Conair Compact Loader B32 User Manual
Basic 32  
Loader Control  
B32 Model  
Installation  
Operation  
Maintenance  
Troubleshooting  
The Conair Group, Inc.  
One Conair Drive  
Pittsburgh, PA 15202  
Phone: (412) 312-6000  
Fax: (412)-312-6001  
Instant Access  
Parts and Service  
(800) 458-1960  
(814) 437-6861  
www.conairnet.com  
UGC007/0702  
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INTRODUCTION .........................................1-1  
Purpose of the User Guide.....................................................1-2  
How the Guide is Organized .................................................1-2  
Your Responsibility as a User .............................................. 1-2  
ATTENTION: Read this so no one gets hurt ........................1-3  
TABLE OF  
CONTENTS  
DESCRIPTION . . . . . . . . . . . . . . . . . . . .2-1  
What is the B32? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2  
Typical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2  
How it Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3  
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4  
INSTALLATION . . . . . . . . . . . . . . . . . . . .3-1  
Unpacking the Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2  
Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . .3-3  
Installing the B32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4  
Wiring Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4  
Mounting the Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5  
Connecting to the B32 . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6  
Wiring Loaders to the B32 . . . . . . . . . . . . . . . . . . . . . . . . .3-7  
Wiring Pumps to the B32 . . . . . . . . . . . . . . . . . . . . . . . . . .3-7  
Wiring Purge Valves to the B32 . . . . . . . . . . . . . . . . . . . . .3-7  
Connecting Main Power to the B32 . . . . . . . . . . . . . . . . . .3-8  
Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9  
Setting Loader Parameters . . . . . . . . . . . . . . . . . . . . . . . .3-10  
Enabling Loaders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11  
Enabling Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11  
Selecting a Password . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12  
OPERATION . . . . . . . . . . . . . . . . . . . . . .4-1  
B32 Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2  
Viewing Loader Status . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3  
Enabling and Disabling Loaders . . . . . . . . . . . . . . . . . . . .4-4  
Enabling and Disabling Pumps . . . . . . . . . . . . . . . . . . . . .4-5  
Configuring Loaders . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6  
Assigning Pumps and Loaders . . . . . . . . . . . . . . . . . . . . . .4-7  
Assigning a Backup Pump . . . . . . . . . . . . . . . . . . . . . . . . .4-8  
Configuring the Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9  
Backing up the PLC Program . . . . . . . . . . . . . . . . . . . . . .4-10  
MAINTENANCE . . . . . . . . . . . . . . . . . . . .5-1  
Preventive maintenance checklist . . . . . . . . . . . . . . . . . . . .5-2  
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Basic 32 Loader Control  
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TROUBLESHOOTING . . . . . . . . . . . . . . . .6-1  
TABLE OF  
CONTENTS  
Before Beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2  
A Few Words of Caution . . . . . . . . . . . . . . . . . . . . . . . . . .6-2  
Identifying the Cause of a Problem . . . . . . . . . . . . . . . . . .6-3  
Clearing Interface Alarms . . . . . . . . . . . . . . . . . . . . . . . . .6-4  
Clearing CPU and I/O alarms . . . . . . . . . . . . . . . . . . . . . .6-5  
Conveying System Alarms . . . . . . . . . . . . . . . . . . . . . . . . .6-6  
Operator Interface Problems . . . . . . . . . . . . . . . . . . . . . . .6-8  
Processor and power problems . . . . . . . . . . . . . . . . . . . . . .6-8  
CPU faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9  
I/O errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9  
APPENDIX  
Customer service information . . . . . . . . . . . . . . . . . . . . . .A-1  
Warranty information . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2  
Restoring the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1  
PARTS/DIAGRAMS  
Wiring Diagrams  
Recommended Spare Parts  
Basic 32 Loader Control  
UGC007/0702  
ii  
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INTRODUCTION  
l Purpose of the User Guide .........1-2  
l How the guide is organized ........1-2  
l Your responsibilities as a user...1-2  
l ATTENTION: Read this so  
no one gets hurt .....................1-3  
UGC007/0702  
Basic 32 Loader Control  
1-1  
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This User Guide describes the Conair Basic 32 Loader  
Control and explains step-by-step how to install, operate,  
maintain and repair this equipment.  
PURPOSE OF  
THE USER  
GUIDE  
Before installing this product, please take a few moments to  
read the User Guide and review the diagrams and safety infor-  
mation in the instruction packet. You also should review man-  
uals covering associated equipment in your system. This  
review won’t take long, and it could save you valuable instal-  
lation and operating time later.  
Symbols have been used to help organize the User Guide and  
call your attention to important information regarding safe  
installation and operation.  
HOW THE  
GUIDE IS  
ORGANIZED  
Symbols within triangles warn of conditions that could  
be hazardous to users or could damage equipment.  
Read and take precautions before proceeding.  
Numbers within shaded squares indicate tasks or steps  
to be performed by the user.  
1
A diamond indicates the equipment’s response to an  
action performed by the user.  
u
An open box marks items in a checklist.  
r
A shaded circle marks items in a list.  
l
You must be familiar with all safety procedures concerning  
installation, operation and maintenance of this equipment.  
Responsible safety procedures include:  
YOUR  
RESPONSIBILITY  
AS A USER  
lThorough review of this User Guide, paying particular  
attention to hazard warnings, appendices and related dia-  
grams.  
lThorough review of the equipment itself, with careful  
attention to voltage sources, intended use and warning  
labels.  
lThorough review of instruction manuals for associated  
equipment.  
lStep-by-step adherence to instructions outlined in this  
User Guide.  
Basic 32 Loader Control  
UGC007/0702  
1-2 INTRODUCTION  
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We design equipment with the user’s safety in mind. You can  
avoid the potential hazards identified on this machine by fol-  
lowing the procedures outlined below and elsewhere in the  
User Guide.  
ATTENTION:  
READ THIS SO NO  
ONE GETS HURT  
WARNING: Improper installation, oper-  
ation or servicing may result in equip-  
ment 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 equipment.  
All wiring, disconnects and fuses should be  
installed by qualified electrical 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 the equipment serial tag and  
data plate.  
WARNING: Electrical shock hazard  
This equipment is powered by electrical voltage  
as specified on the machine serial tag and data  
plate.  
A properly sized conductive ground wire from  
the incoming power supply must be connected  
to the chassis ground terminal inside the  
Input/Output enclosure. Improper grounding can  
result in personal injury and erratic machine  
operation.  
Always disconnect and lock out the incoming  
main power source before opening the electrical  
enclosure or performing non-standard operating  
procedures such as troubleshooting or routine  
maintenance. Only qualified personnel should  
perform troubleshooting procedures requiring  
access to the electrical enclosure while power  
is on.  
UGC007/0702  
Basic 32 Loader Control  
INTRODUCTION 1-3  
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DESCRIPTION  
lWhat is the B32? . . . . . . . . . . . .2-2  
lTypical Applications . . . . . . . . . .2-2  
lHow it Works . . . . . . . . . . . . . . .2-3  
lSpecifications . . . . . . . . . . . . . .2-4  
UGC007/0702  
Basic 32 Loader Control  
2-1  
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The control is mounted on the front of the I/O station. Inside  
is a processor with base, containing up to 8 input/output mod-  
ules. The number of input and output modules will vary with  
the number of vacuum receivers and conveying options.  
WHAT IS THE  
B32?  
Pump  
System 5  
Pump  
System 1  
Pump  
System 6  
Pump  
System 2  
B32  
Pump  
System 3  
Pump  
System 7  
Pump  
System 4  
Pump  
System 8  
Backup  
Pump  
The controller and control automatically turn on when power  
is applied to the I/O station. After a bootup sequence the home  
screen displays. From the home screen the operator can scroll  
to all monitoring and control functions.  
The Basic 32 has been designed for basic conveying applica-  
tions.  
TYPICAL  
APPLICATIONS  
Loader-pump assignments are completely flexible. Individual  
vacuum receivers can be assigned to any one of the eight  
loading systems. Each receiver can be configured for one of  
the following:  
lSingle-material loading.  
lRatio loading, with or without automatic material layering.  
lPositive (air-operated) receiver discharge.  
lMaterial line purging.  
lLoader fill alarm to work with an optional fill sensor  
mounted in the receiver body or direct feed chamber.  
lHopper fill alarm to work with an optional demand sensor  
mounted in a drying hopper or other material vessel.  
lNo alarm.  
Basic 32 Loader Control  
UGC007/0702  
2-2  
DESCRIPTION  
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The B32 communicates with each pump, vacuum receiver and  
material valve wired to Input/Output modules within the con-  
trol enclosure. The B32 controls conveying operation based on  
settings the operator enters on the HMI.  
HOW IT WORKS  
When receivers in a pump system demand material, the B32  
turns on the vacuum pump and dust collector in the appropri-  
ate pump system. It then opens the correct vacuum and mater-  
ial valves to convey material to satisfy the demand.  
The overview screen lets the operator monitor the status of all  
vacuum receivers at a glance. Icons indicate the real-time sta-  
tus of each receiver.  
Other screens allow you to change system settings or to view  
pump systems, loader details, alarm histories.  
