Microprocessor Control System Installation Manual Microprocessor Controlled Dental Vacuum System Installation Manual Effective Date: 05-Aug-05 Review this entire booklet before starting any mechanical or electrical work. Please contact RAMVAC if you have any questions. RAMVAC 3100 First Avenue Spearfish SD 57783 Phone (800) 5-RAMVAC (800) 572-6822 (605) 642-4614 Fax E-mail (605) 642-3776 ramvac@ramvac.com Effective Date: 05-Aug-05
MPC Installation Manual RAMVAC Dental Vacuum System Table of Contents Page MPC Installation Overview Pre-Installation Note... 2 Component List... 3 Understanding the System... 4 System Electrical Schematic... 4 Power Unit System Schematic... 5 Equipment Installation Sequence... 5 Vacuum Pressure Switch Installation... 6 Vacuum Controller Adjustments... 7 Vacuum Pressure Switch Adjustments... 7 Overhead Piping Adjustments... 8 Autowash Installation... 9 MPC Utility Control Mechanical Installation... 10 MPC System Component Diagram... 11 Component Wiring... 12 Connection Chart... 13 MPC System Startup... 14 References MPC PLC LED Chart... 15 MPC Covert Function Chart... 16 MPC Overt Function Chart... 17 Page 1 of 18
RAMVAC Dental Vacuum System MPC Installation Manual Pre-Installation Note All Pre-Installation work should be completed prior to the steps in this manual. Please refer to the Dental Vacuum System Installation Guide, and if included with your project, the RAMVAC Submittal Book. Please call RAMVAC if you have any questions Page 2 of 18
MPC Installation Manual RAMVAC Dental Vacuum System Component List Item Quantity Description/Comments Supplier This Document 1 each MPC System Installation Manual Booklet RAMVAC Documentation 1 each MPC Clinic Guide RAMVAC Power Units As ordered See Proposal, Submittal Book (if supplied) and/or ID label on each Power Unit and compare with Packing List RAMVAC S1 Electrols As ordered Attached to each Power Unit RAMVAC 3 Phase Starter Box As ordered One for each Power Unit with 3 Phase Motors Included only if installation uses three phase electrical power Separating Tanks As ordered See Proposal, Submittal Book (if supplied) and/or ID label on each tank and compare with Packing List Utility Control 1 each Enclosure with micro-processor, terminal boards, and ancillary devices RAMVAC RAMVAC RAMVAC Pressure (vacuum) Switch 1 each Vacuum Strength Monitoring Device RAMVAC Autowash Valves (if ordered) As ordered For tanks and/or piping RAMVAC Autowash Tank Nozzle Assemblies (if ordered) As ordered Tank mounted wash down nozzle RAMVAC Remote Control Panel 1 each Locate in clinic area RAMVAC Disconnects 1 each One for each Power Unit Customer Breakers 1 each One for each Power Unit Customer Wiring, breaker to disconnect 1 each One for each Power Unit Customer Wiring, disconnect to S1 Electrols (Single Phase) 1 each For Power Units Customer Wiring, disconnect to Starter (Three Phase) 1 each For Power Units Customer Wiring, S1 Electrols to Starter (Three Phase) 1 each For Power Units (6 ft. length supplied) RAMVAC Wiring, S1 Electrols to Motor As ordered Factory Installed RAMVAC Wiring, Pressure (vacuum) switch to Utility Control 1 set See MPC Wiring Diagram Customer Wiring to Autowash (if ordered) 1 set See MPC Wiring Diagram Customer Wiring to Remote Control Panel 1 set See MPC Wiring Diagram Customer Wiring, S1 Electrols to Utility Control 1 set See MPC Wiring Diagram Customer Page 3 of 18
