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1. A 2 B Appendix B PLC Troubleshooting and Error Codes Additional resources B 1 Understanding PLC LEDs B 1 Normal operating conditions B 2 Force conditions B 2 Fault error conditions B 2 Fault messages B 3 ii l Table of Contents Introduction Purpose of the user guide 1 2 How the guide is organized 1 2 Your responsibilities as a user 1 3 ATTENTION Read this so no one gets hurt 1 4 S E C T I O N1 Introduction l 1 1 1 Introduction Purpose of the User Guide This User Guide describes Conair s Resin Level Display and explains step by step how to operate maintain and configure this equipment Before using this product please take a few moments to read the User Guide and review the diagrams and safety information in the instruction packet You also should review manuals covering associated equipment in your system This review won t take long and it could save you
2. An audible alarm sounds The red indicator light on the top of the panel illuminates The alarm message window audible alarm and indicator light will remain active until the alarm is acknowledged The red indicator light on the top of the panel illuminates Acknowledging the alarm will silence the audible alarm and close the alarm message window The indicator light will remain active until the alarm con dition is satisfied cleared All active and acknowledged alarms can be viewed in the Alarm List screen Alarm message Alarm message window Operations l 3 9 Acknowledge Alarm To acknowledge an alarm press the Ack All button This will silence the audible alarm and close the alarm message window 3 Operations Acknowledge Alarm 3 10 l Operations Alarm List Screen Overview The Alarm List screen displays active acknowledged alarms with a time stamp View Alarm List To view the Alarm List from the main screen 1 Use the Up Down arrows to scroll to Alarm List 2 Press the Enter button Active Alarms Acknowledge Alarm Operations l 3 11 3 Operations Description of Alarms The following are a list of alarms in the RLD Cause The level of the device is below the low indicator The level of the device is above the high indicator Battery for PLC is either missing or low PLC has a major fault Solution Fill the devi
3. Enter button 3 Use the Up Down arrows to scroll to Configurations 4 Press the Enter button Recurring Alarm Used to set the time for an alarm to occur again after an interval Analog Config Used to assign the Analog input to a device and configure the Analog inputs Analog Options Used to set up automatic measurements for the Analog Inputs Contact Config Used to change program s default contact configuration to the sensor s contact type Controller Config Set up the Controller configuration based upon hardware installed System Configurations l 5 3 Recurring Alarm Conair representative typically sets up the system configurations during installa tion Changing the configurations will effect the operation of the RLD Super2 login is required The recurring alarm timer is used to retrigger acknowledged alarms if the alarm is not cleared after the configured time The time for alarms to be reactivated is 15 minutes to 4 hours 240 minutes Overview of Recurring Alarm Screen Current Recurring Time 5 System Configurations 5 4 l System Configurations Change Recurring Alarm Time To view change the Recurring Alarm from the System Configurations screen 1 Use the Up Down arrows to scroll to Recurring Alarm 2 Press the Enter button 3 When prompted for username and password use pop up keypad to enter the username and password
4. To Reset the Counter enter a 0 into the counter numeric input using the following instructions 1 From the Analog Options screen select Maint 2 Touch the desired Measurement request 3 Using the pop up number pad enter a 0 in the field System Configurations l 5 17 5 System Configurations To Enter Specific Time of Day for Measurement Request To enter a specific time of the day for the measurement request enter the time of day in minutes into the counter numeric input using the following instructions For example if the request is set for daily 1440 minutes the desired time for measure ment is 5 00 PM 1700 hours and the current time is 11 00 AM 1100 hours then set the counter to 1080 the number of hours elapsed X 60 minutes 1 From the Analog Options screen select Maint 2 Touch the desired Measurement Request Frequency 3 Use the pop up number pad to enter the number of minutes of your desired measurement time 4 Repeat steps 2 and 3 for each request 5 18 l System Configurations Description of Controller Configuration Screen View Controller Configuration To view analog status from the System Configuration screen 1 Use the Up Down arrows to scroll to Controller Config 2 Press the Enter arrow Controller configuration Units Analog configuration System Configurations l 5 19 5 System Configurations Change Controller Configurati
5. Configuring Devices continued Configure Device To select a device 1 Touch the Device field A pop up number pad will appear 2 Using the number pad enter the number of the device you would like to configure 3 Operations Continued Configuring Devices continued To enable or disable a device 1 Touch the Enable Disable field A pop up number pad will appear 2 Enter a 1 to enable the device or a 0 to disable the device To configure a device for low alarm 1 Touch the Low Alarm field A pop up number pad will appear 2 Enter a 1 to enable the alarm a 0 to disable the alarm or a 2 to enable a recurring alarm To configure a device for high alarm 1 Touch the High Alarm field A pop up number pad will appear 2 Enter a 1 to enable the alarm a 0 to disable the alarm or a 2 to enable a recurring alarm 3 16 l Operations NOTE Entering a num ber outside the range of of 0 or 1 will not be accepted An error will occur and you will be forced to enter another number Operations 3 17 Description of Analog Status Screen The following screen is only available when 4 8 or 12 Analog Inputs have been configured The level volume and weight are based upon the Analog Input read ing and updated based upon the last measurement To view analog status 1 From the main screen use the Up Down arrows to scroll to ANALOG STATUS 2 Pres
