Milnor MILRAIL User manual

PELLERIN MILNOR CORPORATION Post Office Box 400, Kenner, Louisiana 70063–0400, U.S.A.
Controller Reference
MILRAIL™ Simple
Loop Controller
System
Manual Number: MCRUSB01
Edition (ECN): 2021172

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Contents
1 Preface ...........................................................................................................................................2
1.1 About This Reference Guide and This MILRAIL™ Simple Loop Rail System
Controller .................................................................................................................2
1.1.1 Rail System Terminology ........................................................................................2
1.1.2 The Mast Lift Positions ...........................................................................................3
2 Using the MILRAIL™ Simple Loop Controller Inferface ...........................................................5
2.1 How to Use the MILRAIL™ Simple Loop Controller .....................................................5
2.1.1 Select a user and log in. ..........................................................................................5
2.1.2 The Overview Display.............................................................................................6
2.2 To Edit and Delete Sling Data ...........................................................................................8
3 Troubleshooting...........................................................................................................................10
3.1 Errors ...............................................................................................................................10
3.1.1 The Error Codes ....................................................................................................10
3.1.2 The Alarms Menu..................................................................................................14
3.2 Troubleshooting Inputs and Outputs ...............................................................................15
3.2.1 List of Inputs and Outputs .....................................................................................15
• Inputs...................................................................................................................16
• Outputs ................................................................................................................19
3.3 The Empty Fetch Sequence .............................................................................................21
3.4 Chain Fault Recovery ......................................................................................................22
3.5 How to Contact Milnor®..................................................................................................23
Figures
Figure 1 Parts of the Mast Lift ..................................................................................................3
Figure 2 Mast Lift Positions......................................................................................................4
Figure 3 Main Menu..................................................................................................................5
Figure 4 Login Window ............................................................................................................6
Figure 5 The Overview Display (Example) ..............................................................................7
Figure 6 Mast Lift Positions......................................................................................................8
Figure 7 Edit Sling Data Window .............................................................................................8
Figure 8 Alarms Menu— Active View ...................................................................................14
Figure 9 Alarms Menu— Error History View ........................................................................14
Figure 10 PLC Inputs and Outputs Display ..............................................................................15
Tables
Table 1 Inputs .......................................................................................................................16
Table 2 Outputs .....................................................................................................................19
Table 3 Pellerin Milnor®Corporation Contact Information .................................................23

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1 Preface
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1.1 About This Reference Guide and This MILRAIL™
Simple Loop Rail System Controller
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This controller reference guide explains how to manage and troubleshoot your MILRAIL™ sim-
ple loop rail system controller. It is for supervisors involved in production oversight and mainte-
nance technicians involved in the troubleshooting of the system. A separate operator guide,
MKRUSO01, explains routine operation.
WARNING: Careless use — can cause death or serious injury and property damage.
�Read the machine manuals before you install, operate, service, or clean
the machine.
The staff at Milnor configured your MILRAIL™ simple loop rail system controller interface to
represent your unique rail system. Users are not responsible for configuring or programming the
controller.
1.1.1 Rail System Terminology
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The following list of terms can help you identify the different parts of your rail system.

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Figure 1. Parts of the Mast LiftSlings— Bags full of goods that will be dis-
charged to the CBW®washer’s chute. Slings
are also commonly referred to as bags.
Mast Lift— The device that lifts slings and
transfers them to the rail loop. It consists of
the carriage, the flight bar, and the floor scale.
The mast lift is also commonly referred to as
the elevator. The mast lift has four positions.
See Section 1.1.2 .
Carriage (item A in Figure 1 )— The piece of
rail on the mast lift that holds the flight bar
until it transfers the flight bar to the rail loop.
Flight Bar (item B in Figure 1 )— The device
used to carry a sling along the rail loop. The
operator manually attaches a sling to the
flight bar. The flight bar is also commonly re-
ferred to as the trolley.
Floor Scale (item C in Figure 1 )— A scale
built into the bottom of the mast lift used to
weigh goods.
PVC— An optional device used to raise slings
from a low rail to a higher rail on the rail
loop. PVC stands for Pneumatic Vertical
Conveyor.
Discharger— The device that discharges goods from a sling to the CBW®washer’s chute.
Stop— A device used to temporarily stop and allow the progression of a sling along the rail,
break the momentum of a fast-moving sling, or hold a sling in a particular position (such as
on the discharger).
Buffer— A stop used to temporarily hold one or more slings, to prevent slings from progress-
ing when a line (or device, such as discharger) is already full. For example, the full bag buffer
prevents slings from entering the full bag storage line when the full bag storage line is full.
Lift Bar— A device located before a stop, which the controller uses to determine if a line is
full.
Empty Bag Buffer— A storage location on the rail loop where the flight bar carrying an empty
sling waits after the sling discharges its goods. Here, the operator removes the empty sling
from the flight bar, and the flight bar waits to be retrieved by the mast lift’s carriage.
Full Bag Buffer— A storage location on the rail loop where slings transferred from the mast
lift to the rail loop wait to enter the full bag storage line.
Full Bag Storage Line— A storage location on the rail loop where slings wait to enter the
discharger.
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The mast lift has four different positions, as explained below. The following figure shows an ex-
ample rail system layout with the different mast lift positions.
Preface

