Page 1 U S E R G U I D E UGC038-1113 FLX-128 Central Loading Control Corporate Office: 724.584.5500 Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861...
Page 2 Serial Number(s): Model Number(s): DISCLAIMER: Conair shall not be liable for errors contained in this User Guide or for incidental, consequen- tial damages in connection with the furnishing, performance or use of this information. Conair makes no warranty of any kind with regard to this information, including, but not limited to the implied warranties of merchantability and fitness for a particular purpose.
Page 3: Table Of Contents
Ta b l e o f C o n t e n t s I n t r o d u c t i o n Purpose of the User Guide........1-2 How the Guide Is Organized .
Page 4 Changing Operator Interface Communication Path for Remote Alarms ..3-23 Backup/Restore Controller Program ....... 3-24 Alternate Procedure: Backing Up FLX Program and Settings to SD Card .
Page 5 Troubleshooting Before Beginning ..........6-2 A Few Words of Caution.
Page 6 l Ta b l e o f C o n t e n t s...
Page 7 S E C T I O N I n t r o d u c t i o n P u r p o s e o f t h e U s e r G u i d e ....1 - 2 H o w t h e G u i d e I s O r g a n i z e d .
Page 8: I N T R O D U C T I O N
P u r p o s e o f t h e U s e r G u i d e This User Guide describes the Conair FLX-128 and explains step-by-step how to install and operate this equipment. Before installing this product, please take a few moments to read the User Guide and review the diagrams and safety information in the instruction packet.
Page 9 AT T E N T I O N : R e a d T h i s S o N o O n e G e t s H u r t We design equipment with the user’s safety in mind. You can avoid the potential hazards identified on this machine by following the procedures outlined below and elsewhere in the User Guide.
Page 10 1 - 6 l I n t r o d u c t i o n...
Page 11 S E C T I O N D e s c r i p t i o n W h a t i s t h e F L X C o n t r o l ....2 - 2 Ty p i c a l A p p l i c a t i o n s .
Page 12: What Is The Flx Control
W h a t i s t h e F L X C o n t r o l ? The FLX loading control is a central vacuum conveying control consisting of a main control with I/O capacity and a range of add-on I/O modules allowing conveying system configura- tions up to 128 receivers, 40 pumps (plus 2 back up pumps) and 256 source valves.
Page 13 Total number of receivers on the Receiver expansion panel can be 8 with options (fill sensor) and alarms, or 16 with no options. Selected I/O expansion panels cannot exceed the total FLX capacity of 128 receivers, 40 pumps and 256 source valves. Specifications may change without notice. Check with a Conair representative for the most current information. TPCX053-0313...
Page 14 2 - 4 l D e s c r i p t i o n...
Page 15: I N S T A L L A T I O N
S E C T I O N I n s t a l l a t i o n U n p a c k i n g t h e B o x e s ..... 3 - 2 P r e p a r i n g f o r I n s t a l l a t i o n .
Page 16: Unpacking The Boxes
U n p a c k i n g t h e B o x e s The FLX loading control comes in one or more boxes, depending on options ordered. The boxe(s) include a touch screen interface and other options as ordered: CA U T I O N : L i f t i n g To avoid personal injury or damage to the FLX, lift the equipment out of the box carefully.
Page 17: Preparing For Installation
P r e p a r i n g f o r I n s t a l l a t i o n The FLX is easy to install if you plan the location and prepare the mounting area properly. You should plan the location of the FLX base unit (and any additional control panels to be included in the system) to ensure easy access and minimal wiring.
Page 18: Installing The Flx
I n s t a l l i n g t h e F L X Installation of the FLX consists of: Ì Mounting the base unit. Ì Mounting the optional Remote I/O panel, Remote Operator Interface Enclosure(s), Remote Alarm Enclosure(s), and/or Switch Enclosure(s) and expansion modules, depending upon what was ordered.
Page 19: Mounting The Base Unit
M o u n t i n g t h e B a s e U n i t The FLX base unit should be mounted on a wall, or other secure vertical surface, at a height providing easy access and a clear view of the touch screen panel. 1 Bolt the base unit to the mounting surface.
Page 20: Connecting The Main Power Source
C o n n e c t i n g t h e M a i n Po w e r S o u r c e WA R N I N G : E l e c t r i c a l h a z a r d Before performing maintenance or repairs on this product, disconnect and lock out electrical power sources to prevent injury from unexpected energization or start-up.