6. This section contains fault messages that can occur during operation of the RLD con troller Each table lists the error code description the probable cause and the recom mended descriptive action Continued Appendix l B 4 Appendix B PLC Troubleshooting and Error Codes continued B 5 l Appendix Appendix B PLC Troubleshooting and Error Codes continued Continued Appendix l B 6 Appendix B PLC Troubleshooting and Error Codes continued B 7 l Appendix Appendix B PLC Troubleshooting and Error Codes continued Continued Appendix l B 8 Appendix B PLC Troubleshooting and Error Codes continued Appendix B PLC Troubleshooting and Error Codes continued B 9 l Appendix
7. 3 20 l Operations Changing Languages on the Debug Screen To change language 1 Touch the language field of the Debug screen 2 Use the Up Down arrows to change between languages 3 To make the language selection press the enter arrow Maintenance Clearing interface alarms 4 2 Password maintenance 4 4 Clear PLC errors including I O alarms 4 6 View RLD revisions 4 8 S E C T I O N4 4 Maintenance Maintenance l 4 1 4 2 l Maintenance Clearing Interface Alarms Clearing the alarms only clears the alarm history in the operator interface It does not fix or clear the actual alarm It is recommended this function be completed dur ing troubleshooting or maintenance Super login is required Navigation to Clear Alarms To view the Clear Alarms from the Main Screen 1 Use the Up Down arrows to scroll to Maintenance 2 Press the Enter button 3 Use the Up Down arrows to scroll to Clear Alarms 4 Press the Enter button 5 When prompted for a username and password use the pop up keypad to enter the username and password See the Operations section entitled Password Prompts for more detail 6 Once the password is entered press the Enter button Maintenance l 4 3 4 Maintenance Clearing Interface Alarms continued Clear Alarm List To clear the Alarm list 1 Fr
8. 3 Change recurring alarm time 5 4 Remote horn configuration optional 5 5 Contact configuration 5 6 Description of analog configuration screen 5 10 View analog configuration 5 10 Selecting analog input 5 11 Analog input device assignment 5 11 Analog input configuration 5 12 Description of analog options screen 5 14 View analog options 5 14 Configure measurement request 5 15 Disable measurement request 5 15 To reset counter 5 16 To enter specific time of day for measurement request 5 17 Description of controller configuration screen 5 18 Change controller configuration 5 19 Change analog configuration 5 19 Change units of measurement 5 19 Controller configuration 5 20 S E C T I O N 5 System Configurations 5 System Configurations l 5 1 5 2 l System Configurations Description of System Configurations Screen Navigation to System Configurations To view system configurations from the main screen 1 Use the Up Down arrows to scroll to Maintenance 2 Press the
9. 3 20 4 1 Maintenance Clearing interface alarms 4 2 Password maintenance 4 4 Clear PLC errors including I O alarms 4 6 View RLD revisions 4 8 5 1 System Configurations Description of system configurations screen 5 2 Navigate to system configurations 5 2 Table of Contents l i Recurring alarm 5 3 Change recurring alarm time 5 4 Remote horn configuration optional 5 5 Contact configuration 5 6 Description of analog configuration screen 5 10 View analog input 5 10 Selecting analog input 5 11 Analog input device assignment 5 11 Analog input configuration 5 12 Description of analog opt
10. See the Operations section entitled Password Prompts for more detail Once the password is entered press the Enter button 4 Set the desired recurring alarm time The time can be set from 15 minutes to 4 hours 240 minutes Pressing the time field and a pop up number pad will appear 5 Press enter and the recurring alarm time will be set System Configurations l 5 5 5 System Configurations Remote Horn Configuration optional The Remote Horn Configuration screen is used to configure how the remote horn will operate The remote horn option must be installed The remote horn configurations are as follows To view change the Remote Horn Configuration from the System Configurations screen 1 Use the Up Down arrows to scroll to Remote Horn Configurations screen 2 Press the Enter button 3 When prompted for username and password use the pop up keypad to enter the username and password See the Operations section entitled Password Prompts for more detail Once the password is entered press the Enter button 4 Press the field for the remote horn configuration A pop up number pad will appear 5 Enter 0 for off 1 for all alarms and 2 for high alarms only Configuration Description Off Default Output for remote horn will not be turned on All Alarms Remote horn output will turn on for all alarms High Alarms Only Remote horn output will turn on only for high alarms Contac