RAMVAC Dental Vacuum System MPC Installation Manual Understanding the System RAMVAC MPC systems automatically respond to demand so that clinicians always have the power they need for safe, effortless operation while minimizing energy consumption and hardware use. The system automatically selects the pump with the lowest run-time. After a 30 to 120 second period of constant low pressure, an adjustable pressure switch signals the microprocessor to turn on Power Units as needed to maintain desired vacuum strength. After the system returns to a constant normal vacuum strength for a period of 15 minutes, unneeded power units are shut down. This alternation with record keeping makes sure your pumps get used evenly with no individual pump working longer than the others. If the Autowash option is selected, the microprocessor also controls tank wash down cycles and eliminates the need for additional timers and relays. Multiple pumps automatically selected to run by the computer minimize electrical consumption by operating according to demand. Multiple pumps offer the advantage of extending service life by reducing the operating hours of any one pump. Multiplexing inherently adds to backup capacity by decreasing dependency on any one device. System Electrical Schematic On/Off 5 wires Min. 18 AWG Wire Plug into 115v power Vacuum Pressure Switch Fault 2 wires Min. 18 AWG Wire Remote Switch Panel MPC Enclosure 2 wires Min. 18 AWG Wire 4 wires, min. 18 AWG Wire, to each S1 Electrol Autowash Solenoid Number of Power Units and S1 Electrols may vary Page 4 of 18
MPC Installation Manual RAMVAC Dental Vacuum System Power Unit System Schematic In addition to the MPC system, each individual power unit has a series of electrical and plumbing connections required to do its job. Since this is a generalized diagram, your installation may vary slightly. Factors such as number of tanks and selected accessories will affect your specific installation. Exhaust To Outside Breaker Disconnect HVE Control Signal from MPC Enclosure Facility Vacuum Piping S-Type Filter Required by the Bison 7 & 9 Optional with Bison 3 & 5 Power Gases Continue To Pump Starter (3 phase only) S1 Electrols Tank Power To Motor Liquids and Solids Drain When Vacuum is Off Power Unit Equipment Installation Sequence For the easiest and most efficient installation, equipment should be installed in the following sequence: 1. Tanks... See Separating Tank Installation Booklet 2. Power Units... See Dental Vacuum Installation Booklet 3. Vacuum Pressure Switch... See Page 6 4. Auto Wash Installation... See Page 9 5. MPC Control Mechanical... See Page 10 6. Component Wiring... See Page 12 Page 5 of 18
RAMVAC Dental Vacuum System MPC Installation Manual Vacuum Pressure Switch Installation Vacuum Pressure Switch Assembly Location: Near vacuum line from treatment room; Near Separating Tank(s). Environment: Free from excessive vibration. Non-corrosive atmosphere. Ambient temperature 32 F to 104 F (0 to 40 C) Mount: On vertical surface minimum 24 above Separating Tank Inlet(s). Connect Vacuum Pressure Switch to Vacuum Line Hose Barb Attach customer/contractor supplied vacuum hose to hose barbs. a. Connect switch hose barb to treatment room vacuum line hose barb. b. Use ¼ I.D. metal or plastic tubing c. Tubing must not collapse under 15 Hg vacuum (-7.5psi) or restrict airflow in any way. To Power Units Hose Barb To Power Units Vacuum Line From Treatment Rooms Page 6 of 18
MPC Installation Manual RAMVAC Dental Vacuum System Adjusting the Vacuum Controller Do NOT Adjust the Vacuum Controller if: Any valves are open. Your system has vacuum leaks Vacuum is weak only when more than 2/3 of the rated number of vacuum devices are open. Warning: You can damage equipment by making improper vacuum controller adjustments. Do not exceed motor full load amperes. Please contact RAMVAC if you are at all uncertain about this adjustment. 1. Close all vacuum valves (high volume evacuators, saliva ejectors, surgical suctions) and close any other treatment room vacuum devices (nitrous oxide scavengers, vacuum sinks, vacuum cuspidors). 2. Disconnect inlet line to vacuum unit and cap off inlet. 