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Figure 2. Mast Lift Positions
Legend
A...Top level— The highest lift position,
where the lift transfers slings onto the rail
loop.
B...Empty-bag level— After a sling dis-
charges its goods, the lift waits at this po-
sition to retrieve the flight bar from the
empty bag buffer.
C...Safety level— The operator raises the lift
to this position after he/she attaches a
sling to the flight bar. At the safety level,
the system transitions to automatic mode.
D...Bottom level— The lowest lift position,
where the operator attaches a sling to a
flight bar. This position is also commonly
referred to as the loading level.
E...Rail connecting to the empty bag buffer
(rail loop exit).
F...Rail connecting to the full bag buffer (rail
loop entrance).
G...The carriage with a flight bar and full
sling attached
Preface

2 Using the MILRAIL™ Simple Loop
Controller Inferface
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2.1 How to Use the MILRAIL™ Simple Loop Controller
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The MILRAIL™ simple loop controller uses a touch-sensitive display screen to operate the
system.
CAUTION: Excessive pressure — can damage the display screen.
�Do not push hard on the glass.
�Use only a finger to touch the glass. Do not touch the screen with a
tool.
The Main Menu is the default display on the MILRAIL™ simple loop controller. It is used to log
in and access all the other menus, as shown below.
Figure 3. Main Menu
Legend
A...Access the Overview display
(see Section 2.1.2 ).
B...Access the Alarms Menu (see
Section 3.1.2 : The Alarms
Menu, page 14).
C...Access the Engineers Menu
(see the separate reference
manual, MCRUSB01, for
more information).
D...Access the Login window
(see Section 2.1.1 ).
E...Log out of the current user’s
account
2.1.1 Select a user and log in.
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Select a user and log in to use the MILRAIL™ simple loop controller. There are four types of
users, each with access to different features.
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1. On the Main Menu, touch the button labeled “Login” at the bottom of the screen. The Login
window appears, as shown in the following figure.
Figure 4. Login Window
2. Select a user from the dropdown menu. There are four choices:
• Operator—Has access to most displays but cannot access the PLC Sequences display and
cannot edit sling data.
• Manager—Has access to all displays except the PLC Sequences display.
• Engineer—Has access to all displays.
• Programmer—Has access to all displays.
3. Touch the text box labeled “Password.”
4. Use the keypad to enter the password for the user you selected.
5. Touch the button labeled “Login” in the bottom-right of the window to log in.
2.1.2 The Overview Display
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From the Main Menu, touch the button labeled “Overview” to access the Overview display. The
Overview display depicts a customized, simplified version of your rail system that updates in
real-time.
The display represents slings with square icons on the rail loop, and indicates how many slings
are on the rail, and their locations on the rail. You can choose the data displayed on the sling
icons— category, customer, weight, or destination— using the dropdown menu (item H in the fol-
lowing figure).
The Overview display also shows the locations and status of the mast lift, discharger, and optional
PVC, and indicates if these devices have a sling.
The following figure shows an example rail system and explains how to interpret the Overview
display.
Using the MILRAIL™ Simple Loop Controller Inferface

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Figure 5. The Overview Display (Example)
Legend
A...The mast lift (elevator), with a sling attached. See Figure 6 .
B...Lift-bar proximity switches, which indicate if a line can receive slings. White = can, red = cannot.
C...The data for the incoming sling (on the mast lift). The controller inputs this information automatically.
D...PVC, with a sling attached.
E...The discharger to the CBW®washer’s chute, with a sling attached. The arrow icon indicates when the dis-
charger receives a signal to release the sling contents into the tunnel.
F...Slings, with the Category number displayed.
G...Touch to pause the rail system (without cancelling production).
H...Choose the data displayed on the sling icons— category, customer, weight, or destination.
I...Indicates when production is stopped (when the user presses the system stop button). All devices in the rail
system will stay in their current positions until operation is resumed with the system start button.
J...Return to the Main Menu.
The mast lift icon displays the current position of the mast lift using circular green indicators, as
shown in the following figure. (See Section 1.1.2 : The Mast Lift Positions, page 3 for explana-
tions of the different levels.) Arrows also appear on the mast lift icon to indicate its direction of
movement.
Using the MILRAIL™ Simple Loop Controller Inferface

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Figure 6. Mast Lift Positions
Legend
A...Empty-bag level
B...Safety level
C...Top level
D...Bottom level
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2.2 To Edit and Delete Sling Data
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Slings use the same category and customer data as the previous sling, until you change this infor-
mation manually. If you need to update the category or customer data for the slings, use the fol-
lowing instructions to edit the sling’s data. You can edit a sling’s data at the mast lift, or after the
sling has already entered the rail loop. Furthermore, if a sling accidentally opens and spills goods,
you can delete a sling’s data.
To edit or delete sling data:
1. Touch a sling icon to edit its data. The Edit Sling Data window appears, shown in the follow-
ing figure, which lists the current category, customer, weight, and destination data.
Figure 7. Edit Sling Data Window
Legend
A...Category— identifies a general type of goods,
and thus can also identify the wash formula the
CBW®washer will use.
B...Customer— identifies the customer (commer-
cial laundry) or department (institutional laun-
dry) the batch belongs to.
C...Weight— the dry, soiled weight of a batch, as
measured by the floor scale, or entered man-
ually by the operator.
D...Destination— identifies a storage location with-
in the laundry to send the batch.
E...Undo your changes and close the window.
F...Confirm your changes and close the window.
G...Indicates which position the sling is in on the
Overview display. Ex. The sling is in position
#19 when it is on the mast lift.
Using the MILRAIL™ Simple Loop Controller Inferface