11. valuable installation and operating time later How the Guide is Organized Symbols have been used to help organize the User Guide and call your attention to important information regarding safe installation and operation Symbols within triangles warn of conditions that could be hazardous to users or could damage equipment Read and take precautions before proceeding Numbers indicate tasks or steps to be performed by the user A diamond indicates the equipment s response to an action performed by the user An open box marks items in a checklist A circle marks items in a list Indicates a tip A tip is used to provide you with a suggestion that will help you with the maintenance and the operation of this equipment Indicates a note A note is used to provide additional information about the steps you are following throughout the manual 1 1 2 l Introduction Introduction l 1 3 Your Responsibility as a User You must be familiar with all safety procedures concerning operation mainte nance and configuration of this equipment Responsible safety procedures include Thorough review of this User Guide paying particular attention to hazard warnings appendices and related diagrams Thorough review of the equipment itself with careful attention to voltage sources intended use and warning labels Thorough review of instruction manuals for associated equipment Step by s
12. 5 System Configurations Analog Input Configuration continued 5 Enter the value then press the Enter button 6 Repeat steps 2 through 5 to enter change another configuration NOTE The ESC key cancels the operation and returns to the previous screen 5 14 l System Configurations Description of Analog Options Screen The following screen is only available when analog inputs have been configured There are four 4 Measurement Request Outputs which can be used to automatical ly trigger measurements at a user defined interval View Analog Options To view Analog Status from the SYSTEM CONFIGURATION screen 1 Use the Up Down arrows to scroll to Analog Options 2 Press the Enter button NOTE Measuring devices must have measure request capability and measure request out puts must be connected properly RLD electrical drawings provide additional notes when wiring Measurement requests Help screen Maintenance Screen System Configurations l 5 15 5 System Configurations Configure Measurement Request 1 Touch the desired measurement request 2 Use the pop up number pad to enter the numeric input 3 Repeat steps 1 and 2 for each request Disable Measurement Request 1 Touch the desired measurement request 2 Use the pop up number pad to enter 0 into the field 3 Press the Enter button 0 5 16 l System Configurations To Reset Counter
13. Description of Level Status Screen continued Operations l 3 7 3 Operations Graphic Configuration 1 40 Low Indicators Disabled Below Low Indicator Low Alarm Is Enabled and Active Below Low Indicator Low Alarm Is Disabled N A Above Low Indicator N A N A Illegal State Faulty Indicator or Wired Wrong Configuration 2 20 Low High Indicators Disabled Below Low Indicator Low Alarm Is Enabled and Active Below Low Indicator Low Alarm Is Disabled N A Above Low Indicator and Below High Indicator Above High Indicator High Alarm Is Disabled Above High Indicator High Alarm Is Enabled and Active Illegal State Faulty Indicator or Wired Wrong Configuration 3 12 Low Mid High Indicators Disabled Below Low Indicator Low Alarm Is Enabled and Active Below Low Indicator Low Alarm Is Disabled Above Low Indicator and Below Mid Indicator Above Mid Indicator and Below High Indicator Above High Indicator High Alarm Is Disabled Above High Indicator High Alarm Is Enabled and Active Illegal State Faulty Indicator or Wired Wrong D L L H H F F Description Sequence of Events When an Alarm Occurs The RLD provides visual and audible alarms 3 8 l Operations Alarm occurs An alarm message window is displayed on the operator interface
14. RLD Resin Level Display Corporate Office 724 584 5500 l Instant Access 24 7 Parts and Service 800 458 1960 l Parts and Service 814 437 6861 U S E R G U I D E UGS003 0713 www conairgroup com Please record your equipment s model and serial number s and the date you received it in the spaces provided It s a good idea to record the model and serial number s of your equipment and the date you received it in the User Guide Our service department uses this infor mation along with the manual number to provide help for the specific equipment you installed Please keep this User Guide and all manuals engineering prints and parts lists together for documentation of your equipment Date Manual Number UGS003 0713 Serial Number s Model Number s DISCLAIMER The Conair Group Inc shall not be liable for errors contained in this User Guide or for incidental consequential damages in connection with the furnishing performance or use of this information Conair makes no warranty of any kind with regard to this information including but not limited to the implied warranties of merchantability and fitness for a particular purpose Copyright 2013 l The Conair Group l All rights reserved Table of Contents 1 1 Introduction Purpose of the user guide 1 2 How the guide is organized 1 2 You
15. S YES Controller Configuration NO NO YES YES Clear Major PLC Errors NO NO YES YES Remote Horn Configuration NO NO YES YES 3 Operations Password Prompts When a username and password is required to enter a screen a pop up keypad will appear with Username and Password text fields above the keypad 1 Touch the Username field 2 Use the keypad to enter your username 3 Touch the Password field 4 Use the keypad to enter your password 5 Press the enter key on the keypad Other options ESC Operation canceled and returns to previous screen CLR Clears all characters enter in password field INS Inserts a character before the cursor DEL Deletes character at cursor position Operations l 3 5 Description of Level Status Screen The Level Status provides a graphical representation based upon the indicator inputs A maximum of eight devices will be displayed on the screen The Prev Next buttons will need to be used to view other devices View Level Status To view Level Status from the Main Screen 1 Use the Up Down arrows to scroll to Level Status 2 Press the Enter button Next button used to go to the next set of devices Device number Device graphical representation see table on the next page for detailed descrip tion Prev button used to go to the previous set of devices 3 6 l Operations