UGC007/0702  
Basic 32 Loader Control  
DESCRIPTION 2-3  
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C
SPECIFICATIONS  
3 inch screen  
standard  
A
5.5 inch screen  
(optional)  
B
MODEL  
B32  
Performance characteristics  
Maximum number of vacuum receivers  
Maximum number of vacuum pumps  
Programmable logic controller  
Touchscreen operator interface  
Communications with master control  
Screen size, inches {mm}  
User interface method  
Output voltage to receivers/valves  
Sensor voltage to receivers  
Output voltage to pumps  
Dimensions inches {mm}  
Master control cabinet  
A - Height  
32  
8 (plus back-up)  
Allen Bradley Micrologix 1500  
Allen Bradley PV300 Micro  
DH485  
2.87 X 1.67 {73 X 42}  
Keypad  
24 VDC  
24 VDC  
24 VDC  
31.4 {998}  
23.8 {606}  
12.5 {318}  
B - Width  
C - Depth  
Weight lb {kg}  
Installed  
Shipping  
70 {32}  
85 {39}  
Voltages Total amps  
115V/1 phase/60Hz (master control)  
10  
SPECIFICATION NOTES:  
B32 loader control cable: 18 gauge shielded, 8-conductor may be used  
for standard vacuum receivers with up to one optional output and input,  
otherwise 10-conductor cable is required.  
Specifications can change without notice. Check with your Conair  
representative for the most current information.  
APPLICATION NOTES:  
Conair vacuum receivers come equipped with a quick-disconnect connec-  
tor set that includes 10 feet of cable. Junction boxes must be provided to  
connect the system cable and each vacuum receiver’s connector set.  
CALCULATING CABLE LENGTH:  
Total the distances from the Input/output Station(s) location to each vacu-  
um receiver on the system. Be sure to account for reasonable slack at  
each loading station for connections, cable routing, etc.  
Basic 32 Loader Control  
UGC007/0702  
2-4  
DESCRIPTION  
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INSTALLATION  
lUnpacking the Boxes . . . . . . . . . . .3-2  
lPreparing for Installation . . . . . . . .3-3  
lInstalling the B32 . . . . . . . . . . . . . .3-4  
lWiring Considerations . . . . . . . . . .3-4  
lMounting the Control . . . . . . . . . .3-5  
lConnecting to the B32 . . . . . . . . . .3-6  
lWiring Loaders to the B32 . . . . . . .3-7  
lWiring Pumps to the B32 . . . . . . . .3-7  
lWiring Purge Valves to the B32 . . .3-7  
lConnecting Main Power . . . . . . . . .3-8  
lInitial setup . . . . . . . . . . . . . . . . . . .3-9  
lSetting Loader Parameters . . . . .3-10  
lEnabling Loaders . . . . . . . . . . . . .3-11  
lEnabling Pumps . . . . . . . . . . . . . .3-11  
lSelecting a Password . . . . . . . . . .3-12  
UGC007/0702  
Basic 32 Loader Control  
3-1  
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The B32 central loading control comes in one box. The box  
should include:  
UNPACKING  
THE BOXES  
Carefully remove the B32 components from  
1
their shipping containers, and set upright.  
2 Remove all packing material, protective paper,  
tape and plastic.  
3
Carefully inspect all components to make sure  
no damage occurred during shipping. Notify the shipper  
immediately if damage is found.  
4 Take a moment to record serial numbers,  
the software version number and electrical power specifi-  
cations in the blanks provided on the back of the the User  
Guide’s title page. The information will be helpful if you  
ever need service or parts.  
5 You are now ready to begin installation.  
Follow the preparation steps on the next page, paying par-  
ticular attention to all wiring consideration and recom-  
mendations.  
Basic 32 Loader Control  
UGC007/0702  
3-2  
INSTALLATION  
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You should plan the location of the B32 control to ensure easy  
access and minimal wiring.  
PREPARING FOR  
INSTALLATION  
Select a mounting location for the control.  
1
The interface and Input/Output enclosure can be mounted  
on a wall or other stable vertical surface.  
Select a location that:  
rIs central to loaders that the B32 will control. Keep  
the B32 Input/Output station as close as possible to the  
loading stations to minimize the amount of wire needed to  
connect the vacuum receivers to the control.  
rProvides adequate clearance for safe operation and  
maintenance. The control should be mounted at a height  
that allows the operator to easily see and touch the screen.  
Maintain at least 3 feet (1m) clearance in front of the con-  
trol for safe access to the Input/Output enclosure.  
rProvides a clean, dry, vibration-free environment.  
Exposure to wide temperature variations, high ambient  
temperature, power line fluctuations, caustic fumes or  
excessive amounts of dust, dirt, vibration, shock and  
moisture could harm performance and reduce the life of  
this equipment.  
rProvides a grounded source of 115 VAC power.  
The three-prong power cord supplied with the B32 con-  
trol requires a grounded 115 VAC outlet rated for at least  
15 amp service.  
2 Plan the power/communication cable routes.  
rReview all wiring guidelines and diagrams provided  
in the manuals and electrical diagrams supplied with the  
B32 control and your conveying equipment before begin-  
ning installation. See WIRING CONSIDERATIONS.  
rKeep communication wires away from sources of  
static electricity. Static electricity can damage the con-  
trols.Communication cables should not be run near the  
material lines and hoses, which produce large amounts of  
static electricity when material is conveyed. You should  
use shielded cable unless you run wires through metal  
conduit.  
rAvoid running communication cables across power  
feed lines. If you must run the cable across power feed  
lines, run the cable at right angles to the lines.  
UGC007/0702  
Basic 32 Loader Control  
INSTALLATION 3-3  
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Installation of the B32 control consists of:  
rMounting the enclosure.  
rWiring loaders to the control.  
INSTALLING  
THE B32  
rWiring pumps to the control.  
rWiring material valves to the control.  
rConnecting the control to a main power source.  
rInitial setup of the system control.  
WARNING: Improper installation may  
result in equipment damage or personal  
injury.  
WIRING  
CONSIDERATIONS  
● Disconnect and lock out the main power supply to  
equipment in the conveying system before wiring  
power and communication cables between the  
B32 control, vacuum receivers, pumps, dust col-  
lectors and material valves.  
● Install all wiring, disconnects and fuses in accor-  
dance with electrical codes in your region. All  
electrical installations should be done only by  
qualified electrical technicians.  
● Always refer to the wiring diagrams supplied with  
your control before making electrical connections.  
The diagrams show the most accurate electrical  
component information.  
● Protect communication cables from sources of  
static electricity and electrical noise.  
● Use shielded cable or run wire through a contigu-  
ous metal conduit or wireway. Failure to use a  
metal shield can expose the controls to static  
electricity, which can damage electronic compo-  
nents.  
● Do not run communication cables near material  
lines and hoses, which produce large amounts of  
static electricity when conveying material.  
● Keep communication cables at least 5 ft. (1.5 m)  
from electric motors, transformers, rectifiers, arc  
welders, generators, induction furnaces and  
sources microwave radiation.  
● Avoid running communication cable across power  
feed lines. If you must run cable across power  
lines, run the cable at right angles to the line.  
Keep the cable at least 6 inches (0.15 m) from AC  
power lines of less than 20 A; 1 foot (0.30 m) from  
lines of 20A to 100 kVA; and 2 feet (0.60 m) from  
lines of 100 kVA or more.  
Basic 32 Loader Control  
UGC007/0702  
3-4  
INSTALLATION  
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WARNING: Improper installation may  
result in equipment damage or personal  
injury.  
● Always maintain a safe ground. Follow the safe  
grounding procedures in the wiring diagram pack-  
age. Ground the shielded cable inside the  
Input/Output enclosure only.  
● Do not operate the equipment at power levels other  
than those specified on the the equipment data  
plate.  
The B32 Input/Output enclosure should be  
mounted on a wall, or other secure vertical  
surface, at a height providing easy access  
and a clear view of the touchscreen panel.  
MOUNTING  
THE CONTROL  
Bolt the control to the  
mounting surface. Use the mounting  
brackets on the I/O enclosure.  
1
2 Ground the control enclosure.  
Connect a ground wire to the control. Follow procedures  
outlined by your regional electrical codes and the wiring  
diagrams included with this manual.  
UGC007/0702  
Basic 32 Loader Control  
INSTALLATION 3-5  
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WARNING: Improper installation  
may result in equipment damage or  
personal injury.  
Always refer to the wiring diagrams that came  
with your controls before making electrical con-  
nections. The diagrams show the most accurate  
electrical component information.  
CONNECTING TO  
THE B32  
Use shielded cable unless you run wires in  
metal conduit. Failure to use a metal shield will  
expose the controls to static electricity, which  
can damage electronic components.  
When using shielded cable, make sure the  
shield is grounded inside the I/O stations only.  
It is also important to keep the communication  
wires away from conveying lines, which can  
produce large amounts of static electricity.  
Each vacuum receiver, pump and  
material valve in the system must be  
wired to power or common/ground  
Input/Output modules  
terminals and Input/Output modules  
inside the B32 control enclosure.  
Each loader requires at least six  
wire connections to the  
Input/Output enclosure.  
One additional wire is required for  
each option or for a three-wire sensor used for either demand  
or loader full inputs. Connect the loader cable wires to the I/O  
station according to the color codes:  
Basic 32 Loader Control  
UGC007/0702  
3-6  
INSTALLATION  
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The loader wires connect to power terminals or terminals on  
the I/O modules inside the control enclosure. The number of  
loaders and options in the conveying system will determine  
the number of connections that are required.  
WIRING LOADERS  
TO THE B32  
Refer to the electrical prints included with this manual for all  
electrical connections to the loader control. All loader outputs  
are 24 VDC and all demand and fill sensor inputs are 24  
VDC.  
IMPORTANT: Always refer  
to the wiring diagrams that  
came with your controls  
before making electrical  
connections. The diagrams  
show the most accurate  
electrical component infor-  
mation.  
A general list of loader electrical connections is included in  
the appendix.  
The B32 can run eight vacuum pumps and one backup pump.  
Refer to the electrical prints included with this manual for all  
electrical connections to the loader control. All pump outputs  
are 24 VDC and all overload inputs are 24 VDC.  
