MCS-401A – MCS-401 SINGLE STATION CONTROL PACKAGE · 2/10/2018 · The following describes installation of typical system components. Some of them are optional and may not be required

MCS-401A – MCS-401 SINGLE STATION CONTROL

PACKAGE

© NOVATEC, Inc. 2018 All Rights Reserved MCS-401A-MCS-401 IM 10 FEB 2018

MCS-401A 24 VDC I/O

MCS-401-A 115 VAC I/O

MCS-401A-MCS-401 IM 10 FEB 2018

© Novatec, Inc. 2018 All Rights Reserved 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-401A-MCS-401 IM 10 FEB 2018 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.

MCS-401A-MCS-401 IM 10 FEB 2018


Contents 1.0 DRAWING LIST ................................................................................................................ 4 2.0 PRINCIPLE OF OPERATION ........................................................................................... 4 3.0 UNPACKING AND INSPECTION ..................................................................................... 4 4.0 MECHANICAL INSTALLATION ........................................................................................ 4

4.1 General.......................................................................................................................... 4 4.2 Vacuum Power Unit ..................................................................................................... 5 4.3 Cyclone Filter ............................................................................................................... 5 4.4 Compressed Air Blowback .......................................................................................... 5

5.0 ELECTRICAL INSTALLATION ......................................................................................... 6 5.1 Wiring for MCS-401A – 115 VAC ................................................................................. 6 5.2 Wiring for MCS-401A – 24 VDC – 115 or 230 VAC Supply ........................................ 7

6.0 OPERATION ..................................................................................................................... 8 6.1 Control Description...................................................................................................... 8 6.2 Preset Controller Values ............................................................................................. 8 6.3 Changing Loading Parameters ................................................................................... 8

7.0 PARAMETERS EXPLANATION ....................................................................................... 8 7.1 Load Time: Pmp/LT ...................................................................................................... 8 7.2 Dump Time: Pmp/DT .................................................................................................... 9 7.3 Seek Time: Pmp/ST ...................................................................................................... 9 7.4 Alarm Time: Alm/AT ..................................................................................................... 9 7.5 Alarm Count: Alm/CT ................................................................................................. 10 7.6 Blowback Count; BB/Cnt........................................................................................... 10

8.0 SETTING THE TIME ....................................................................................................... 10 9.0 RUNNING HOUR COUNTER .......................................................................................... 10 10.0 WARRANTY .................................................................................................................. 11

MCS-401A-MCS-401 IM 10 FEB 2018


1.0 DRAWING LIST

MCS-401A CONTROLLER PART NUMBER/DWG NUMBER 115 VOLTS AC MCS-401A-12 24 VOLTS DC–115VAC MCS-401A

NOTE: 230 VAC incoming power option for MCS-401 and MCS-401A: VOLT-FTS-21 2.0 PRINCIPLE OF OPERATION MCS-401A controllers are designed to operate a single vacuum power unit to convey material to a single vacuum receiver station. The MCS-401A controller cannot control either a proportioning valve or a purge valve. However they are equipped with an alarm output. 3.0 UNPACKING AND INSPECTION

The MCS-401A 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 MECHANICAL 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 receivers, 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. Some of them are optional and may not be required in your system.

MCS-401A-MCS-401 IM 10 FEB 2018


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 combination starter with fused disconnect switch. An electrical ground wire is also required. A clean, dry supply of 80-120 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 Cyclone Filter Locate the cyclone filter as close as possible to the vacuum power unit. Provide access to the material catch pan or fines drum, located at the bottom of the cyclone, 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.

4.4 Compressed Air Blowback Some vacuum receivers are provided with a compressed air blow back solenoid valve for cleaning the filter, depending on the application. The pulse blow back solenoid valve is wired to the main control panel (115-VAC signal neutral) or (24 VDC and 0 VDC). A clean, dry supply of 80-120 PSIG compressed air is required. Connect it to either the compressed air accumulator tank supplied on large vacuum receivers or directly to the pulsed blow back solenoid valve only that is supplied on smaller vacuum receivers.