16. aterial levels are conveniently displayed from one centralized control platform The RLD is capable of being configured to monitor low mid or high levels of material within a silo or surge bin the RLD can be customized to fit your mate rial level monitoring needs Audible and visual warning indicators will energize to alert you to individual warning indications for each monitored silo surge bin or other storage vessels Three Configurations Configurable low and high alarms Configurable recurring low and high alarms Configurable recurring alarm time 15 minutes to 4 hours Configurable remote horn Graphical representation of devices PLC back up and restore Audible and visual alarming Configurable contacts N O or N C for level indicators and Security password protected operations Optional continuous silo level monitoring with 4 8 or 12 available quanti ties of analog input modules Optional Ethernet Communications 2 2 l Functionality Features Configuration Maximum Number of Devices Level Indicators 1 40 Low Configurable Alarm 2 20 Low Configurable Alarm High Configurable Alarm 3 12 Low Configurable Alarm Mid High Configurable Alarm IMPORTANT Changes in configuration require wiring changes WARNING Electrical connections should be made only by qualified personnel Optional analog continous silo level monitoring is avai
17. been changed press the OK button If the password change was unsuccessful press Change Password again 4 6 l Maintenance Clear PLC Errors Including I O Alarms PLC and I O input output alarms will stop the RLD control These errors may be caused by problems with the power supply processor modules and input or output modules The error is indicated by error codes on the PLC errors screen or by LEDs on the PLC and or associated hardware It is recommended prior to clearing PLC errors to write down the error code and verify hardware See Appendix B for PLC Troubleshooting and Error Codes Super2 login is required To Clear PLC Errors from the Main Screen 1 Use the Up Down arrows to scroll to Maintenance 2 Press the Enter button 3 Use the Up Down arrows to scroll to PLC Errors 4 Press the Enter button 5 When prompted for a username and password use the pop up keypad to enter the username and password See the Operations section entitled Password Prompts for more detail Once the password is entered press the Enter button 6 Press the Major Error field to view the error code You may want to write down and log the Major Error for future troubleshooting purposes Major Error 4 Maintenance Maintenance l 4 7 Clear PLC Errors Including I O Alarms continued 7 Clear the Major Error a Press the Major Error field b The entry field should read 00000 If th
18. ce above the low indicator Fill device above high indicator Check battery on the PLC replace if nec essary Reset PLC errors See Maintenance sec tion entitled Clear PLC errors including I O alarms Alarm Silo number assigned to silo Low Level Alarm Silo number assigned to silo High Level Alarm Battery Low Replace Battery PLC Fault 3 12 l Operations Configuring Devices The Level Configuration screen is used to configure a device Configurations asso ciated with a device are Enable Disable Low Alarm and High Alarm controller configurations 2 and 3 only The Level Configuration screen is password protect ed Descriptions of Configurations Enable Disable When enabled the device will be active Low Alarm the alarm is triggered when the level within the device is below the low indicator Disabled No visual No audible alarm Low Alarm Enabled A visual alarm will be triggered and stay active until the alarm is cleared level returns above the low indicator An audible alarm will be triggered and stay active until acknowledged Low Recurring Alarm Enabled A visual alarm will be triggered and stay active until the alarm is cleared level returns above the low indicator An audible alarm will be triggered and stay active until acknowledged If the level within the device does not go above the low indicator within the configured time the audible alarm will be reacti
19. e Assignment Configurations 8 steps System Configurations l 5 11 5 System Configurations Selecting Analog Input 1 Touch the Analog Input field 2 Use the number pad to navigate to the input you would like to configure Analog Input Device Assignment 1 Select Analog input to assign device to 2 Touch the Device Assignment field 3 Use the pop up number pad to enter the device number of the device you would like to assign 5 12 l System Configurations Analog Input Configuration 1 Select analog input to configure 2 Touch the Step field to select the Analog Configuration Step A pop up number pad will appear 3 Enter the number of the configuration to be added or changed Listed below are the 8 configurations 4 Once the step configuration is selected press the configuration data to enter A pop up number pad will appear NOTE For initial configu ration start with step 1 and continue to step 8 after each configuration STEP CONFIGURATION 1 Silo Height 2 Cone Height 3 Cylinder Diameter 4 Cone Bottom Diameter 5 Material Bulk Density 6 Sensor Blocking Distance 7 High Alarm Percentage 8 Low Alarm Percentage Step 6 Sensor Blocking Distance Step 5 Material Bulk Density Step 3 Cylinder Diameter Step 7 High Percentage Alarm Step 1 Silo Height Step 2 Cone Height Step 8 Low Percentage Alarm Step 4 Cone Bottom Diameter System Configurations l 5 13