WIRING PUMPS  
TO THE B32  
The B32 can operate up to 32 purge valves, which are used to  
remove material from the lines at the end of a loading cycle.  
Since purge valves are located at the material source instead  
of at the loader, separate wiring connections to the B32 are  
required.  
WIRING PURGE  
VALVES TO THE  
B32  
(OPTIONAL)  
UGC007/0702  
Basic 32 Loader Control  
INSTALLATION 3-7  
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The B32 Input/Output enclosure is equipped with a three-  
prong plug and power cord. Each optional remote touchscreen  
panel also has its own plug and power cord.  
CONNECTING  
MAIN POWER  
TO THE B32  
1 Plug the power cord(s) into a grounded 115  
VAC outlet rated for at least 15 Amp service.  
Make sure the control enclosure is grounded.  
2
WARNING: Electrical shock hazard  
Failure to provide proper grounding can cause  
control malfunctions and could result in personal  
injury from electrical shock.  
The control must be connected to a grounded  
power source. A properly sized conductive  
ground wire must be connected to the chassis  
ground terminal inside the Input/Output enclo-  
sure.  
Basic 32 Loader Control  
UGC007/0702  
3-8 INSTALLATION  
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Before you can begin conveying, you must configure and  
identify the loaders and conveying features you want to use.  
INITIAL SETUP  
Procedures on the following pages will explain how to:  
rSet loader parameters  
rEnable pumps and loaders  
rSelect security password  
To begin Initial Setup:  
Turn on power to the B32.  
The Power ON/OFF switch is on the left side of the con-  
trol enclosure.  
1
Wait for the control to boot.  
2
Do not touch the control until it completes the bootup and  
initialization process. Process takes a few seconds. When  
the control has initialized, the Main Screen displays.  
Display screen  
Navigation arrows  
Selection arrows  
Navigation buttons  
UGC007/0702  
Basic 32 Loader Control  
INSTALLATION 3-9  
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CAUTION: Incorrect configurations will  
cause the B32 control to stop.  
SETTING  
LOADER  
Before enabling loaders and loading functions,  
make sure the loader, valve or option has been  
installed in the system. Each loader and feature  
must be wired to a correctly installed and enabled  
input or output module. The B32 will fault and the  
loading control will stop if the required I/O module  
has not been installed for the feature you enabled.  
PARAMETERS  
The loader must be correctly installed and wired before setting  
parameters.  
To set loader parameters from the main screen:  
1 Use the Up/Down arrows to scroll to  
Loader Settings.  
2
Press the Enter arrow.  
The Loader Settings screen displays. Use the  
up/down arrows to scroll to Settings.  
3 Press the Enter arrow.  
The Settings screen displays. Use the left/right  
arrows to scroll to move the cursor to the Loader  
field. Use the up/down arrows to select loader.  
Use the Scroll Down/Up buttons to set the  
4
loader  
parameters: loader number, virgin time in seconds,  
dump time in seconds and pump number.  
Basic 32 Loader Control  
UGC007/0702  
3-10 INSTALLATION  
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To enable the loaders from the main screen:  
ENABLING  
LOADERS  
1
2
Use the Up/Down arrows to scroll to  
Loader Settings.  
Press the Enter arrow.  
The Loader Settings screen displays. Use the  
up/down arrows to scroll to Loader Enable.  
Press the Enter arrow.  
3
The Loader Enable screen displays. Use the  
up/down arrows to increase and decrease the  
loader number. Use the scroll down/up buttons to  
enable/disable the loader.  
To enable the pumps from the main screen:  
ENABLING  
PUMPS  
1 Use the Up/Down arrows to scroll to  
Loader Settings.  
Press the Enter arrow.  
2
3
The Loader Settings screen displays. Use the  
up/down arrows to scroll to Pump Enable.  
Press the Enter arrow.  
The Pump Enable screen displays. Use the up/down  
arrows to increase and decrease the pump number.  
Use the scroll down/up buttons to enable/disable the  
pump.  
UGC007/0702  
Basic 32 Loader Control  
INSTALLATION 3-11  
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The B32 provides password security to prevent unauthorized  
changes to loader or system settings.  
SELECTING A  
PASSWORD  
1
Use the Up/Down arrows to scroll to  
System Config. Entering the System Configuration  
screen requires a Supervisor 2 password.  
2
Enter the password.  
To enter the password use the up/down arrows to  
scroll through the alphanumeric list. When the cor-  
rect letter/number is highlighted use the right Select arrow  
to move to the next digit. Continue until the whole pass-  
word is selected. The initial passwords are set at the fac-  
tory:  
● Supervisor 1: 7373  
● Supervisor 2: 54647  
Change these passwords and record the new passwords in  
a safe place.  
3 Press the Enter arrow.  
The Factory Configuration screen displays. Use the  
scroll up/down buttons to scroll to the New field.  
Use the up/down arrows to scroll through the alphanu-  
meric list. When the correct letter/number is highlighted  
use the right Select arrow to move to the next digit.  
Continue until the whole password is selected.  
Press the Enter arrow.  
4
The Password Administration screen displays. Use  
the up/down arrows to scroll through the alphanu-  
meric list. When the correct letter/number is highlighted  
use the right Select arrow to move to the next digit.  
Continue until the whole password is selected.  
5 Press the Enter arrow to accept the  
password.  
Press the Main button to return to the  
main screen.  
6
Basic 32 Loader Control  
UGC007/0702  
3-12 INSTALLATION  
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OPERATION  
lB32 Control Features . . . . . . . . . . .4-2  
lViewing Loader Status . . . . . . . . . .4-3  
lEnabling and Disabling  
Loaders . . . . . . . . . . . . . . . . . . . . .4-4  
lEnabling and Disabling  
Pumps . . . . . . . . . . . . . . . . . . . . .4-5  
lConfiguring Loaders . . . . . . . . . . .4-6  
lAssigning Pumps and Loaders . . .4-7  
lAssigning a Backup Pump . . . . . .4-8  
lConfiguring the Alarm . . . . . . . . . .4-9  
lBacking up PLC Program . . . . . .4-10  
UGC007/0702  
Basic 32 Loader Control  
4-1  
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The B32 operator interface allows you to view the status of the vacu-  
um receivers and pumps in your conveying system at a glance. It  
also provides access to screens to enter settings for each loading sta-  
tion, view alarms and change system parameters.  
B32  
CONTROL  
FEATURES  
Quick-reference guides  
Scroll to:  
● Enable/disable loaders  
and pumps  
● Set load times, layers  
and dump times  
● View loader status and  
alarm list  
Loader Settings  
Scroll to:  
● Set loader parameters  
● View loader status  
● Enable loaders  
● Enable pumps  
● View alarm list  
Loader Configuration  
Allows you to:  
● Configure a loader  
● Assign a loader to a pump  
● Assign a backup pump  
● Configure loader alarms  
● Backup PLC program and settings  
● Restore a program  
System Configuration  
Prevent accidental or unautho-  
rized changes to system settings  
with security password.  
● Display and clear PLC errors  
Basic 32 Loader Control  
UGC007/0702  
4-2 OPERATION  
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To view loader status from the main screen:  
VIEWING  
LOADER  
STATUS  
1
2
Use the Up/Down arrows to scroll to  
Loader Settings.  
Press the Enter arrow.  
The Loader Settings screen displays. Use the  
up/down arrows to scroll to Loader 1-16.  
Press the Enter arrow.  
3
The Loader Status screen displays. The current status  
of each loader and pump displays. The status choices  
include:  
E
D
L
- enabled  
- in demand  
- loading  
- disabled  
- running  
E
R
The status of up to 16 loaders and four pumps display sta-  
tus on each screen.  
Use the Scroll Down/Up buttons to view  
the remaining loaders and pumps.  
4
UGC007/0702  
Basic 32 Loader Control  
OPERATION 4-3  
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WARNING: Develop and follow procedures  
for safe operation of the system to avoid pos-  
sible injury or equipment damage.  
ENABLING  
AND DISABLING  
LOADERS  
The B32 allows operators and maintenance  
personnel to disable and enable conveying system  
components from remote locations. Unexpected  
energization of these components could result in  
equipment damage or injury.  
Safe operating procedures should include:  
r Disconnect any loader, pump or material  
valve from main power and/or compressed air  
sources before servicing. Ensure that all energy  
sources for the device are locked out and  
tagged.  
rBefore removing lockout devices or enabling  
pumps, loaders or material valves, make sure  
that all personnel are clear of the machine,  
tools have been removed and any safety guards  
have been reinstalled.  
To enable the loaders from the main screen:  
1
2
Use the Up/Down arrows to scroll to  
Loader Settings.  
Press the Enter arrow.  
The Loader Settings screen displays. Use the  
up/down arrows to scroll to Loader Enable.  
Press the Enter arrow.  
3
The Loader Enable screen displays. Use the  
up/down arrows to increase and decrease the  
loader number. Use the Scroll Down/Up buttons to  
enable/disable the loader.  
Press the Enter arrow to save the change.  
4
5
Press the Previous button to return to  
the last screen you were viewing, or the Main  
button to return to the Main screen.  
Basic 32 Loader Control  
UGC007/0702  
4-4 OPERATION  
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WARNING: Develop and follow procedures  
for safe operation of the system to avoid pos-  
sible injury or equipment damage.  
ENABLING  
AND DISABLING  
PUMPS  
The B32 allows operators and maintenance  
personnel to disable and enable conveying system  
components from remote locations. Unexpected  
energization of these components could result in  
equipment damage or injury.  
Safe operating procedures should include:  
r Disconnect any loader, pump or material  
valve from main power and/or compressed air  
sources before servicing. Ensure that all energy  
sources for the device are locked out and  
tagged.  
rBefore removing lockout devices or enabling  
pumps, loaders or material valves, make sure  
that all personnel are clear of the machine,  
tools have been removed and any safety guards  
have been reinstalled.  