Page 21: Preparing To Configure The I/O
P r e p a r i n g t o C o n f i g u r e t h e I / O The FLX-128 conveying control system represents the ultimate in flexibility and system configuring. As a result, before it is wired, the components of your system need to be con- figured for their location, function and specific wiring connection points.
Page 22: Understanding I/O Card Functions
U n d e r s t a n d i n g I / O L o c a t i o n s ( c o n t i n u e d ) Once all the I/O modules are installed and inter-connected via Ethernet network wiring the system will recognize these modules and they will appear on the system set-up screen accordingly.
Page 23: Using The Setup Wizard
U s i n g t h e S e t u p W i z a r d Using the Setup Wizard is the most simple way to complete the initial setup of your FLX system. Use the following procedure to complete the initial setup process: 1 Provide power to the FLX.
Page 24: Configuring The I/O
C o n f i g u r i n g t h e I / O NOTE: If you have utilized the setup wizard, you have 1 Provide power to the FLX. already configured the I/O. Installation: Using the 2 Wait for the control to initialize.
Page 25 C o n f i g u r i n g R e m o t e I / O a n d E x p a n s i o n I / O M o d u l e s NOTE: If you have utilized Configure Remote I/O only if the Remote I/O is required for your current system needs and the setup wizard, you have...
Page 26: Configuring Remote I/O And Expansion I/O Modules
C o n f i g u r i n g R e m o t e I / O a n d E x p a n s i o n I / O M o d u l e s ( c o n t i n u e d ) 9 From the I/O Configure screen, press the INPUT or OUTPUT card to be configured.
Page 27: Wiring Receivers
W i r i n g R e c e i v e r s The receiver wires connect to power terminals or terminals on the I/O slots inside the con- trol enclosure. The number of receivers and options in the conveying system will determine the number of connections that are required.
Page 28: Customizing Network Connections
C u s t o m i z i n g N e t w o r k C o n n e c t i o n s Overview of FLX System Network The FLX system with Ethernet option uses the Modbus TCP/IP specification. Modbus TCP/IP uses TCP/IP and Ethernet to carry the data of the Modbus message structures between FLX system hardware.
Page 29 C u s t o m i z i n g N e t w o r k C o n n e c t i o n s ( C o n t i n u e d ) Conair Default Network Addresses Hardware...
Page 30 C h a n g i n g N e t w o r k A d d r e s s e s f o r F L X C o n t r o l l e r P L C a n d / o r F L X R e m o t e I / O C o n t r o l l e r ( Wa g o 8 8 0 ) Verify that the PC to be con- nected is on the same net-...
Page 31: Changing Network Addresses For Flx Controller Plc And/Or
C h a n g i n g N e t w o r k A d d r e s s e s f o r F L X C o n t r o l l e r P L C a n d / o r F L X R e m o t e I / O C o n t r o l l e r ( Wa g o 8 8 0 ) ( C o n t i n u e d ) From the Navigation menu, select TCP/IP.
Page 32: Changing Network Addresses For Main And Remote Operator Interfaces
The main NOTE: This page also includes the DNS for the operator interface email option. will reboot and Operation: FLX-128 Email start up with the Feature for more informa- new network tion. addresses. Repeat steps 2...
Page 33: Changing Operator Interface Communication Path To Controller (Plc)
C h a n g i n g O p e r a t o r I n t e r fa c e C o m m u n i c a t i o n Pa t h t o C o n t r o l l e r ( P L C ) The network address of the controller (PLC) must be entered into the operator interface so the operator interface knows where to pull the data from.
Page 34: Changing Operator Interface Communication Path To Remote I/O Controller
C h a n g i n g O p e r a t o r I n t e r fa c e C o m m u n i c a t i o n Pa t h t o R e m o t e I / O C o n t r o l l e r ( P L C ) The network address of the Remote I/O Controller (PLC) must be entered into the operator interface so the operator interface knows where to pull the data from.
Page 35: Changing Network Addresses For Remote Alarms
C h a n g i n g N e t w o r k A d d r e s s e s f o r R e m o t e A l a r m s ( Wa g o 3 5 2 ) Verify that the PC to be con- nected is on the same net- work as the FLX remote...
Page 36 C h a n g i n g N e t w o r k A d d r e s s e s f o r R e m o t e A l a r m s ( Wa g o 3 5 2 ) ( C o n t i n u e d ) From the Navigation menu, select TCP/IP.