20. e entry field reads 00000 press the Enter button If the entry field does not read 00000 use the pop up number pad to enter 00000 Press the Enter button upon completion 8 Press OK in the Reset field The mode will be Program 9 A qualified electrical service technician should open the control enclosure and locate the small access door on the left side of the PLC Inside this access door is a toggle switch 10 Toggle the RUN REM PROG switch to RUN then PROG then RUN The mode displayed on the screen should now be Run If the mode did not change contact Conair Service WARNING The electrical enclo sure cabinet should be opened only by qualified per sonnel Conair s Instant Access 24 7 Parts and Service number is 800 458 1960 Outside the U S dial 814 437 6861 4 8 l Maintenance View RLD Revisions The RLD revisions consist of the PLC revision is read from the PLC and the Operator Interface revision This information is important when contacting service To view RLD revisions from the Main screen 1 Use the Up Down arrows to scroll to Maintenance 2 Press the Enter button 3 Use the Up Down arrows to scroll to RLD Revisions 4 Press the Enter button System Configurations Description of system configurations screen 5 2 Navigate to system configurations 5 2 Recurring alarm 5
21. e of shipment against defects in material and workmanship under the normal use and service for which it was recommended except for parts that are typically replaced after normal usage such as filters liner plates etc Conair s guarantee is limited to replacing at our option the part or parts determined by us to be defective after examination The customer assumes the cost of transportation of the part or parts to and from the factory Performance Warranty Conair warrants that this equipment will perform at or above the ratings stated in specific quotations covering the equipment or as detailed in engineering specifica tions provided the equipment is applied installed operated and maintained in the recommended manner as outlined in our quotation or specifications Should performance not meet warranted levels Conair at its discretion will exer cise one of the following options Inspect the equipment and perform alterations or adjustments to satisfy per formance claims Charges for such inspections and corrections will be waived unless failure to meet warranty is due to misapplication improper installation poor maintenance practices or improper operation Replace the original equipment with other Conair equipment that will meet original performance claims at no extra cost to the customer Refund the invoiced cost to the customer Credit is subject to prior notice by the customer at which time a Return Goods Author
22. gure low and high alarms associated Super login Required Inhibit Analog Inhibits continuous silo level monitoring Analog option must be configured and monitoring sensor must have inhibit feature available Maintenance RLD HMI and PLC Revisions Clear all active alarms Super Login Required Change passwords Super2 Login Required Save or Restore RLD configuration to memory module Super2 Login Required View and reset PLC errors Super2 Login Required System Configurations Recurring alarm analog configurations analog options contact configurations and controller configurations Configure recurring alarm timer preset Super Login Required Configure remote horn Super2 Login Required Configure device contacts Super2 Login Required Configure RLD Super2 Login Required Main Screen Options Operations l 3 3 3 Operations RLD Control Features continued Control Button Descriptions Up Down arrows are used to step through the Main Screen menu options and or single step through options or alphanumeric characters Main button is used to return to the Main Screen In some cases the Main button is used as an option button In these instances text will appear on the interface above the button Previous button is used to return the previous screen viewed In some cases the Previous button is used as an option button In these cases text will ap
23. guring System Configurations l 5 9 5 System Configurations Contact Configuration continued To configure a low contact 1 Touch the Low Contact field A pop up number pad will appear 2 Use the number pad to change the contact type For N O normally open enter 0 For N C normally closed enter 1 To configure a mid contact Controller Configuration 3 only 1 Touch the Low Contact field A pop up number pad will appear 2 Use the number pad to change the contact type For N O normally open enter 0 For N C normally closed enter 1 To configure a high contact Controller Configuration 2 and 3 1 Touch the Low Contact field A pop up number pad will appear 2 Use the number pad to change the contact type For N O normally open enter 0 For N C normally closed enter 1 NOTE Depending on your system config uration your screen may appear slightly different than shown 5 10 l System Configurations Description of Analog Configuration Screen The following screen is only available when 4 8 or 12 analog inputs have been configured The analog input must be configured prior to operation View Analog Configuration To view Analog Status from the System Configuration screen 1 Use the Up Down arrows to scroll to Analog Configuration 2 Press the Enter button Current Analog Input Current Devic