To enable the pumps from the main screen:  
1
2
Use the Up/Down arrows to scroll to  
Loader Settings.  
Press the Enter arrow.  
The Loader Settings screen displays. Use the  
up/down arrows to scroll to Pump Enable.  
Press the Enter arrow.  
3
The Pump Enable screen displays. Use the up/down  
arrows to increase and decrease the pump number.  
Use the scroll down/up buttons to enable/disable  
the pump.  
NOTE: When a pump is disabled the loader completes its  
load cycle before the pump is de-energized.  
4 Press the Enter arrow to save the change.  
Press the Previous button to return to  
the last screen you were viewing, or the Main  
button to return to the Main screen.  
5
UGC007/0702  
Basic 32 Loader Control  
OPERATION 4-5  
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You may need to change loader settings whenever you change  
materials or to obtain the best conveying performance.  
CONFIGURING  
LOADERS  
To configure loaders from the main screen:  
Use the Up/Down arrows to scroll to  
1
2
Loader Config.  
Press the Enter arrow.  
The Loader Configuration screen displays. Use the  
up/down arrows to scroll to Option Config.  
3 Press the Enter arrow.  
The Option Configuration screen displays. Use the  
up/down arrows to increase and decrease the loader  
number. Use the scroll down/up buttons to select  
option:  
● Discharge  
● Ratio  
● Ratio with Calc  
● Purge  
● Material valve  
● No option  
4
5
Press the Enter arrow to save the change.  
Press the Previous button to return to  
the last screen you were viewing, or the Main  
button to return to the Main screen.  
Basic 32 Loader Control  
UGC007/0702  
4-6 OPERATION  
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You may need to change loader and pump assignments to  
match the conveying system vacuum and XXXX  
ASSIGNING  
LOADERS AND  
PUMPS  
To assign loaders and pumps from the main screen:  
Use the Up/Down arrows to scroll to  
Loader Config.  
1
Press the Enter arrow.  
The Loader Configuration screen displays. Use  
the up/down arrows to scroll to Pump Assign.  
2
Press the Enter arrow.  
3
The Pump Assignment screen displays. Use the  
up/down arrows to choose the loader number.  
Use the scroll down/up buttons to choose the  
pump number.  
Press the Enter arrow to save the change.  
4
5
Press the Previous button to return to  
the last screen you were viewing, or the Main  
button to return to the Main screen.  
UGC007/0702  
Basic 32 Loader Control  
OPERATION 4-7  
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A backup pump can be assigned to replace any of the eight  
pump systems during operation.  
ASSIGNING A  
BACKUP PUMP  
To assign a backup pump:  
1 Use the Up/Down arrows to scroll to  
Loader Config.  
Press the Enter arrow.  
2
3
The Loader Configuration screen displays. Use the  
up/down arrows to scroll to VP Back-Up Select.  
Press the Enter arrow.  
The Pump Back-up Select screen displays. Use the  
scroll down/up buttons to select a backup pump  
(pumps 1 through 8) or no backup pump.  
4 Press the Enter arrow to save the change.  
Press the Previous button to return to  
the last screen you were viewing, or the Main  
button to return to the Main screen.  
5
Basic 32 Loader Control  
UGC007/0702  
4-8 OPERATION  
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Te loader can be configured for demand alarm, fill alarm or no  
alarm.  
CONFIGURING  
THE ALARM  
To configure the alarm from the main screen:  
1 Use the Up/Down arrows to scroll to  
Loader Config.  
Press the Enter arrow.  
2
3
The Loader Configuration screen displays. Use the  
up/down arrows to scroll to Alarms.  
Press the Enter arrow.  
The Alarm Configuration screen displays. Use the  
scroll down/up buttons to choose the alarm config-  
uration you want:  
● No alarm  
● Demand alarm  
● Fill alarm  
Press the Enter arrow to save the change.  
4
5
Press the Previous button to return to  
the last screen you were viewing, or the Main  
button to return to the Main screen.  
UGC007/0702  
Basic 32 Loader Control  
OPERATION 4-9  
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To back up the PLC program and save the configuration:  
BACKING UP  
PLC PROGRAM  
(OPTIONAL)  
1 Use the Up/Down arrows to scroll to  
Loader Config.  
Press the Enter arrow.  
2
3
The Loader Configuration screen displays. Use  
the up/down arrows to scroll to Save Config.  
Press the Enter arrow.  
The Save Configuration screen displays. Use the  
up/down arrows to scroll to Program Mode  
4 Press the Enter arrow.  
The Program Mode screen displays. Use the  
up/down arrows to to select Save to EEPROM.  
The screen displays message when transfer is  
complete.  
Use the Up/Down arrows to select  
Run Mode.  
5
NOTE: All pumps must be disabled to save the configura-  
tion. This insures that all putputs are turned off.  
Press the Enter arrow to save the change.  
6
7
Press the Previous button to return to  
the last screen you were viewing, or the Main  
button to return to the Main screen.  
Basic 32 Loader Control  
UGC007/0702  
4-10  
OPERATION  
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MAINTENANCE  
lMaintenance checklist . . . . . . . .5-2  
UGC007/0702  
Basic 32 Loader Control  
5-1  
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You should develop a preventive maintenance schedule for all  
components in the conveying system to ensure optimum  
operation and performance.  
PREVENTIVE  
MAINTENANCE  
CHECKLIST  
The B32 may require the following maintenance checks:  
lWhenever you change materials  
rVerify the loader settings for pump systems or loaders  
effected by the material change. Pay particular attention  
to load times and dump times. See CHANGING LOADER  
SETTINGS in the Operation section.  
lQuarterly  
rCheck power and cable connections and wires.  
Over time, the power and cable connections between  
the B32 and conveying system components may  
become loose or wires may become worn. Tighten any  
loose connections and replace any wire or cable that has  
become worn or damaged.  
Basic 32 Loader Control  
UGC007/0702  
5-2  
MAINTENANCE  
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TROUBLESHOOTING  
lBefore Beginning . . . . . . . . . . . .6-2  
lA Few Words of Caution . . . . . .6-2  
lIdentifying the Cause  
of a Problem . . . . . . . . . . . . . . .6-3  
lClearing Interface Alarms . . . . .6-4  
lClearing CPU and I/O alarms . . .6-5  
lConveying System alarms . . . . .6-6  
lOperator Interface  
Problems . . . . . . . . . . . . . . . . .6-8  
lProcessor and Power  
Problems. . . . . . . . . . . . . . . . . 6-8  
lCPU faults . . . . . . . . . . . . . . . . .6-9  
lI/O errors . . . . . . . . . . . . . . . . . .6-9  
UGC007/0702  
Basic 32 Loader Control  
6-1  
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Before you begin troubleshooting:  
BEFORE  
BEGINNING  
oFind the manuals and wiring diagrams that  
were shipped with your equipment.  
These materials contain details you will need to diagnose and  
repair problems in specific components, including custom  
wiring, features or I/O options not covered in this User Guide.  
WARNING: Improper installation, opera-  
tion or servicing may result in equip-  
ment damage or personal injury.  
The B32 should be installed, adjusted, and ser-  
viced only by qualified technical personnel who  
are trained in the operation and troubleshooting of  
this type of equipment.  
A FEW WORDS  
OF CAUTION  
DANGER: Electrical shock hazard  
Diagnosing the cause of electrical system and  
CPU problems in this equipment may require the  
use of precision electronic measuring equipment,  
as well as access to the electrical enclosure  
while power is on. Only qualified electrical techni-  
cians, trained in the use of this equipment and in  
avoiding exposure to voltage hazards, should  
perform procedures that require access to the  
enclosure while power is on.  
WARNING: Develop and follow procedures  
for safe operation and maintenance of the  
system.  
The B32 allows operators and maintenance  
personnel to disable and enable conveying sys-  
tem components from remote locations.  
Unexpected energization of these components  
could result in equipment damage or injury.  
Safe maintenance procedures should include:  
rDisconnect any loader, pump or material valve  
from main power and/or compressed air  
sources before servicing. Ensure that all ener-  
gy sources for the device are locked out and  
tagged.  
rBefore removing lockout devices and enabling  
system components, verify that all personnel  
are clear of the machine, tools have been  
removed, and any safety guards have been  
reinstalled.  
Basic 32 Loader Control  
UGC007/0702  
6-2 TROUBLESHOOTING  
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The TROUBLESHOOTING section explains how to clear an  
alarm, and provides diagnostic tables to help you determine  
the cause of the alarm.  
IDENTIFYING THE  
CAUSE OF A  
PROBLEM  
Diagnostic tables have been divided into:  
rConveying System Alarms.  
These tables focus on the “No Material” and “Pump  
Overload” alarms that the B32 displays on the Alarm  
Summary screen. The B32 continues to control the system and  
the alarming loading station will load.  
rPower and Processor Problems.  
These tables focus on power supply and processor problems  
indicated by Micrologix 1500 LEDs located inside the I/0  
enclosure. These problems cause the B32 control to stop.  
IMPORTANT: Refer to the  
manuals supplied by the  
manufacturers of loaders,  
pumps and material valves  
in your system for additional  
diagnostic and repair infor-  
mation.  
rCPU Faults.  
These tables focus on Hex error codes that apply to the  
Micrologix 1500 and are displayed as faults on the Rack &  
Slot screen. These problems cause the B32 control to stop.  
UGC007/0702  
Basic 32 Loader Control  
TROUBLESHOOTING 6-3  
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When a conveying problem occurs, the screen displays the  
alarm message and the audible alarm sounds.  
CLEARING  
INTERFACE  
ALARMS  
To silence the alarm and fix the problem:  
Press the Enter button.  