Page 37: Changing Operator Interface Communication Path For Remote Alarms
C h a n g i n g O p e r a t o r I n t e r fa c e C o m m u n i c a t i o n Pa t h f o r R e m o t e A l a r m s From the Main screen, press the Setup button.
Page 38: Backup/Restore Controller Program
B a c k u p / R e s t o r e C o n t r o l l e r P r o g r a m The FLX controller (Wago 880) memory allocation is as follows: RAM Memory The RAM memory is used to create variables not required for communication with the interfaces but for internal processing.
Page 39 B a c k u p / R e s t o r e C o n t r o l l e r P r o g r a m ( C o n t i n u e d ) Once the FTP site opens, select Page from Internet Explorer toolbar and then click Open FTP Site in Windows Explorer.
Page 40 B a c k u p / R e s t o r e C o n t r o l l e r P r o g r a m ( C o n t i n u e d ) Once connected, open Internet Explorer and enter the following address: ftp://10.1.61.1 For the Remote I/O Controller (PLC) enter 10.1.61.100 or the cus- tomized address.
Page 41 A l t e r n a t e P r o c e d u r e : F L X P r o g r a m a n d S e t t i n g s B a c k u p t o S D C a r d The main program and all settings of the FLX system reside in the WAGO PLC located in the main enclosure box.
Page 42 A l t e r n a t e P r o c e d u r e : F L X P r o g r a m a n d S e t t i n g s B a c k u p t o S D C a r d ( C o n t i n u e d ) Press the Features tab under navigation.
Page 43: R E M O T E A C C E S S Vi A We B Pa G E S
IP address in replacement of the 10.1.61.1 Enter the user name and password for your security level. NOTE: The default username is “conair” and the default password is “Web Access”. These settings can be changed by users with the appropriate security level. Users logged in as Supervisor will be able to view the current username and password for each user.
Page 44 3 - 3 0 l I n s t a l l a t i o n...
Page 45: Opera Tion
S E C T I O N O p e r a t i o n Navigating the FLX Control Panel ....4-2 The FLX Control Panel ..... . . 4-3 Control Function Flow Charts .
Page 46: Navigating The Flx Control Panel
A Help Navigation Button shows a group of buttons with a brief descrip- tion of each button function. The MVP Button allows you to access the Conair Material Vision Proofing system. ( C o n t i n u e d )
Page 47 The Email Alarms Button allows you to access the email setup screen of the FLX control. This function is optional. For more information about adding the email option or any other options to your FLX-128, contact Conair. Conair’s sales number is 724-584-5500. Conair’s Instant Access 24/7 Parts and Service number is 800-458-1960.
Page 48: The Flx Control Panel
T h e F L X C o n t r o l Pa n e l Below is a screen from the FLX while in operation. This screen is shown as a sample of functionality of a typical FLX screen. See the functional descriptions below.
Page 49: Control Function Flow Charts
C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e H o m e s c r e e n Help Overview Security...
Page 50 C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e H o m e s c r e e n ( c o n t i n u e d ) Home Alarm Log...
Page 51 C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e S e c u r i t y M a n a g e r s c r e e n ( l o g i n ) Security Manager ( C o n t i n u e d ) O p e r a t i o n l...
Page 52 C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e P u m p N e t w o r k s c r e e n Pump Network Help...
Page 53 C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e D e v i c e S e l e c t s c r e e n Device Select Help next Device group page Device group...
Page 54 C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e A l a r m s s c r e e n Home Alarm Log Clearing...
Page 55 C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e M a i n t e n a n c e s c r e e n Home Maintenance screen...
Page 56 C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e S e t u p s c r e e n Home Setup screen PM/Maint Setup...
Page 57 C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e A d va n c e d S e t u p s c r e e n Advanced Setup screen Default Names I/O Configuration...
Page 58 C o n t r o l F u n c t i o n F l o w C h a r t s F r o m t h e A d va n c e d S e t u p s c r e e n ( c o n t i n u e d ) Advanced Setup screen Remote Alarm...
Page 59: Help Screens
H e l p Help screens Help screens are available from most screens. The help varies from general overview to detailed instructions. If Help is available for a screen, a question mark button will be pres- ent in the upper right corner on the green title bar. Press this button to access the help infor- mation.
Page 60: Login/Logout
L o g i n / L o g o u t To Log in The user will have to log in for operator actions or screens which require security. Once logged in, the user will remain logged in until either the user logs out or the login times out (10 minutes).