24. h with Low Level Indicator Mid Level Indicator High Level Indicator A Configurable Low Alarm A Configurable High Alarm IMPORTANT Always refer to the wiring diagrams that came with your RLD before making electrical connections n o it p ir c s e D n o it a r u g if n o C g o l a n A 0 NO ANALOG INPUTS No Analog Inputs are available v e d 4 o t p U S T U P N I G O L A N A 4 1 ices can be assigned to an analog input v e d 8 o t p U S T U P N I G O L A N A 8 2 ices can be assigned to an analog input t u p ni g ola n a n a o t d e n gis s a e b n a c s e civ e d 2 1 o t p U S T U P N I G O L A N A 2 1 3 NOTE The units of the analog values can be entered in English or Metric English is the default We re Here to Help Conair has made the largest investment in customer support in the plastics industry Our service experts are available to help with any problem you might have installing and oper ating your equipment Your Conair sales representative also can help analyze the nature of your problem assuring that it did not result from misapplication or improper use How to Contact Customer Service To contact Customer Service personnel call NOTE Normal operation hours are 8 00 AM 5 00 PM EST After hours emergency service is available at the same phone number Y
25. ions screen 5 14 View analog options 5 14 Configure measurement request 5 15 Disable measurement request 5 15 To reset counter 5 16 To enter specific time of day for measurement request 5 17 Description of controller configuration screen 5 18 Change controller configuration 5 19 Change analog configuration 5 19 Change units of measurement 5 19 Controller configuration 5 20 A Appendix We re here to help A 1 How to contact customer service A 1 Before you call A 1 Equipment guarantee A 2 Performance warranty A 2 Warranty limitations
26. ization Number RGA will be issued by Conair s Service Department Returned equipment must be well crated and in proper operating condition including all parts Returns must be prepaid Purchaser must notify Conair in writing of any claim and provide a customer receipt and other evidence that a claim is being made Warranty Limitations Except for the Equipment Guarantee and Performance Warranty stated above Conair disclaims all other warranties with respect to the equipment express or implied arising by operation of law course of dealing usage of trade or otherwise including but not limited to the implied warranties of merchantability and fitness for a particular purpose A 1 l Appendix Appendix B PLC troubleshooing error codes B 2 A p p e n d i x B Appendix l B B 1 l Appendix Appendix B PLC Troubleshooting and Error Codes Additional Resources 1764 UM001A US P MicroLogix 1500 User Manual 1762 RM001B US P MicroLogix 1200 and 1500 Programmable Controllers Instruction Set Reference Manual 1764 IN001A ML P MicroLogix 1500 Base Units Understanding PLC LEDS The Controller status LEDs provide a mechanism to determine the current status of the controller if a programming device is not present or available Continued Appendix l B 2 Appendix B PLC Troubleshooting and Error Codes continued Normal Operating Conditions The Power and Run LEDs are on The COM 0 LED wi
27. lable for each of the configurations shown above Operations RLD control features 3 2 Security 3 4 Password prompts 3 5 Description of level status screen 3 6 Sequence of events when an alarm occurs 3 8 Acknowledge alarm 3 9 Alarm list screen overview 3 10 Descriptions of alarms 3 11 Configuring devices 3 12 Description of analog status screen 3 17 Description of inhibit analog screen 3 18 Description of debug screen 3 19 Changing languages on the debug screen 3 20 S E C T I O N3 3 Operations Operations l 3 1 3 2 l Operations RLD Control Features The RLD operator interface allows you to view the status of the monitored material vessels devices at a glance It also provides access to view alarms configure devices such as silos surge bins perform maintenance and change system configurations Shown below are the Main Screen selection options with a brief description of the tasks associated with the option Level Status View the status of the configured devices silos surge bins Alarm List View active acknowledged alarms Level Configuration Enable Disable devices confi
28. ll be on to indicate com munication between the controller and the operator interface If a force condition is active the Force LED turns on and remains on until all forces are removed Force Conditions In normal operating conditions no forces should be installed If a force is active the Force LED turns on and remains on until all forces are removed Fault Error Condition If an error exists within the controller the controller LEDs operate as described in the following table If the LEDs Indicate The Following Error Exists Probable Cause Recommended Action All LED off No input power or Power supply No line power Verify Proper line voltage and error Connections to the controller Power Supply Overload This problem can occur intermittently if power supply is overloaded when output loading and temperature varies Power and FAULT LEDs Hardware faulted Processor Hardware Error Cycle power Contact your local Conair on solid Service representative if the error persists Loose Wiring Verify connections to the controller Power LED on and FAULT Application Fault Hardware Software 1 Obtain PLC error code LED flashing Major Fault Detected 2 Remove hardware software condition causing fault 3 Reset PLC error 4 Place controller in Run Mode 5 Contact your local Conair Service Representative if the error persists B 3 l Appendix Appendix B PLC Troubleshooting and Error Codes continued Fault Messages