1
This acknowledges the alarm. The alarm text is  
removed from the screen. The screen returns to the Main  
screen. NOTE: pressing the Enter button only acknowl-  
edges the alarm; it does not fix the problem.  
View Alarm list.  
2
From the Main screen use the Up/Down arrows to  
scroll to Loader Settings. Press Enter. The Loader  
Settings screen displays.  
3 Use the Up/Down arrows to scroll to  
Alarm List. Press Enter to display alarms. The  
alarm list displays up to 25 alarms, starting with the  
most current. All acknowledged alarms have a check  
mark  
next to the text. All alarms show the hour, minute and  
second the alarm occurred. Alarms are automatically  
removed from the list when the condition is corrected.  
Fix the problem.  
4
Refer to the diagnostic tables in this section and any man-  
uals supplied with this device to determine the cause of  
the problem and to repair the problem.  
5 Press Main button to return to main screen  
or the Previous button to return to the last screen  
viewed.  
Basic 32 Loader Control  
UGC007/0702  
6-4  
TROUBLESHOOTING  
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CPU and Iinput/Output errors will stop the B32 control.  
CLEARING CPU  
AND I/O ALARMS  
These errors may be caused by problems with the power sup-  
ply, processor or Input/Output modules. The error is indicated  
by error codes on the PLC Error screen or by LEDs on the  
B32 MicroLogix1500 CPU and power supply modules.  
To clear and fix a CPU or I/O error from the Main screen:  
Use the Up/Down arrows to scroll to  
Loader Config.  
1
Press the Enter arrow.  
2
3
The Loader Configuration screen displays. Use  
the up/down arrows to scroll to PLC Errors.  
Press the Enter arrow.  
The Errors screen displays. The alphanumeric error  
code is listed. The error code is reported in hexidecimal  
format, with the first two digits identifying a specific I/O  
module slot. If the digits are 1F, an exact slot cannot be  
determined. Refer to the Fault Messages and Error Code  
in the appendix of this manual for a complete listing and  
follow the recommended action for correcting the error.  
4 Clear the error code from the Major  
Error field by entering four zeros (0000)  
using the Select Left/Right arrows.  
5 Press the Scroll Down button  
to move to the Reset field. There are three choice  
available in the Reset field: Fault, Error and OK. Continue  
to press the Scroll down button until you reach OK.  
Press the Enter button to save the reset.  
Press the Home button to return to the home screen.  
6
UGC007/0702  
Basic 32 Loader Control  
TROUBLESHOOTING 6-5  
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The No Material Alarm can be triggered in two ways:  
lThe Alarm Check signals an alarm after the operator-set  
number of consecutive loading attempts fails to satisfy the  
receiver’s demand for material.  
lThe optional fill sensor in the receiver or hopper is not sat-  
isfied after one loading cycle.  
CONVEYING  
SYSTEM  
ALARMS  
Possible cause Solution  
Alarm  
There is no material at rVerify that there is enough  
No Material Alarm  
the source.  
material at the source,  
including regrind sources if  
a ratio valve is used.  
rVerify that the material line  
is connected to the correct  
source of material.  
Loader Settings are  
incorrect.  
If the parameters set on the  
Loader Settings screen are  
incorrect, material demand  
may not be satisfied.  
rVerify that the Load Time,  
or Load Time plus Purge  
Time, is sufficient to fill the  
receiver. Adjust as needed.  
rVerify that the Alarm  
Check allows a sufficient  
number of loading cycles to  
fill the receiver. Adjust as  
needed.  
rVerify that the loader is  
assigned to the correct  
pump system.  
If there are leaks in the system,  
the pump cannot pull a good  
vacuum and the receiver may  
have no or little material flow-  
ing into it. Check the vacuum  
pump gauge. If the reading is  
low, check all hoses, gaskets,  
receiver lids, and valves for  
signs of damage or wear.  
There is a leak in the  
vacuum system.  
Replace as needed.  
Basic 32 Loader Control  
UGC007/0702  
6-6  
TROUBLESHOOTING  
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CONVEYING  
SYSTEM  
ALARMS  
Alarm  
Solution  
Possible cause  
No Material Alarm  
(continued)  
Verify that the vacuum pump  
is on, connected to the B32  
and working correctly. Refer to  
the pump manual.  
Vacuum pump is not  
working correctly.  
The fill/demand sensor or  
demand switch is not  
working properly.  
rVerify that sensors and  
switches are connected  
correctly at the loader or  
hopper and at the control.  
rVerify that fill and demand  
sensors are set at the correct  
height and adjusted proper-  
ly. Refer to manuals sup-  
plied with the fill or  
demand signaling device.  
Compressed air lines are  
not connected correctly.  
If a compressed air line is not  
connected to vacuum or mater-  
ial valves, the valves cannot  
open to allow the pump to  
draw material into the receiver.  
Verify that compressed air  
lines supplying the correct  
pressure have been connected  
to the vacuum sequencing  
valve, ratio valve, pocket con-  
veying or purge valve.  
The vacuum pump  
overload has tripped.  
Pump Overload  
This alarm will prevent the  
pump from being energized  
until the overload is corrected.  
Refer to the pump manual to  
correct the problem.  
UGC007/0702  
Basic 32 Loader Control  
TROUBLESHOOTING 6-7  
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WARNING: Electrical shock hazard  
Diagnosing electrical and processor problems  
require access to the electrical enclosure while  
power is on. Only qualified electrical technicians,  
who are trained in how to avoid voltage hazards,  
should perform troubleshooting procedures that  
require access to the B32 Input/Output enclo-  
sure while power is on.  
OPERATOR  
INTERFACE  
PROBLEMS  
Fault  
Solution  
Possible cause  
Terminal does not  
power up.  
Improper connection to  
power source  
rVerify wiring and connec-  
tions to power source.  
Incorrect input voltage  
level.  
rVerify correct voltage is  
present at power terminals.  
DC power wires reversed  
(DC terminals only).  
rMake sure DC power posi-  
tive and negative are con-  
nected to the proper termi-  
nals.  
rVerify power terminal  
block is snapped onto base  
of PV300 Micro.  
Power terminal block not  
fully seated (PV300 ter-  
minals only).  
WARNING: Electrical shock hazard  
PROCESSOR  
AND POWER  
PROBLEMS  
Diagnosing electrical and processor problems  
require access to the electrical enclosure while  
power is on. Only qualified electrical technicians,  
who are trained in how to avoid voltage hazards,  
should perform troubleshooting procedures that  
require access to the B32 Input/Output enclo-  
sure while power is on.  
Fault  
Solution  
Possible cause  
See APPENDIX C “TROUBLESHOOTING YOUR SYSTEM” for a complete listing of  
process and power faults, causes and solutions.  
Basic 32 Loader Control  
UGC007/0702  
6-8  
TROUBLESHOOTING  
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WARNING: Electrical shock hazard  
Diagnosing electrical and processor problems  
require access to the electrical enclosure while  
power is on. Only qualified electrical technicians,  
who are trained in how to avoid voltage hazards,  
should perform troubleshooting procedures that  
require access to the B32 Input/Output  
CPU FAULTS  
enclosure while power is on.  
Error/Alarm  
Solution  
Possible cause  
See APPENDIX D: “FAULT MESSAGES AND ERROR CODES” for a complete listing of  
CPU faults, causes and solutions.  
WARNING: Electrical shock hazard  
I/O ERRORS  
Diagnosing electrical and processor problems  
require access to the electrical enclosure while  
power is on. Only qualified electrical technicians,  
who are trained in how to avoid voltage hazards,  
should perform troubleshooting procedures that  
require access to the B32 Input/Output enclo-  
sure while power is on.  
Possible cause Solution  
Error  
See APPENDIX D: “FAULT MESSAGES AND ERROR CODES” for a complete listing of  
input/output errors, causes and solutions.  
UGC007/0702  
Basic 32 Loader Control  
TROUBLESHOOTING 6-9  
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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 operating  
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.  
WE’RE HERE  
TO HELP  
To contact Customer Service personnel, call:  
HOW TO CONTACT  
CUSTOMER  
SERVICE  
From outside the United States, call: 814-437-6861  
You 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.  
If you do have a problem, please complete the  
following checklist before calling Conair:  
BEFORE YOU  
CALL ...  
rMake sure you have all model, serial and parts list  
numbers for your particular equipment. Service  
personnel will need this information to assist you.  
rMake sure power is supplied to the equipment.  
rMake sure that all connectors and wires within  
and between control systems and related  
components have been installed correctly.  
rCheck the troubleshooting guide of this manual  
for a solution.  
rThoroughly examine the instruction manual(s)  
for associated equipment, especially controls.  
Each manual may have its own troubleshooting  
guide to help you.  
Additional manuals and  
prints for your Conair  
equipment may be  
ordered through the  
Customer Service or  
Parts Departments for a  
nominal fee.  
rCheck that the equipment has been operated as  
described in this manual.  
rCheck accompanying schematic drawings for  
information on special considerations.  
UGC007/0702  
SERVICE INFORMATION  
APPENDIX A1  
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Conair guarantees the machinery and equipment on this order,  
for a period as defined in the quotation from date 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 fil-  
ters, liner plates, etc.). Conair’s guarantee is limited to replac-  
ing, 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.  
EQUIPMENT  
GUARANTEE  
Conair warrants that this equipment will perform at or above  
the ratings stated in specific quotations covering the equip-  
ment or as detailed in engineering specifications, provided the  
equipment is applied, installed, operated and maintained in the  
recommended manner as outlined in our quotation or specifi-  
cations.  
