MAGUIRE Novatec MCS-405A User manual

MCS-405A FIVE STATION
CONTROL PACKAGE
© NOVATEC, Inc. 2018 All Rights Reserved
MCS-405A IM 13 OCT 2018

© 2018 Novatec, Inc All Rights Reserved 2
MCS-405A IM 13 OCT 2018
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-405A IM 13 OCT 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.

© 2018 Novatec, Inc All Rights Reserved 3
MCS-405A IM 13 OCT 2018
Contents
1.0 DRAWING LIST................................................................................................................3
2.0 PRINCIPLE OF OPERATION...........................................................................................4
3.0 UNPACKING AND INSPECTION.....................................................................................4
4.0 INSTALLATION................................................................................................................4
4.1 General .........................................................................................................................4
4.2 Vacuum Power Unit.....................................................................................................5
4.3 Station Valve................................................................................................................5
4.4 Cyclone Filter...............................................................................................................5
5.0 ELECTICAL INSTALLATION ...........................................................................................6
5.1 Wiring for MCS-405A –115Volt AC ............................................................................6
5.2 Wiring for MCS-405A –24 Volt DC.............................................................................7
6.0 OPERATION.....................................................................................................................8
6.1 General .........................................................................................................................8
6.2 Proportioning or Purge Control..................................................................................9
6.3 Preset Parameter Values ............................................................................................9
6.4 Changing Loading Parameters...................................................................................9
7.0 PARAMETERS EXPLANATION.......................................................................................9
7.1 Load Time: Pmp/LT ...................................................................................................10
7.2 Dump Time: Pmp/DT .................................................................................................10
7.3 Seek Time: Pmp/ST ...................................................................................................10
8.0 SETTING THE TIME.......................................................................................................10
9.0 RUNNING HOUR COUNTER .........................................................................................10
10.0 WARRANTY..................................................................................................................11
1.0 DRAWING LIST
MCS-405A
CONTROLLER
PART NUMBER
DRAWING NUMBER
24 VOLTS DC-115VAC
MCS-405A
115 VOLTS AC
MCS-405A-12
24 VOLTS DC-230VAC
MCS-405A

© 2018 Novatec, Inc All Rights Reserved 4
MCS-405A IM 13 OCT 2018
2.0 PRINCIPLE OF OPERATION
Novatec MCS-405A 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-405A 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-405A 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.

© 2018 Novatec, Inc All Rights Reserved 5
MCS-405A IM 13 OCT 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
optional 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 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 80-120 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.

© 2018 Novatec, Inc All Rights Reserved 6
MCS-405A IM 13 OCT 2018
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-405A –115Volt 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-405A control box in a secure location.
2. Refer to drawings MCS-405A-12D1-5.
3. Loosen clamp screws allowing the door to be opened.
4. Open the hinged door.
Note: Wire number 2 is the neutral wire.
5. Motor Starter. Connect wire (wire number 27 in drawing) from the normally
closed contact of overload for the vacuum power unit to the output terminal Q7
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 26 in drawing) from
the VBV solenoid to the output terminal Q6 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 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.

© 2018 Novatec, Inc All Rights Reserved 7
MCS-405A IM 13 OCT 2018
8. Station valve solenoid. Connect wire (wire number 21,22,23,24,25 in drawing)
from the output terminal on the PLC (Q1, Q2, Q3, Q4, Q5) 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. Units have a molded 7 foot power cable with plug. Install in a dedicated
receptacle.
5.2 Wiring for MCS-405A –24 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-405A control box with power supply box in a secure location.
2. Refer to drawings MCS-405AD1-5.
3. Loosen clamp screws allowing the door to be opened.
4. Open the hinged door.
Note: Wire number 2 is the negative wire.
5. Motor Starter. Connect wire (wire number 27 in drawing) from the normally
closed contact of overload for the vacuum power unit to the output terminal
Q7 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 26 in drawing) from
the VBV solenoid to the output terminal Q6 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 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 21,22,23,24,25 in drawing)
from the output terminal on the PLC (Q1, Q2, Q3, Q4, Q5) 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 supply voltage (240vac models only) to wires at the bottom of the
power supply box. (Refer to drawing MCS-405AD4). Voltage (or Hot) to the
red wire, Neutral (or Common) to the white wire, and ground to the green
wire. 120VAC powered units have a molded 7 foot power cable with plug
attached. Install in a dedicated receptacle.

© 2018 Novatec, Inc All Rights Reserved 8
MCS-405A IM 13 OCT 2018
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 8 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.

© 2018 Novatec, Inc All Rights Reserved 9
MCS-405A IM 13 OCT 2018
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-405A controller is preset at the factory with the following values.
FUNCTION
TIMER
FACTORY SETTING
Station 1 Load Time
Pmp1/LT
5.00 Seconds
Station 1 Dump Time
Pmp1/DT
5.00 Seconds
Station 2 Load Time
Pmp2/LT
5.00 Seconds
Station 2 Dump Time
Pmp2/DT
5.00 Seconds
Station 3 Load Time
PmP3/LT
5.00 Seconds
Station 3 Dump Time
Pmp3/DT
5.00 Seconds
Station 4 Load Time
Pmp4/LT
5.00 Seconds
Station 4 Dump Time
Pmp4/DT
5.00 Seconds
Station 5 Load Time
Pmp5/LT
5.00 Seconds
Station 5 Dump Time
Pmp5/DT
5.00 Seconds
Seek-time
ST/T
45.00 Seconds
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.
7.0 PARAMETERS EXPLANATION

© 2018 Novatec, Inc All Rights Reserved 10
MCS-405A IM 13 OCT 2018
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: 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.
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-405Aallowyoutokeeptrackofthosehoursautomatically.
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-405A display on the home screen.

© 2018 Novatec, Inc All Rights Reserved 11
MCS-405A IM 13 OCT 2018
10.0 WARRANTY - Effective 7 FEB 2018
NOVATEC, INC. offers COMPREHENSIVEPRODUCTWARRANTIESonallof
ourplastics auxiliaryequipment.WewarranteachNOVATECmanufacturedproduct
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 toreceivefull creditfor thepart 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 itsuse, whether based uponwarranty, 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. Novatecshall not in anyeventbe
held liable for any special, indirect or consequential damages.
Commodities not manufactured by Novatec are warrantedandguaranteed
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
dayswill invalidatethewarranty.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-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.
1-Year
Infrared Dryers
UltraVac Vacuum Pumps
Vacuum Regenerative Blower Pumps
Custom Equipment of any kind unless otherwise specified

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 warrantyof 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 warrantyis void if coalescing filters are not replaced ona 6-monthoryearlybasis(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 ifthevacuumsealedge isdamaged
frommishandling.Wedonotwarrantycanistersdamagedfromimproperhandling.Wedo,however,warrantytheseals.
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.