29. om the Main screen navigate to the maintenance menu and choose Clear Alarms 2 Press the Clear All Alarms button NOTE To abort cancel operation and leave alarms in list press the Menu button 4 4 l Maintenance Password Maintenance The passwords for Super and Super2 can be changed You must be logged in at the user level for which would like to change the password Overview of Password Maintenance Screen super Login as a user To change user level password Current user level Logout of user level Maintenance l 4 5 4 Maintenance Password Maintenance continued Change the Password from the Main Screen To change the password from the Main Screen 1 Use the Up Down arrows to scroll to Maintenance 2 Press the Enter button 3 Use the Up Down arrows to scroll to Password Maint 4 Press the Enter button 5 When prompted for a username and password use the pop up keypad to enter the username and password See the Operations section entitled Password Prompts for more detail Once the password is entered press the Enter button 6 Press the Change Password button A pop up key pad will appear 7 On the new pop up keypad use the fields for Username New Password and Verify New Password to enter your username and the new password 8 Once complete press the Enter button 9 When prompted that password has
30. on 1 Touch the field next to Configuration 2 Use the pop up number pad to select the controller configuration 1 40 Low Level 2 20 Low High Level Change Analog Configuration 1 Touch the field next to Analog Configuration 2 Use the pop up number pad to select the analog configuration option 1 4 inputs 2 8 inputs 3 12 inputs Change Units of Measurement 1 Touch the field next to Units 2 Use the pop up number pad to select the units 0 English 1 Metric NOTE See the Sytstem Configuration section entitled Controller Configuration for more detail 5 20 l System Configurations Controller Configuration The RLD has three configurations Each configuration coincides with the input wiring Refer to the electrical drawings for proper wiring Description of Controller Configurations If the Optional Continuous silo level monitoring 4 8 or 12 available quantities of analog input modules have been installed they must be configured CAUTION Electrical connections should be made only by qualified personnel Configuration Description CONFIGURATION 1 40 LOW LEVEL Maximum of 40 devices Each with Low Level Indicator A Configurable Low Alarm CONFIGURATION 2 20 LOW HIGH LEVEL Maximum of 20 Devices Each with Low Level Indicator High Level Indicator A Configurable Low Alarm A Configurable High Alarm CONFIGURATION 3 12 LOW MID HIGH LEVEL Maximum of 12 Devices Eac
31. ou can commission Conair service personnel to provide on site service by contacting the Customer Service Department Standard rates include an on site hourly rate with a one day minimum plus expenses Before You Call If you do have a problem please complete the following checklist before calling Conair Make sure you have all model serial and parts list numbers for your particular equipment Service personnel will need this information to assist you Make sure power is supplied to the equipment Make sure that all connectors and wires within and between control systems and related components have been installed correctly Check the troubleshooting guide of this manual for a solution Thoroughly examine the instruction manual s for associated equipment especially controls Each manual may have its own troubleshooting guide to help you Check that the equipment has been operated as described in this manual Check accompanying schematic drawings for information on special considerations Additional manuals and prints for your Conair equipment may be ordered through the Customer Service or Parts Department for a nominal fee Most manuals can be download ing free of charge from the product section of the Conair website www conairgroup com Appendix l A 1 Equipment Guarantee Conair guarantees the machinery and equipment on this order for a period as defined in the quotation from dat
32. pear on the interface above the button Choice buttons are used to select the option and or function above the button on the interface Enter button is used to complete an operation 3 4 l Operations Security The RLD provides security for screens that have operational effects on the way the RLD will function There are three levels of security The security levels are opera tor which is the default Super and Super2 The chart below shows the level of password required to complete common tasks Default Passwords Security Levels Passwords Operator not required Super 2 Super2 3 NOTE Super and Super 2 passwords can be changed by authorized personnel Instructions for changing the passwords can be found in the maintenance section See Maintenance section entitled Password Maintenance Tasks Password Level Required OPERATOR SUPER SUPER2 SERVICE View Level Status YES YES YES YES View Acknowledge Alarms YES YES YES YES Inhibit Analog Measurements YES YES YES YES Enable Disable Devices NO YES YES YES Setup Devices Alarms NO YES YES YES Clear Alarms NO YES YES YES Configure Recurring Alarm Timer NO NO YES YES Password Maintenance NO NO YES YES Save Restore Configuration NO NO YES YES Contact Configuration NO NO YES YES Analog Config NO NO YES YES Analog Options NO NO YE
33. r responsibilities as a user 1 3 ATTENTION Read this so no one gets hurt 1 4 2 1 Description What is the Resin Level Display RLD 2 2 3 1 Operations RLD control features 3 2 Security 3 4 Password prompts 3 5 Description of level status screen 3 6 Sequence of events when an alarm occurs 3 8 Acknowledge alarm 3 9 Alarm list screen overview 3 10 Descriptions of alarms 3 11 Configuring devices 3 12 Description of analog status screen 3 17 Description of inhibit analog screen 3 18 Description of debug screen 3 19 Changing languages on the debug screen