PERFORMANCE  
WARRANTY  
Should performance not meet warranted levels, Conair at its  
discretion will exercise one of the following options:  
lInspect the equipment and perform alterations or adjust-  
ments to satisfy performance 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 oper-  
ation.)  
lReplace the original equipment with other Conair equip-  
ment that will meet original performance claims at no  
extra cost to the customer.  
lRefund the invoiced cost to the customer. Credit is subject  
to prior notice by the customer at which time a Return  
Goods Authorization Number (RGA) will be issued by  
Conair’s Service Department. Returned equipment must  
be well crated and in proper operating condition, includ-  
ing all parts. Returns must be prepaid.  
Purchaser must notify Conair in writing of any claim and pro-  
vide a customer receipt and other evidence that a claim is  
being made.  
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 other-  
wise, including but not limited to the implied warranties of  
merchantability and fitness for a particular purpose.  
WARRANTY  
LIMITATIONS  
A2  
APPENDIX  
WARRANTY INFORMATION  
IMS0003/0796  
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The program can be restored to the plant configuration if for  
some reason the program has been interrupted.  
RESTORING THE  
PROGRAM  
To restore the program:  
1 Use the Up/Down arrows to scroll to  
Loader Config.  
Press the Enter arrow.  
The Loader Configuration screen displays. Use the  
up/down arrows to scroll to Save Config  
2
3 Press the Enter arrow.  
The Save Configuration screen displays. Use the  
scroll up/down buttons to select Program Mode.  
Press the Enter arrow to save the change.  
4
5
Press the Previous button to return to  
the last screen you were viewing, or the Main  
button to return to the Main screen.  
UGC007/0702  
RESTORING THE PROGRAM  
APPENDIX B1  
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Appendix  
C
Troubleshooting Your System  
This chapter describes how to troubleshoot your controller. Topics include:  
• understanding the controller LED status  
• controller error recovery model  
• identifying controller faults  
• calling Rockwell Automation for assistance  
The controller status LEDs provide a mechanism to determine the current status of  
the controller if a programming device is not present or available.  
Understanding  
Controller LEDs  
LED  
Color  
off  
Indicates  
POWER  
no input power  
D.C. INPUTS  
green  
off  
power on  
RUN  
controller is not in Run mode or REM Run  
controller is in Run mode or REM Run  
24V SINK / SOURCE  
green  
POWER  
DC/RELAY OUT  
RUN  
FAULT  
FORCE  
BAT. LO  
green  
flashing  
system is not in Run mode; memory module transfer is in  
progress  
COMM  
0
24V SOURCE  
DCOMM  
FAULT  
off  
no fault detected  
red flashing faulted user program  
red  
processor hardware fault or critical fault  
FORCE  
off  
no forces installed  
amber  
off  
forces installed  
BATTERY LOW  
COMM 0  
battery OK  
red  
battery needs replacement (See page B-2.)  
flashes when communications are active  
off  
green  
off  
COMM 1  
flashes when communications are active  
(1764-LRP only)  
green  
off  
(1)  
user configured communications mode is active  
default communications mode active  
input is not energized  
DCOMM  
green  
off  
INPUTS  
amber  
off  
input is energized (logic status)  
output is not energized  
OUTPUTS  
amber  
output is energized (logic status)  
(1) When using a 1764-LRP processor, the DCOMM LED applies only to Channel 0.  
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C-2  
Troubleshooting Your System  
When Operating Normally  
The POWER and RUN LEDs are on. If a force condition is active, the FORCE  
LED turns on and remains on until all forces are removed.  
When an Error Exists  
If an error exists within the controller, the controller LEDs operate as described in  
the following tables.  
If the LEDS The Following  
indicate: Error Exists  
Probable Cause Recommended Action  
All LEDS off No input power or No Line Power  
power supply error  
Verify proper line voltage and  
connections to the controller.  
Power Supply  
Overloaded  
This problem can occur intermittently if  
power supply is overloaded when output  
loading and temperature varies.  
Power and Hardware faulted Processor  
FAULT LEDs  
on solid  
Cycle power. Contact your local  
Conair Service representative if  
the error persists.  
Hardware Error  
Loose Wiring  
Verify connections to the controller.  
Power LED Application fault  
Hardware/  
Software Major  
Fault Detected  
4. Monitor Status File Word S:6 for  
major error code. See page C-4 for  
more information.  
5. Remove hardware/software  
condition causing fault.  
on and  
FAULT LED  
flashing  
6. Clear Major Error Halted flag, bit  
S2:1/13.  
7. Attempt a controller Run mode entry.  
If unsuccessful, repeat recommended  
action steps above or contact your  
Coniar Service representative.  
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Troubleshooting Your System  
C-3  
Use the following error recovery model to help you diagnose software and hardware  
problems in the micro controller. The model provides common questions you  
might ask to help troubleshoot your system. Refer to the recommended pages  
within the model for further help.  
Controller Error  
Recovery Model  
Identify the error code  
and description.  
Is the error  
hardware  
No  
Start  
related?  
Yes  
Refer to page C-2 for  
probable cause and  
recommended action.  
Are the wire  
connections  
tight?  
Tighten wire  
connections.  
No  
No  
Yes  
No  
Is power supplied  
to the controller?  
Clear fault.  
Is the Power  
LED on?  
Check power.  
Yes  
Yes  
Refer to page C-2 for  
probable cause and  
recommended action.  
No  
Correct the condition  
causing the fault.  
Is the RUN  
LED on?  
Yes  
Is an input LED  
accurately showing  
status?  
No  
No  
Is the Fault LED on?  
Yes  
Return controller to  
RUN or any of the  
REM test modes.  
Yes  
See page C-2 for  
probable cause and  
recommended action.  
See page C-2 for  
probable cause and  
recommended action.  
Test and verify  
system operation.  
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C-4  
Troubleshooting Your System  
While a program is executing, a fault may occur within the operating system or  
your program. When a fault occurs, you have various options to determine what  
the fault is and how to correct it. This section describes how to clear faults and  
provides a list of possible advisory messages with recommended corrective actions.  
Identifying Controller  
Faults  
Automatically Clearing Faults  
You can automatically clear a fault by cycling power to the controller when the  
Fault Override at Power-up bit (S:1/8) is set in the status file.  
You can also configure the controller to clear faults and go to RUN every time the  
controller is power cycled. This is a feature that OEMs can build into their  
equipment to allow end users to reset the controller. If the controller faults, it can  
be reset by simply cycling power to the machine. To accomplish this, set the  
following bits in the status file:  
• S2:1/8 - Fault Override at Power-up  
• S2:1/12 - Mode Behavior  
If the fault condition still exists after cycling power, the controller re-enters the fault  
mode. For more information on status bits, refer to the MicroLogix 1200 and  
MicroLogix 1500 Instruction Set Reference Manual.  
You can declare your own application-specific major fault by  
NOTE  
writing your own unique value to S:6 and then setting bit S:1/13  
to prevent reusing system defined codes. The recommended  
values for user defined faults are FF00 to FF0F.  
Manually Clearing Faults Using the Fault Routine  
The occurrence of recoverable or non-recoverable user faults can cause the user  
fault subroutine to be executed. If the fault is recoverable, the subroutine can be  
used to correct the problem and clear the fault bit S:1/13. The controller then  
continues in the Run or test mode.  
The subroutine does not execute for non-user faults. Refer to the MicroLogix 1200  
and MicroLogix 1500 Instruction Set Reference Manual for information on creating a  
user fault subroutine.  
Fault Messages  
Refer to the MicroLogix 1200 and 1500 Instruction Set Reference Manual for the  
controller fault messages that can occur during operation of the MicroLogix 1500  
programmable controllers. Each fault message includes the error code description,  
the probable cause, and the recommended corrective action.  
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Appendix  
D
Fault Messages and Error Codes  
This chapter describes how to troubleshoot your controller. Topics  
include:  
• identifying controller faults  
• contacting Rockwell Automation for assistance  
While a program is executing, a fault may occur within the operating  
Identifying Controller  
Faults  
system or your program. When a fault occurs, you have various options to  
determine what the fault is and how to correct it. This section describes  
how to clear faults and provides a list of possible advisory messages with  
recommended corrective actions.  
Automatically Clearing Faults  
You can automatically clear a fault by cycling power to the controller  
when the Fault Override at Power-Up bit (S:1/8) is set in the status file.  
You can also configure the controller to clear faults and go to RUN every  
time the controller is power cycled. This is a feature that OEMs can build  
into their equipment to allow end users to reset the controller. If the  
controller faults, it can be reset by simply cycling power to the machine.  
To accomplish this, set the following bits in the status file:  
• S2:1/8 - Fault Override at Power-up  
• S2:1/12 - Mode Behavior  
If the fault condition still exists after cycling power, the controller  
re-enters the fault mode. For more information on status bits, see System  
Status File on page C-1.  
You can declare your own application-specific major fault  
NOTE  
by writing your own unique value to S:6 and then setting  
bit S:1/13 to prevent reusing system defined codes. The  
recommended values for user-defined faults are FF00 to  
FF0F.  
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UGC007/0702  
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D-2  
Fault Messages and Error Codes  
Manually Clearing Faults Using the Fault Routine  
The occurrence of recoverable or non-recoverable user faults can cause  
the user fault subroutine to be executed. If the fault is recoverable, the  
subroutine can be used to correct the problem and clear the fault bit S:1/  
13. The controller then continues in the Run or test mode.  
The subroutine does not execute for non-user faults. See User Fault  
Routine on page 18-6 for information on creating a user fault subroutine.  
Fault Messages  
This section contains fault messages that can occur during operation of  
the MicroLogix 1200 and MicroLogix 1500 programmable controllers. Each  
table lists the error code description, the probable cause, and the  
recommended corrective action.  