3. Remove vacuum controller filter and loosen lock-nut. Lock-Nut Adjustment Nut 4. Manually turn vacuum unit on and turn adjustment nut to raise or lower vacuum pressure. 5. When vacuum gauge reaches desired reading, tighten lock-nut and replace filter. 6. Manually turn vacuum unit off. 7. Uncap inlet and reconnect inlet line to vacuum unit. 8. Repeat steps 1 to 7 for each vacuum unit and then adjust Vacuum Pressure Switch. Adjusting Vacuum Pressure Switch For typical installations, the Vacuum Pressure Switch is factory set at 6 inches of mercury. For atypical installations requiring higher vacuum, such as those with overhead piping, you may need to adjust the switch to a higher setting. Adjustment Compartment cover NOTE: ** Adjust the pressure switch to 1 below the Vacuum Controller pressure setting. ** 1/2 turn of Adjustment Screw adjusts vacuum level approximately 5 HG. 1. Open Wiring Compartment cover and disconnect wires from Com and NC terminals. Insulate wires from the pressure switch case and each other. 2. Open treatment room vacuum devices until the vacuum gauge indicates a vacuum reading 1 below the Vacuum Controller setting. 3. Apply a continuity tester across Com and NC terminals of pressure switch. 4. Open Adjustment Compartment cover and adjust pressure switch by turning the adjustment screw until the circuit closes as indicated on your tester. Wiring Compartment cover 5. Re-connect wires, close the Adjustment Compartment and Wiring Compartment covers. Page 7 of 18
RAMVAC Dental Vacuum System MPC Installation Manual Overhead Piping Adjustments In order for the MPC system to work properly, the correct adjustment must be set on the: 1. Power Unit s Vacuum Controller 2. Vacuum Pressure Switch The factory settings are correct and should not be changed for installations with: 1. Below grade piping with a Maximum Lift Height to the separating tank of 7 feet or less. 2. Overhead piping with a Maximum Lift Height of 7 feet or less. Note: Adjustments on this page can only be made to Pressure Switch shown below. Contact RAMVAC if you do NOT have this switch. What s Maximum Lift Height? It s the greatest vertical distance water must travel uphill in the vacuum system. To determine Maximum Lift Height, measure the greatest distance water must travel uphill from the lowest point to the highest point in the system. Be sure to check the height of all piping and hoses in the mechanical room and all treatment rooms. For below grade piping with a lift height to the Separating Tank greater than 7 feet, or overhead piping with a lift height greater than 7 feet the following adjustments must be made: Adjust the Vacuum Controller: 1. Measure the maximum lift height. 2. Adjust vacuum controllers to correspond with Maximum Lift Height as shown in the chart to the right. 3. See Adjusting the Vacuum Controller and Adjusting the Vacuum Pressure Switch. Warning: Do not exceed motor full load amperes. Please contact RAMVAC if you are at all uncertain about this adjustment. Maximum Lift Height Vacuum Controller Setting 7 Feet 7.5 Hg 8 Feet 8.3 Hg 9 Feet 9.2 Hg 10 Feet 10.2 Hg 11 Feet 11.0 Hg 12 Feet 12.0 Hg Page 8 of 18
MPC Installation Manual RAMVAC Dental Vacuum System Autowash Installation These steps detail the mechanical installation of the Autowash components. For electrical details, see MPC System Component Diagram. Make Connections According To Diagram Water Valve RAMVAC supplied Mount with valve body below coil. Comply with flow direction arrows located on valve body. 3/8 soft copper or equivalent Customer Supplied Manifold Customer Supplied Tank Spray Nozzle Assembly RAMVAC Supplied Water Filter Customer Supplied Autowash Tank Installation (for 2 or more tanks) Facility Vacuum Lines (from Treatment Rooms) Autowash Spray Nozzles To Power Units Page 9 of 18