Page 61: Alarms
A l a r m s Alarm Summary When an alarm occurs, an audible sound will be triggered and the operator interface will display a flashing alarm message. To view an alarm from any operator screen, press the Alarm button. The following buttons are available from the Alarms log screen: PREV (previous) - The previous button is used...
Page 62 A l a r m s ( c o n t i n u e d ) Alarm Legend The alarm text will appear on the Alarm screen, and the Alarm History screen as colored text. Cleared alarm Cleared alarms are represented on the screen by green text. This alarm condition has been remedied and this alarm remains only in the history until it is cleared from the history.
Page 63: Typical Navigation
Ty p i c a l n a v i g a t i o n The FLX-128 system supports up to 40 pumps (plus two back-up), which can service up to 128 devices (based on I/O configuration). The FLX system provides multiple ways to navi- gate through the system, via pump navigation, or device navigation.
Page 64: Icon Descriptions
I c o n D e s c r i p t i o n s Icons are used to symbolize the different types of devices and the actual state of their operation. Pump Icons A choice of two icons may be selected for pump representa- tion to align the icon to the actual type of pump being employed, by pressing this button on the pump set-up screen: The two types are positive displacement (left) and regenerative (right).
Page 65 I c o n D e s c r i p t i o n s ( c o n t i n u e d ) Receiver Icon Function Description Faded: The receiver is disabled and will not be serviced by the pump.
Page 66 I c o n D e s c r i p t i o n s ( c o n t i n u e d ) Multi-Source Receiver Icon Function Description Faded: The multi-source receiver is disabled and will not be serviced by the pump.
Page 67 I c o n D e s c r i p t i o n s ( c o n t i n u e d ) Purge Valve (shown on the right): This valve includes a second inlet, equipped with an air filter that also permits air purging of the conveying line, once material conveying is complete.
Page 68 I c o n D e s c r i p t i o n s ( c o n t i n u e d ) Purge Valves (left) are typically installed on a material con- veying line, wherever needed, and include two inlets on one end: One for incoming material and one for purging air.
Page 69: Pump Network Screen
P u m p N e t w o r k S c r e e n On this screen, all the pumps will be shown. Each pump icon displays the pump number, name, and the status of the pump. The pump status can be determined by the color of the pump icon’s background.
Page 70: Pump Screen
P u m p S c r e e n On this screen, all the devices including their number, name, and status being serviced by the pump are shown. The loader status icons display their current status. (See Operation: Icon Descriptions for more information.) The Pump is enabled and disabled by pressing the Enabled/Disabled button under the pump icon.
Page 71: Assign A Backup Pump
P u m p S c r e e n ( c o n t i n u e d ) Pressing the Pump icon opens the Pump Detail window. The following is displayed: • Pump Starts – The number of times the pump is commanded to turn on. •...
Page 72 P u m p O p t i o n s S e t u p S c r e e n ( c o n t i n u e d ) To view the Pump Options Setup screen: From the Pump Network screen, press on the pump you would like to view.
Page 73 P u m p O p t i o n s S e t u p S c r e e n ( c o n t i n u e d ) S e t t i n g I d l e M o d e Ti m e This feature allows a pump to remain on during times of demand and idle, rather than shutting off and then turning back on when there is a demand.
Page 74: Devices Screen
D e v i c e s S c r e e n On this screen, all the devices including their number, name, and status are shown. The loader status icons display their current status. (See Operation: Icon Descriptions for more information.) Pressing the device icon opens a window that displays the individual device detail.
Page 75: Individual Device Screen
I n d i v i d u a l D e v i c e S c r e e n On this screen, the loader including the number, name, and status is displayed. The sta- tus can be deciphered by the color of the device icon’s background. A “P”...
Page 76 I n d i v i d u a l D e v i c e S c r e e n ( c o n t i n u e d ) NOTE: Dry Air text indicates closed loop operation.
Page 77 I n d i v i d u a l D e v i c e S c r e e n ( c o n t i n u e d ) Regrind Time When Ratio is configured, the Regrind time and Ratio Cycles will be visible. Regrind Time is the number of seconds (0-300) that regrind, or a second material, should be loaded with a virgin material.
Page 78: Loader Maintenance Screen
L o a d e r M a i n t e n a n c e S c r e e n The Maintenance screen displays the current cycle counts of valves. The PM setpoint for each device is shown. The PM setpoint is configured from the PM/Maint Setup screen (accessed from the Setup screen).