Error  
Code  
(Hex)  
Advisory Message Description  
Fault  
Classification  
Recommended Action  
0001  
NVRAM ERROR  
The default program is loaded to the Non-User  
• Re-download or transfer the program.  
• Verify battery is connected (MicroLogix  
1500 only).  
• Contact your Conair Service  
representative if the error persists.  
controller memory. This occurs:  
• if a power down occurred during  
program download or transfer  
from the memory module.  
• RAM integrity test failed.  
• FLASH integrity test failed  
(MicroLogix 1200 only).  
0002  
UNEXPECTED RESET • The controller was unexpectedly Non-User  
reset due to a noisy environment  
• Refer to proper grounding guidelines and  
using surge suppressors in your controller’s  
User Manual.  
or internal hardware failure.  
• The default program is loaded.  
(MicroLogix 1500 only)  
• Verify battery is connected (MicroLogix  
1500 only).  
• Retentive Data is lost. See page  
C-12. (MicroLogix 1200 only)  
• Contact your Conair service  
representative if the error persists.  
0003  
0004  
MEMORY MODULE  
USER PROGRAM IS  
CORRUPT  
Memory module memory error. This Non-User  
error can also occur when going to  
the Run mode.  
Re-program the memory module. If the error  
persists, replace the memory module.  
MEMORY INTEGRITY While the controller was powered Non-User  
ERROR up, ROM or RAM became corrupt.  
• Cycle power on your unit. Then,  
re-download your program and start up  
your system.  
• Refer to proper grounding guidelines and  
using surge suppressors in your controller’s  
User Manual.  
• Contact your Coniar Service  
representative if the error persists.  
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Fault Messages and Error Codes  
D-3  
Error  
Code  
(Hex)  
Advisory Message Description  
Fault  
Classification  
Recommended Action  
0006  
MEMORY MODULE  
HARDWARE FAULT  
The memory module hardware  
faulted or the memory module is  
incompatible with OS.  
Non-User  
• Upgrade the OS to be compatible with  
memory module.  
• Obtain a new memory module.  
0007  
0008  
MEMORY MODULE  
TRANSFER ERROR  
Failure during memory module  
transfer.  
Non-User  
Non-User  
Re-attempt the transfer. If the error persists,  
replace the memory module.  
FATAL INTERNAL  
SOFTWARE ERROR  
An unexpected software error  
occurred.  
• Cycle power on your unit. Then,  
re-download your program and re-initialize  
any necessary data.  
• Start up your system.  
• Refer to proper grounding guidelines and  
using surge suppressors in your controller’s  
User Manual.  
• Contact your Conair Service  
representative if the error persists.  
0009  
FATAL INTERNAL  
An unexpected hardware error  
Non-User  
• Cycle power on your unit. Then,  
re-download your program and re-initialize  
any necessary data.  
HARDWARE ERROR occurred.  
• Start up your system.  
• Refer to proper grounding guidelines and  
using surge suppressors in your controller’s  
User Manual.  
• Contact your Conair Service  
representative if the error persists.  
000A  
000B  
OS MISSING OR  
CORRUPT  
The operating system required for Non-User  
• Download a new OS using ControlFlash.  
the user program is corrupt or  
missing.  
• Contact your local Rockwell Automation  
representative for more information about  
available operating systems your  
controller.  
BASE HARDWARE  
FAULT  
The base hardware faulted or is  
incompatible with the OS.  
Non-User  
• Upgrade the OS using ControlFlash.  
• Replace the Controller (MicroLogix 1200  
only).  
• Replace the Base Unit (MicroLogix 1500  
only).  
• Contact your Conair Service  
representative for more information about  
available operating systems your  
controller.  
0011  
0012  
EXECUTABLE FILE 2 IS Ladder File 2 is missing from the  
Non-User  
• Re-compile and reload the program.  
MISSING  
program.  
LADDER PROGRAM  
ERROR  
The ladder program has a memory Non-User  
integrity problem.  
• Reload the program or re-compile and  
reload the program. If the error persists, be  
sure to use RSI programming software to  
develop and load the program.  
• Refer to proper grounding guidelines and  
using surge suppressors in your controller’s  
User Manual.  
0015  
I/O CONFIGURATION The user program I/O configuration Non-User  
FILE ERROR is invalid.  
Re-compile and reload the program, and enter  
the Run mode. If the error persists, be sure to  
use RSI programming software to develop  
and load the program.  
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D-4  
Fault Messages and Error Codes  
Error  
Code  
(Hex)  
Advisory Message Description  
Fault  
Classification  
Recommended Action  
0016  
STARTUP  
The user fault routine was executed Recoverable  
• Either reset bit S:1/9 if this is consistent  
with the application requirements, and  
change the mode back to RUN, or  
PROTECTION FAULT at power-up, prior to the main ladder  
program. Bit S:1/13 (Major Error  
Halted) was not cleared at the endof  
the User Fault Routine. The User  
Fault Routine ran because bit S:1/9  
was set at power-up.  
• clear S:1/13, the Major Error Halted bit,  
before the end of the User Fault Routine.  
0017  
0018  
NVRAM/MEMORY  
MODULE USER  
PROGRAM  
Bit S:2/9 is set in the controller and Non-Recoverable Transfer the memory module program to the  
the memory module user program  
does not match the controller user  
program.  
controller and then change to Run mode.  
MISMATCH  
MEMORY MODULE  
USER PROGRAM  
INCOMPATIBLE WITH  
OS  
The user program in the memory  
module is incompatible with the OS.  
Non-User  
• Upgrade the OS using ControlFlash to be  
compatible with the memory module.  
• Obtain a new memory module.  
• Contact your local Rockwell Automation  
representative for more information about  
available operating systems your  
controller.  
001A  
0020  
USER PROGRAM  
INCOMPATIBLE WITH with the OS.  
OS AT POWER-UP  
The user program is incompatible  
Non-User  
• Upgrade the OS using ControlFlash.  
• Contact your Conair Service  
representative for more information about  
available operating systems your  
controller.  
MINOR ERROR AT  
END-OF-SCAN  
DETECTED  
A minor fault bit (bits 0-7) in S:5 was Recoverable  
set at the end of scan.  
• Correct the instruction logic causing the  
error.  
• Enter the status file display in your  
programming software and clear the fault.  
• Enter the Run mode.  
0021  
EXPANSION POWER A power failure is present on the  
FAIL (EPF) expansion I/O bank.  
Non-User  
Re-apply power to the expansion I/O bank.  
See Important note below.  
(MicroLogix 1500 only) This error code is present only when  
the controller is powered, and power  
is not applied to the expansion I/O  
bank. This is a self-clearing error  
code. When power is re-applied to  
the expansion I/O bank, the fault is  
cleared. See Important note below.  
If this fault occurs while the system is in the RUN mode, the controller faults. When expansion I/O  
power is restored, the controller clears the fault and re-enters the RUN mode.  
If you change the mode switch while this fault is present, the controller may not re-enter the RUN mode  
when expansion I/O power is restored.  
IMPORTANT  
If an EPF condition is present and expansion I/O power is OK, toggle the mode switch to PROGRAM and  
then to RUN. The fault should clear and the controller enters the RUN mode.  
0022  
0023  
WATCHDOG TIMER  
EXPIRED, SEE S:3  
The program scan time exceeded the Non-Recoverable • Determine if the program is caught in a  
watchdog timeout value (S:3H).  
loop and correct the problem.  
• Increase the watchdog timeout value in  
the status file.  
STI ERROR  
An error occurred in the STI  
configuration.  
Recoverable  
See the Error Code in the STI Function File for  
the specific error.  
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Fault Messages and Error Codes  
D-5  
Error  
Code  
(Hex)  
Advisory Message Description  
Fault  
Classification  
Recommended Action  
0028  
INVALID OR  
• A fault routine number was  
Non-User  
• Either clear the fault routine file number  
NONEXISTENT USER  
FAULT ROUTINE  
VALUE  
entered in the status file, number  
(S:29), but either the fault routine  
was not physically created, or  
(S:29) in the status file, or  
• create a fault routine for the file number  
reference in the status file (S:29). The file  
number must be greater than 2 and less  
than 256.  
• the fault routine number was less  
than 3 or greater than 255.  
0029  
INSTRUCTION  
INDIRECTION  
OUTSIDE OF DATA  
SPACE  
An indirect address reference in the Recoverable  
ladder program is outside of the  
entire data file space.  
Correct the program to ensure that there are  
no indirect references outside data file space.  
Re-compile, reload the program and enter the  
Run mode.  
002E  
0030  
EII ERROR  
An error occurred in the EII  
configuration.  
Recoverable  
Non-User  
See the Error Code in the EII Function File for  
the specific error.  
SUBROUTINE  
NESTING EXCEEDS  
LIMIT  
The JSR instruction nesting level  
exceeded the controller memory  
space.  
Correct the user program to reduce the  
nesting levels used and to meet the  
restrictions for the JSR instruction. Then  
reload the program and Run.  
0031  
0032  
UNSUPPORTED  
INSTRUCTION  
DETECTED  
The program contains an  
instruction(s) that is not supported  
by the controller.  
Non-User  
• Modify the program so that all instructions  
are supported by the controller.  
• Re-compile and reload the program and  
enter the Run mode.  
SQO/SQC/SQL  
OUTSIDE OF DATA  
FILE SPACE  
A sequencer instruction length/  
position parameter references  
outside of the entire data file space.  
Recoverable  
• Correct the program to ensure that the  
length and position parameters do not  
point outside data file space.  
• Re-compile, reload the program and enter  
the Run mode.  
0033  
0034  
BSL/BSR/FFL/FFU/LFL/ The length/position parameter of a Recoverable  
LFU CROSSED DATA BSL, BSR, FFL, FFU, LFL, or LFU  
• Correct the program to ensure that the  
length and position parameters do not  
point outside of the data space.  