RAMVAC Dental Vacuum System MPC Installation Manual MPC Utility Control Mechanical Installation Mount the MPC Enclosure to a vertical surface in a mechanical room that meets the following requirements: Adequate working space and lighting Ambient temperature between 32 F (0 C) and 104 F (40 C) Relative humidity between 20% and 90% No condensation occurs due to sudden temperature changes Protection from excessive shocks and vibrations Protection from corrosive or inflammable gases At least 8 (200 mm) from high voltage power Page 10 of 18
MPC Installation Manual RAMVAC Dental Vacuum System MPC System Component Diagram (3 Pump System shown) A B C E F G D H I J K L K L K L M N O O O P A B C D E F G H I J K L M N O P Programmable Logic Controller (PLC) Input Power Terminal Board Ground Lug Transformer CX Terminal Board Remote Panel Terminal Board C1 Terminal Board Transformer Fuse (1 amp AGC) CX Fuse (½ amp AGC) VIN Fuse (½ amp AGC) Motor Running Signal Relays (12v DC) Pump Start Relays (24v AC) Autowash Relay Pressure Switch Terminal Board S1 Electrols Terminal Boards Autowash Terminal Board Page 11 of 18
RAMVAC Dental Vacuum System MPC Installation Manual Component Wiring Wire Vacuum Pressure Switch to MPC Terminal Blocks inside MPC Enclosure Min. 18 AWG Wire Pressure Switch COM COM N/C N/C Wire Nuts Wire Remote Control Panel to MPC On/Off 1 2 3 4 Min. 18 AWG Wire Remote Panel Fault 5 Wire Nuts 1 2 3 4 5 Wire Autowash Solenoid to MPC Autowash Solenoid Leads Min. 18 AWG Wire Auto Wash Wire Nuts AW1 AW2 Wire S1 Electrols to MPC S1 Electrol #1 Repeat S1 Electrols hookup for every power unit in your installation 5 6 F H F G H 5 6 J K Min. 18 AWG Wire Connect terminals to corresponding S1 Electrol connectors (One set of terminals for each S1 Electrols) Page 12 of 18
MPC Installation Manual RAMVAC Dental Vacuum System Connection Chart (5 Pump System shown) Contractor Wiring Component Utility Control Enclosure Factory Wired To Terminal Board Remote Control Panel Remote Panel On/Off switch pigtail 1 terminal 1 CX Terminal Board PLC Input - On/Off switch pigtail 2 terminal 2 PLC Input 0 light cmn pigtail 3 terminal 3 CY Terminal Board PLC Output + On light pigtail 4 terminal 4 PLC Output 20 Fault light pigtail 5 terminal 5 PLC Output 21 Autowash Solenoid Autowash terminal 1 terminal AW1 Autowash Relay Terminal terminal 2 terminal AW2 Autowash Relay Terminal Pressure Switch Pressure Switch common terminal COM CX Terminal Board PLC Input CX norm closed terminal N/C PLC Input 5 S1 Electrols #1 S1 Electrols #1 S1 terminal connector 5 terminal 5 PLC Input 1 S1 terminal connector 6 terminal 6 CX Terminal Board PLC Input CX S1 terminal connector F terminal F C1 Terminal Board PLC Output C1 S1 terminal connector H terminal H PLC Output 23 S1 Electrols #2 S1 Electrols #2 S1 terminal connector 5 terminal 5 PLC Input 2 S1 terminal connector 6 terminal 6 CX Terminal Board PLC Input CX S1 terminal connector F terminal F C1 Terminal Board PLC Output C1 S1 terminal connector H terminal H PLC Output 24 S1 Electrols #3 S1 Electrols #3 S1 terminal connector 5 terminal 5 PLC Input 3 S1 terminal connector 6 terminal 6 CX Terminal Board PLC Input CX S1 terminal connector F terminal F C1 Terminal Board PLC Output C1 S1 terminal connector H terminal H PLC Output 25 S1 Electrols #4 S1 Electrols #4 S1 terminal connector 5 terminal 5 PLC Input 4 S1 terminal connector 6 terminal 6 CX Terminal Board PLC Input CX S1 terminal connector F terminal F C1 Terminal Board PLC Output C1 S1 terminal connector H terminal H PLC Output 26 S1 Electrols #5 S1 Electrols #5 S1 terminal connector 5 terminal 5 PLC Input 5 S1 terminal connector 6 terminal 6 CX Terminal Board PLC Input CX S1 terminal connector F terminal F C1 Terminal Board PLC Output C1 S1 terminal connector H terminal H PLC Output 27 Page 13 of 18