MCS-401A-MCS-401 IM 10 FEB 2018


5.0 ELECTRICAL 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.

5.1 Wiring for MCS-401A – 115 VAC

Dangerous Voltage! Do not put your finger or any object in the program SD card slot. If the power supply is not connected properly, the slot for the SD card may carry voltage. The SD card cover must be in place at all times. NOTE: the SD card is optional and is not needed for normal operation. 1. Mount the MCS-401A control box in a secure location. 2. Refer to applicable drawing number shown on page 4. 3. Remove screws (item number 3 in drawing) allowing the cover plate to be removed. 4. Remove the cover plate (item number 2 in drawing). Note: Wire number 2 is the neutral or negative wire. 5. Motor Starter. Connect wire nut (wire number 4 in drawing) to the normally closed contact

of overload for the vacuum power unit. (Typical Novatec motor starters are shown on drawing SK-836A). Connect the motor starter coil to wire nut (wire number 2 in drawing).

6. Blow back solenoid (optional). Connect wire nut (wire number 5 in drawing) to the blow back solenoid (located on the lid of the vacuum chamber). Connect the blow back solenoid to wire nut (wire number 2 in drawing).

7. VBV (vacuum breaker valve solenoid). Connect the wire nut (wire number 7 in drawing) to the VBV solenoid. Connect the VBV solenoid to wire nut (wire number 2 in drawing). Also connect (wire number 9 to wire number 3) on units with VBV solenoid. On units without a VBV solenoid, do not connect wire number 3 to wire number 9.

8. Level switch. Connect wire nut (wire number 3 in drawing) to the level switch. Connect the level switch to wire nut (wire number 8 in drawing).

Note: If using a capacitance type proximity switch, install a 22k ohm 1 watt resistor across terminal N and I1 on the LOGO module, as shown on the electrical drawing. If using photoelectric sensors, connect the 2 blue wires to wire number 2. Connect the 2 brown wires to wire number 3. Connect the black wire to wire number 8. 9. Terminate ground (GND) wire to mounting screw. 10. Connect the high voltage (208,230,460,575) to L1, L2, L3 of the motor starter or optional

combination starter. 11. Insert plug into an outlet that supplies clean 115 VAC.

MCS-401A-MCS-401 IM 10 FEB 2018


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.

5.2 Wiring for MCS-401A – 24 VDC – 115 or 230 VAC Supply

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 slot for the SD card may carry voltage. The SD card cover must be in place at all times. NOTE: the SD card is optional and is not needed for normal operation. 1. Mount the MCS-401A control box in a secure location. 2. Refer to applicable drawing number shown on page 4. 3. Remove screws (item number 3 in drawing) allowing the cover plate to be removed. 4. Remove the cover plate (item number 2 in drawing). Note: Wire number 2 is the neutral or negative wire. 5. Motor Starter. Connect wire nut (wire number 4 in drawing) to the normally closed

contact of overload for the vacuum power unit. (Typical Novatec motor starters are shown on drawing SK-836A). Connect the motor starter coil to wire nut (wire number 2 in drawing).

6. Blow back solenoid (optional). Connect wire nut (wire number 5 in drawing) to the blow back solenoid (located on the lid of the vacuum chamber). Connect the blow back solenoid to wire nut (wire number 2 in drawing).

8. VBV (vacuum breaker valve solenoid). Connect the wire nut (wire number 7 in drawing) to the VBV solenoid. Connect the VBV solenoid to wire nut (wire number 2 in drawing). Also jumper input 2 connect (wire number J1 to wire number 3) on units with VBV solenoid. On units without a VBV solenoid, do not connect wire number 3 to wire number J1.

9. Level switch. Connect wire nut (wire number 3 in drawing) to the level switch. Connect the level switch to wire nut (wire number 8 in drawing).

Note: If using a capacitance type proximity switch, install a 22k ohm 1 watt resistor across terminal N and I1 on the LOGO module, as shown on the electrical drawing. If using photoelectric sensors, connect the 2 blue wires to wire number 2. Connect the 2 brown wires to wire number 3. Connect the black wire to wire number 8.

