s), not a hopper for collecting loaded material. NOTE: DO NOT ALLOW VACUUM RECEIVER TO OVERFILL. 7.2 Dump Time: Pmp/DT Measured in seconds, this is the setting for how long the loader will remain at rest after loading, to allow material to evacuate the loader. This setting may be increased in case the material is very slow moving. 7.3 Seek Time: ST/T Also measured in seconds, this parameter controls how long the vacuum pump will seek for a call for loading before the vacuum breaker valve is activated, allowing ambient air to pass through instead of shutting down, which causes undue wear. 8.0 SETTING THE TIME The following describes how to set the internal clock. This clock is for reference only and has no effect on the operation or function of the controller. The controller does not have a battery to maintain the time when power is off. Instead it uses a capacitor that has reserve power for 80 hours. If power is off for a longer period of time, the clock will need to be reset. 9.0 RUNNING HOUR COUNTER It is advantageous to know how many hours your vacuum system has been running so you know when maintenance is required. The MCS-406 allows you to keep track of those hours automatically. The running hours of the vacuum pump (whenever the pump is energized) are counted and displayed in the lower right-hand corner of the MSC-406 display on the home screen NOVATEC, Inc. All Rights Reserved Page 10

11 10.0 WARRANTY WARRANTY NOVATEC, INC. - Effective Date 7 FEB 2018 NOVATEC, INC. offers COMPREHENSIVE PRODUCT WARRANTIES on all of our plastics auxiliary equipment. We warrant each NOVATEC manufactured product to be free from defects in materials and workmanship, under normal use and service for the periods listed under Warranty Periods. The obligation of Novatec, under this warranty, is limited to repairing or furnishing, without charge, a similar part to replace any part which fails under normal use due to a material or workmanship defect, within its respective warranty period. It is the purchaser s responsibility to provide Novatec with immediate written notice of any such suspected defect. Warranted replacement parts are billed and shipped freight pre-paid. The purchaser must return the suspect defective part, freight prepaid and with identifying documentation to receive full credit for the part returned. Novatec shall not be held liable for damages or delay caused by defects. No allowance will be made for repairs or alterations without the written consent or approval of Novatec. The provisions in equipment specifications are descriptive, unless expressly stated as warranties. The liability of Novatec to the purchaser, except as to title, arising out of the supplying of the said equipment, or its use, whether based upon warranty, contract or negligence, shall not in any case exceed the cost of correcting defects in the equipment as herein provided. All such liability shall terminate upon the expiration of said warranty periods. Novatec shall not in any event be held liable for any special, indirect or consequential damages. Commodities not manufactured by Novatec are warranted and guaranteed to Novatec by the original manufacturer and then only to the extent that Novatec is able to enforce such warranty or guaranty. Novatec, Inc. has not authorized anyone to make any warranty or representation other than the warranty contained here. Nonpayment of invoice beyond 90 days will invalidate the warranty. A renewed warranty can be purchased directly from Novatec. Please note that we always strive to satisfy our customers in whatever manner is deemed most expedient to overcome any issues in connection with our equipment. Warranty Periods: Note: All warranty periods commence with the shipment of the equipment to the customer. 5-Year (Except 1-Year on Non-Novatec Buy-Out Items) Resin Drying to Include NovaWheel Dryers * Dual Bed Dryers NovaDrier * NDM-5 Membrane Dryer Gas-Fired Process Heaters Gas-Fired Regeneration Heaters Drying Hoppers Central Drying Hopper Assemblies Heater/Blower Units and Hot-Air Dryer Silo Dehumidifiers NovaVac Dryers * Nitrogen NovaDriers (Nitro) DryTemp Plus Central System Controls to Include FlexTouch Series Controls FlexXpand Series Controls OptiFlex Series Controls PLC Communications Modules Greenboard Communications Modules LOGO! Mini PLC MCS-600 Series Controls (Distributed I/O) MCS-400 Series Controls CL Silo Manager Moisture Measurement Equipment to Include MoistureMaster PET Resin Crystallizers Resin Blending and Feeding to Include WSB Blenders, MaxiBatch & Feeders * Gaylord Sweeper Systems Downstream Extrusion Equipment to Include C and NC Bessemer Series Cutters NPS Bessemer Series Pullers NPC Mini Puller/Cutter All NS Series Servo Saws All Cooling and Vacuum Tanks Manufactured by Novatec Resin Conveying and Systems Components to Include GSL Series Vacuum Loaders GlassVu Loaders, Receivers and Hoppers VL/VLP Series Loaders VRH, VR, VR-FL & VRP Series Receivers Compressed Air Loaders AL-B Barrel Loader Cyclone Dust Collectors Conveying System Accessories Surge Bins Valves and Accessories Electronic Metal Separators Quick Select Manifolds Tilt Tables Filter Dust Collectors Drawer Magnets Velocity Control Valves 3-Year Resin Conveying System Components to Include ** VPDB Vacuum Positive Displacement Pumps ** SVP Vacuum Pumps ** MVP Vacuum Pumps ** Railcar Unloading Systems **5-Year Extended Warranty - When a MachineSense data plan is activated for products with **, Novatec automatically extends the warranty to 5 years. The data plan must be activated within 60 days after product shipment, and remain active through the warranty period to maintain extended warranty eligibility. The first 6-months of data plan usage is free from Novatec. Infrared Dryers UltraVac Vacuum Pumps Vacuum Regenerative Blower Pumps Custom Equipment of any kind unless otherwise specified 1-Year 2018 NOVATEC, Inc. All Rights Reserved Page 11

12 Exclusions: Routine maintenance/replacement parts are excluded from the warranty. These include, but are not limited to: hoses, desiccant, filters, filter elements, wiper seals, gaskets, dew point sensors, infrared lamps, motors, internal solenoids, fuses and motor brushes. Use with abrasive materials will void the warranty of any standard product. Wear resistant options may be available to extend usable service life with abrasive materials. Novatec reserves the right to limit the warranty if the customer installs replacement parts that do not meet the specifications of the original parts supplied by Novatec. *Specific Exclusions: 1. NovaDrier and NovaDrier-Nitro warranty is void if coalescing filters are not replaced on a 6-month or yearly basis (per instruction manual) and/or membrane has been exposed to ozone. 2. NovaVac Dryer -The ability of the canisters to hold vacuum will be compromised if the vacuum seal edge is damaged from mishandling. We do not warranty canisters damaged from improper handling. We do, however, warranty the seals. 3. LOAD CELLS on our WSB s are covered by Novatec standard warranty as long as they have not been damaged from improper handling. 4. Desiccant Wheel Warranty will be void if the wheel has been exposed to plasticizer, dust or other contaminants as a result of negligence on the part of the processor. This warranty shall not apply to equipment: 1. Repaired or altered without written approval of NOVATEC unless such repair or alteration was, in our judgment, not responsible for the failure 2. Which has been subject to misuse, negligence, accident or incorrect wiring by others 3. Warranty is void if processing rates exceed manufacturer-recommended levels or if damage is caused by ineffective power isolation and/or power spikes/sags or incorrect installation. NOTE: All conditions and content of this warranty are subject to changes without notice.