• Re-compile, reload the program and enter  
the Run mode.  
FILE SPACE  
instruction references outside of the  
entire data file space.  
NEGATIVE VALUE IN A negative value was loaded to a  
TIMER PRESET OR  
ACCUMULATOR  
Recoverable  
• If the program is moving values to the  
accumulated or preset word of a timer,  
make certain these values are not  
negative.  
timer preset or accumulator.  
• Reload the program and enter the Run  
mode.  
0035  
ILLEGAL  
INSTRUCTION IN  
INTERRUPT FILE  
The program contains a Temporary Non-Recoverable • Correct the program.  
End (TND), Refresh (REF), or Service  
Communication instruction in an  
interrupt subroutine (STI, EII, HSC) or  
user fault routine.  
• Re-compile, reload the program and enter  
the Run mode.  
0036  
0037  
003B  
003C  
INVALID PID  
PARAMETER  
An invalid value is being used for a Recoverable  
PID instruction parameter.  
Process Control Instruction for  
more information about the PID instruction.  
HSC ERROR  
PTO ERROR  
PWM ERROR  
An error occurred in the HSC  
configuration.  
Recoverable  
See the Error Code in the HSC Function File  
for the specific error.  
An error occurred in the PTO  
instruction configuration.  
Recoverable or  
Non-User  
See the Error Code in the PTO Function File for  
the specific error.  
An error occurred in the PWM  
instruction configuration.  
Recoverable or  
Non-User  
See the Error Code in the PWM Function File  
for the specific error.  
Basic 32 Loader Control  
UGC007/0702  
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D-6  
Fault Messages and Error Codes  
Error  
Code  
(Hex)  
Advisory Message Description  
Fault  
Classification  
Recommended Action  
003D  
INVALID SEQUENCER A sequencer instruction (SQO, SQC, Recoverable  
Correct the user program, then re-compile,  
reload the program and enter the Run mode.  
LENGTH/POSITION  
SQL) length/position parameter is  
greater than 255.  
003E  
INVALID BIT SHIFT OR A BSR or BSL instruction length  
Recoverable  
Correct the user program or allocate more  
data file space using the memory map, then  
reload and Run.  
LIFO/FIFO  
parameter is greater than 2048 or an  
FFU, FFL, LFU, LFL instruction length  
parameter is greater than 128 (word  
file) or greater than 64 (double word  
file)  
PARAMETER  
003F  
COP/FLL OUTSIDE OF A COP or FLL instruction length  
Recoverable  
Non-User  
• Correct the program to ensure that the  
length and parameter do not point outside  
of the data file space.  
• Re-compile, reload the program and enter  
the Run mode.  
DATA FILE SPACE  
parameter references outside of the  
entire data space.  
0050  
0051  
0052  
0070  
CONTROLLER TYPE  
MISMATCH  
A particular controller type was  
selected in the user program  
configuration, but did not match the  
actual controller type.  
• Connect to the hardware that is specified  
in the user program, or  
• Reconfigure the program to match the  
attached hardware.  
BASE TYPE  
MISMATCH  
A particular hardware type (AWA, Non-User  
BWA, BXB) was selected in the user  
program configuration, but did no  
match the actual base.  
• Connect to the hardware that is specified  
in the user program, or  
• Reconfigure the program to match the  
attached hardware.  
MINIMUM SERIES  
ERROR  
The hardware minimum series  
selected in the user program  
configuration was greater than the  
series on the actual hardware.  
Non-User  
• Connect to the hardware that is specified  
in the user program, or  
• Reconfigure the program to match the  
attached hardware.  
EXPANSION I/O  
TERMINATOR  
REMOVED  
The required expansion I/O  
terminator was removed.  
Non-Recoverable • Check the expansion I/O terminator on the  
last  
I/O module.  
(MicroLogix 1500 only)  
• Cycle power.  
xx71(1)  
EXPANSION I/O  
The controller cannot communicate Non-Recoverable • Check connections.  
HARDWARE ERROR with an expansion I/O module.  
• Check for a noise problem and be sure  
proper grounding practices are used.  
• Replace the module.  
• Cycle power.  
xx79(1)  
0080  
Non-Recoverable  
Non-User  
EXPANSION I/O  
MODULE ERROR  
An expansion I/O module generated  
an error.  
• Refer to the I/O Module Status (IOS) file.  
• Consult the documentation for your  
specific I/O module to determine possible  
causes of a module error.  
EXPANSION I/O  
TERMINATOR  
REMOVED  
The required expansion I/O  
terminator was removed.  
• Check expansion I/O terminator on last I/O  
module.  
• Cycle power.  
(MicroLogix 1500 only)  
xx81(1)  
Non-User  
EXPANSION I/O  
The controller cannot communicate  
• Check connections.  
• Check for a noise problem and be sure  
proper grounding practices are used.  
HARDWARE ERROR with an expansion I/O module.  
• Replace the module.  
• Cycle power.  
Basic 32 Loader Control UGC007/0702  
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Fault Messages and Error Codes  
D-7  
Error  
Code  
(Hex)  
Advisory Message Description  
Fault  
Classification  
Recommended Action  
0083  
MAX I/O CABLES  
EXCEEDED  
The maximum number of expansion Non-User  
I/O cables allowed was exceeded.  
• Reconfigure the expansion I/O system so  
that it has an allowable number of cables.  
• Cycle power.  
0084  
0085  
MAX I/O POWER  
SUPPLIES EXCEEDED I/O power supplies allowed was  
exceeded.  
The maximum number of expansion Non-User  
• Reconfigure the expansion I/O system so  
that it has the correct number of power  
supplies.  
MAX I/O MODULES The maximum number of expansion Non-User  
EXCEEDED  
• Reconfigure the expansion I/O system so  
that it has an allowable number of  
modules.  
I/O modules allowed was exceeded.  
• Cycle power.  
xx86(1)  
Non-User  
Non-User  
EXPANSION I/O  
An expansion I/O module could not  
• Change the baud rate in the user program  
MODULE BAUD RATE communicate at the baud rate  
I/O configuration, and  
ERROR  
specified in the user program I/O  
configuration.  
• Re-compile, reload the program and enter  
the Run mode, or  
• Replace the module.  
• Cycle power.  
xx87(1)  
I/O CONFIGURATION • The expansion I/O configuration  
MISMATCH  
• Either correct the user program I/O  
configuration to match the actual  
configuration, or  
in the user program didnot match  
the actual configuration, or  
• The expansion I/O configuration  
in the user program specified a  
module, but one was not found,  
or  
• With power off, correct the actual I/O  
configuration to match the user program  
configuration.  
• The expansion I/O module  
configuration data size for a  
module was greater than what  
the module is capable of holding.  
xx88(1)  
Non-User  
EXPANSION I/O  
MODULE  
CONFIGURATION  
ERROR  
The number of input or output image  
words configured in the user  
program exceeds the image size in  
the expansion I/O module.  
• Correct the user program I/O configuration  
to reduce the number of input or output  
words, and  
• Re-compile, reload the program and enter  
the Run mode.  
xx89(1)(2)  
Non-User  
Non-User  
EXPANSION I/O  
MODULE ERROR  
An expansion I/O module generated  
an error.  
• Refer to the I/O status file.  
• Consult the documentation for your  
specific I/O module to determine possible  
causes of a module error.  
xx8A(1)(2)  
EXPANSION I/O  
CABLE  
CONFIGURATION  
MISMATCH ERROR  
• Either an expansion I/O cable is  
configured in the user program,  
but no cable is present, or  
• an expansion I/O cable is  
configured in the user program  
and a cable is physically present,  
but the types do not match.  
• Correct the user program to eliminate a  
cable that is not present  
• Re-compile, reload the program and enter  
the Run mode, or  
• Add the missing cable.  
• Cycle power.  
Basic 32 Loader Control  
UGC007/0702  
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D-8  
Fault Messages and Error Codes  
Error  
Code  
(Hex)  
Advisory Message Description  
Fault  
Classification  
Recommended Action  
xx8B(1)(2)  
Non-User  
EXPANSION I/O  
POWER SUPPLY  
CONFIGURATION  
MISMATCH ERROR  
• Either an expansion I/O power  
supply is configured in the user  
program, but no power supply is  
present, or  
• Correct the user program to eliminate a  
power supply that is not present  
• Re-compile, reload the program and enter  
the Run mode, or  
• an expansion I/O power supply is  
configured in the user program  
and a power supply is physically  
present, but the types do not  
match.  
• With power removed, add the missing  
power supply.  
xx8C(1)(2)  
Non-User  
EXPANSION I/O  
OBJECT TYPE  
MISMATCH  
An expansion I/O object (i.e. cable,  
power supply, or module) in the user  
program I/O configuration is not the  
same object type as is physically  
present.  
• Correct the user program I/O configuration  
so that the object types match the actual  
configuration, and  
• Re-compile, reload the program and enter  
the Run mode. Or  
• Correct the actual configuration to match  
the user program I/O configuration.  
• Cycle power.  
0x1F39 INVALID STRING  
LENGTH(3)  
The first word of string data contains Recoverable  
a negative, zero, or value greater  
than 82.  
Check the first word of the string data  
element for invalid values and correct the  
data.  
(1) xx indicates module number. If xx = 0, problem cannot be traced to a specific module.  
(2) The xx in this error code means that the error occurs at the location of the last properly configured Expansion I/O module +1. You should use this information in conjunction  
with the specific error code to determine the source of the problem.  
(3) Applies to MicroLogix 1500 1764-LSP Series B and 1764-LRP Processors.  
Basic 32 Loader Control UGC007/0702  
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