RAMVAC Dental Vacuum System MPC Installation Manual MPC System Startup 5 Power Units or Less Please call RAMVAC Tech Service with questions or, if at any time during Start-Up LED or equipment response is not as described below. Step PLC LED response (See MPC PLC LED Chart for location of LEDs) 1. Close all treatment room vacuum valves. none Ensure power is available to all S1 Electrols as indicated by the illumination of each S1 Electrols Power On light. 2. Plug power cord into 115v AC receptacle. PWR and RUN LEDs illuminate. Input LED #7 (vacuum weak) illuminates. 3. Start system by pressing Remote Control Panel on/off button to on. The Power Units with the least total run time turns on. if Power Unit #1 turns on: if Power Unit #2 turns on: if Power Unit #3 turns on: if Power Unit #4 turns on: if Power Unit #5 turns on: When vacuum becomes strong : 4. Create weak vacuum signal by removing vacuum line from vacuum pressure switch. After a 30 second delay, additional Power Units turn on with a 20-40 second delay between each additional power unit. when Power Unit #1 is on: when Power Unit #2 is on: when Power Unit #3 is on: when Power Unit #4 is on: when Power Unit #5 is on: 5. Restore a strong vacuum signal by reattaching the vacuum line to the vacuum pressure switch. After a minimum run time of 15 minutes, the additional Power Units turn off with a 15 minute period of strong vacuum, between each power unit. when Power Unit #1 stops: when Power Unit #2 stops: when Power Unit #3 stops: when Power Unit #4 stops: when Power Unit #5 stops: Input LED #0 (remote panel switch on ) illuminates. Input LED #1 and Output LED #3 illuminate. Input LED #2 and Output LED #4 illuminate. Input LED #3 and Output LED #5 illuminate. Input LED #4 and Output LED #6 illuminate. Input LED #5 and Output LED #7 illuminate. Input LED #7 (vacuum weak) goes out. Input LED #7 (vacuum weak) illuminates. Input LED #1 and Output LED #3 illuminate. Input LED #2 and Output LED #4 illuminate. Input LED #3 and Output LED #5 illuminate. Input LED #4 and Output LED #6 illuminate. Input LED #5 and Output LED #7 illuminate. Input LED #7 (vacuum weak) goes out. Input LED #1 and Output LED #3 extinguish. Input LED #2 and Output LED #4 extinguish. Input LED #3 and Output LED #5 extinguish. Input LED #4 and Output LED #6 extinguish. Input LED #5 and Output LED #7 extinguish. 6. After 3 hours of single pump operation with vacuum remaining strong: The Power Unit that was running, will turn off and the next in-line Power Unit will take over. Page 14 of 18
MPC Installation Manual RAMVAC Dental Vacuum System MPC PLC LED Chart FLT RUN PWR L 0 1 2 3 4 5 6 7 H Input (L) LEDs LED illuminates when: Output (H) LEDs LED illuminates when: 0 Remote Panel Switch is On 0 Turn On Remote Panel System On/Off light 1 Pump #1 confirmed On 1 Turn On Remote Panel Fault light 2 Pump #2 confirmed On 2 Turn On Autowash solenoid (if installed) 3 Pump #3 (if installed) confirmed On 3 Turn On Pump #1 4 Pump #4 (if installed) confirmed On 4 Turn On Pump #2 5 Pump #5 (if installed) confirmed On 5 Turn On Pump #3 (if installed) 6 (not used) 6 Turn On Pump #4 (if installed) 7 Pressure Switch closed vacuum is weak 7 Turn On Pump #5 (if installed) MPC CONTROL LEDS PWR Power light illuminates when power is applied to MPC control. RUN Run light illuminates when MPC control is functioning. FLT Fault light illuminates if MPC control is malfunctioning. Page 15 of 18
RAMVAC Dental Vacuum System MPC Installation Manual NOTES Page 16 of 18
MPC Installation Manual RAMVAC Dental Vacuum System NOTES Page 17 of 18
RAMVAC Dental Vacuum System MPC Installation Manual NOTES Page 18 of 18
MPC Installation Manual RAMVAC Dental Vacuum System Microprocessor Control Installation Manual Effective date: 15-Mar-05 Spearfish, SD 57783 FAX (605) 642-3776 3100 First Avenue (800) 5-RAMVAC www.ramvac.com Page 19 of 18