34. s the enter arrow 3 Operations Device Number Current Level Volume and Weight of material in the silo or bin Analog Input currently being viewed 3 18 l Operations Description of Inhibit Analog Screen The following screen is only available when Analog Inputs have been configured There are 4 Inhibit Analog Outputs which can be used to inhibit measurements to the attached measuring devices View Inhibit Analog Screen 1 From the Main screen use the Up Down arrows to scroll to INHIBIT ANALOG 2 Press the enter arrow Inhibit Enable Analog Measurement 1 Touch the field of the Analog measurement to be inhibited or enabled A pop up number pad will appear 2 Using the number pad enter a 1 to inhibit measurement or a 0 to enable measurement NOTE Measuring devices must have inhib ited capability and inhibit signals must be connect ed properly RLD electri cal drawings provide additional notes when wiring Operations 3 19 Description of Debug Screen Navigate to the Debug Screen through the Main Menu The Debug Screen allows you to check communication status view the node address and view the current login and security level View Debug screen 1 From the Main screen use the Up Down arrows to scroll to the Debug screen 2 Press the enter arrow Node Address Available languages User Level Access Levels
35. t Configuration The Contact Configuration screen allows both Normally Open and Normally Closed contacts be used on any input The contact must be configured for the contact type of the sensor Changing this configuration will effect the operation of the RLD Super2 login is required Typical Contact Configurations Navigation to Contact Configuration Screen To view change the Contact Configuration from the System Configurations screen 1 Use the Up Down arrows to scroll to Contact Config 2 Press the Enter button 3 When prompted for username and password use the pop up keypad to enter the username and password See the Operations section entitled Password Prompts for more detail Once the password is entered press the Enter button Sensor Typical Configuration LOW N O Normally Open MID N O Normally Open HIGH N O Normally Open 5 6 l System Configurations Contact Configuration continued Contact Configuration Screen Overview Current Device Contact Configurations System Configurations l 5 7 Contact settings 0 normally open 1 normally closed 5 8 l System Configurations Continued Contact Configuration continued Configure Contact To select a device 1 Touch the Device field A pop up number pad may appear depending on the number of devices in your system 2 Enter the device number that you would like to start confi
36. tep adherence to instructions outlined in this User Guide 1 Introduction ATTENTION Read this so no one gets hurt We design equipment with the user s safety in mind You can avoid the potential hazards identified on this machine by following the procedures outlined below and elsewhere in the User Guide WARNING Improper installation operation or servicing may result in equipment damage or personal injury This equipment should be installed adjusted and serviced by qualified technical personnel who are familiar with the construction operation and potential hazards of this type of machine All wiring disconnects and fuses should be installed by qualified elec trical technicians in accordance with electrical codes in your region Always maintain a safe ground Do not operate the equipment at power levels other than what is specified on the machine serial tag and data plate WARNING Electrical hazard Before performing any work on this item disconnect and lock out elec trical power sources to prevent injury from unexpected energization or startup 1 4 l Introduction Description What is the Resin Level Display RLD 2 2 S E C T I O N2 2 Description Functionality Features l 2 1 What is the Resin Level Display RLD The Resin Level Display RLD has been designed for material fill sensing and alarming applications The RLD monitors material levels for up to 40 silos or surge bins All m
37. vated 3 Operations Operations l 3 13 Configuring Devices continued High Alarm the alarm is triggered when the level within the device is above the high indicator Disabled No visual alarm No audible alarm High Alarm Enabled A visual alarm will be triggered and stay active until the alarm is cleared level returns below the high indicator An audible alarm will be triggered and stay active until acknowledged High Recurring Alarm Enabled A visual alarm will be triggered and stay active until the alarm is cleared level returns below the high indicator An audible alarm will be triggered and stay active until acknowledged If the level within the device does not go below the high indicator within the configured time the audible alarm will be reactivated Navigation to the Level Configuration Screen To view the Level Configuration screen from the Main Screen 1 Use the Up Down arrows to scroll to Level Config 2 Press the Enter button 3 When prompted for the username and password use the pop up key pad to enter the username and password See the Operations section entitled Password Prompts for more detail 4 Once the password is entered press the Enter button Continued 3 14 l Operations Configuring Devices continued Level Configuration Screen Overview Current Device Alarm Configuration Enable Disable Device Operations 3 15

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