10. Connect the high voltage (208,230,460,575) to L1, L2, L3 of the motor starter combination starter.

11. Connect supply voltage (100vac to 240vac) to wires at the bottom of power supply box. Voltage (or Hot) to the red wire, Neutral (or Common) to the white wire, and ground to the green wire.

MCS-401A-MCS-401 IM 10 FEB 2018


6.0 OPERATION

6.1 Control Description

The MCS-401A series vacuum loading control employs a mini-PLC Control for loading functions. The control is housed in a rugged enclosure and is factory programmed for functions related to vacuum loading. NOTE: The user may adjust certain parameters of the control to fine tune their loader’s operation, but changing settings other than those listed can damage control operation.

6.2 Preset Controller Values The MCS-401 controller is preset at the factory with the following values.

FUNCTION TIMER FACTORY SETTING

Load Time Pmp/LT 15.00 Seconds Dump Time Pmp/DT 10.00 Seconds Seek Time Pmp/ST 45.00 Seconds Alarm Time Alm/AT 0.00 Seconds

Blowback Count B29:TL 3 Counts

6.3 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. 7.0 PARAMETERS EXPLANATION

7.1 Load Time: Pmp/LT

MCS-401A-MCS-401 IM 10 FEB 2018


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 receiver 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.

When the load time is completed, the Vacuum Breaker Valve on the vacuum pump will open, allowing material in the vacuum receiver to fall through the dump valve. The filter will also be cleaned during the dump time with pulses of compressed air (Blowback), if equipped with optional Blowback. The dump time and the number of pulses used to clean the filter are adjustable by changing the Pmp/DT and BB/Cnt values respectively in the "Settings” menu of the controller. The dump time should be set 1 to 2 seconds greater than the time necessary for the receiver to completely empty. Enter the number of pulses required to clean the filter (BB/Cnt) as the pulse value. The load and dump/pulse cycles will continue until the drying hopper or surge bin is full, at which time the material will hold the dump valve flapper open, placing the system in a seek mode, timer Pmp/ST. If the hopper remains full until the end of the seek time, the pump will shut down. As material is withdrawn from the hopper, the material level will fall, the flapper will close, and the receiver will again be activated to automatically pull material into the receiver thus keeping the hopper full.

On machine mount units the load and dump/pulse 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 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. 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: Pmp/ST

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. 7.4 Alarm Time: Alm/AT

Measured in seconds, is the pause time between the completion of Motor On Time and movement of the discharge flapper. This time setting drives the No-Load alarm feature by determining if material was actually loaded and dumped, but prevents false alarms from slow moving material discharge. This setting may be increased if nuisance alarms occur from slow moving material (IE: fluffy regrind) that is typically slow to evacuate the loader. It may be decreased if the No-Load alarm is too slow to respond to your material supply needs (IE: frequent shortages of material flow).

MCS-401A-MCS-401 IM 10 FEB 2018


7.5 Alarm Count: Alm/CT

This number represents how many consecutive “no-load” alarms will cause the alarm horn to sound.

7.6 Blowback Count; BB/Cnt Sets the number of blowback pulses that occur following loading for the compressed air system to clean the filter(s). Compressed is blown down through the filters in the opposite direction of the vacuum loading air, blasting collected fines and dust from the filter media and into the loaded material. Typically, more blasts will clean the filters better and extend the time between manual filter cleaning and provide more efficient loading. However, compressed air is expensive and too many blasts waste this resource. Also, blasts that extend beyond the dump sequence may actually be strong enough to create dusting issues around the loader.

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-401A allow 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-401A display on the home screen.

MCS-401A-MCS-401 IM 10 FEB 2018


10.0 WARRANTY – Effective 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. Non-payment 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 *

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

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 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-YearResin 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.

1-Year

Infrared Dryers UltraVac Vacuum Pumps

Vacuum Regenerative Blower Pumps Custom Equipment of any kind unless otherwise specified

MCS-401A-MCS-401 IM 10 FEB 2018

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.

Documents

MCS-401A – MCS-401 SINGLE STATION CONTROL PACKAGE · 2/10/2018 · The following describes installation of typical system components. Some of them are optional and may not be required