Page 79: Test I/O Screen
Te s t I / O S c r e e n A screen to test the I/O is accessible by pressing the Device Detail button. The loader must be disabled and proper login is required to test I/O. I/O available to test depends upon I/O configuration and loader configuration. Press the Test button of the output to test.
Page 80: Device Configuration Screen
D e v i c e C o n f i g u r a t i o n S c r e e n Each loader/receiver is configured individually. Proper login is required. From the loader screen press the Setup button. Depending upon I/O configurations, some loader configurations may not be available.
Page 81 D e v i c e C o n f i g u r a t i o n S c r e e n ( c o n t i n u e d ) Ratio NOTE: If both output This feature allows control of more than one material into one vacuum receiver.
Page 82: Reverse Regrind/Regrind Recover Y Navigation
R e v e r s e R e g r i n d / R e g r i n d R e c o v e r y N a v i g a t i o n View Pump Network by pressing the...
Page 83: Multi-Source Loader Network Screen
M u l t i - S o u r c e L o a d e r N e t w o r k S c r e e n On this screen, the multi-source loader and attached granulators will be shown. Each icon displays the number, name, and the status of the granulator and multi-source loader.
Page 84 M u l t i - S o u r c e L o a d e r S c r e e n On this screen, the multi-source loader including the number, name, and status is displayed. The status is indicated by the icon. (See Operation: Icon Descriptions) A “P”...
Page 85: Multi-Source Test I/O Screen
M u l t i - S o u r c e Te s t I / O S c r e e n A screen to test the I/O is accessible by pressing the Device Detail button. The loader must be disabled and proper login is required to test I/O.
Page 86: Multi-Source Loader Configuration Screen
M u l t i - S o u r c e L o a d e r C o n f i g u r a t i o n S c r e e n Each multi-source loader is configured individually. Proper login is required. From the multi-source loader screen press the Setup button to access the configuration screen.
Page 87: Multi-Source Loader Configuration Screen
G r a n u l a t o r ( G r i n d e r ) S c r e e n On this screen, the granulator including the number, name, and status is displayed. The sta- tus is indicated by the icon.
Page 88: Grinder Test I/O
G r i n d e r Te s t I / O A screen to test the I/O is accessible by pressing the I/O button. The granulator must be dis- abled and proper login is required to test I/O. I/O available to test depends upon I/O configuration and loader configuration.
Page 89: Flx Initial Setup
F L X I n i t i a l S e t u p Prior to operation the FLX requires an initial setup. The setup of the FLX should be com- pleted as follows: Configure I/O. The I/O should have been configured prior to wiring, but needs to be verified before operation.
Page 90: Using The Setup Wizard
U s i n g t h e S e t u p W i z a r d The setup wizard is used for initial setup only. From the main screen, select Setup. From the Setup screen, select Advanced Setup. Select Setup Wizard.
Page 91: Flx Setup
F L X S e t u p Pump Names The Pump Names screen is used to customize/change the name of the pump. The number of pumps shown is based upon the I/O con- figuration. Source Names The Source Names screen is used to customize/change the name of the source.
Page 92 The Clear Setups and I/O configuration returns data to default values. This feature is only to be used by Conair service. If data is cleared the setups and configurations would have to be entered and the system would have to be setup as if it was an initial install.
Page 93 F L X S e t u p ( c o n t i n u e d ) Changing Passwords The passwords for the users can be changed. To change the passwords the “admin” login must be used and the password for the user to change must be known. From the Main screen, select Setup.
Page 94 Change button for the NOTE: The Factory task/operation Defaults button will change security level the security back to Conair defaults. to be changed. The current NOTE: The security level level of securi- settings are stored in the ty for the task operator interface.
Page 95 F L X S e t u p ( c o n t i n u e d ) Configure I/O The I/O of the FLX control will need to be configured prior to wiring loaders, pumps, and valves. The FLX base I/O is not config- urable.
Page 96 F L X S e t u p ( c o n t i n u e d ) Remote Alarm The IP address of the Ethernet Coupler located in the Remote Alarm Box must be config- ured prior to connecting alarm box to the FLX system’s Ethernet network. Refer to Appendix –...
Page 97: Maintenance
S E C T I O N M a i n t e n a n c e P r e v e n t a t i v e M a i n t e n a n c e S c h e d u l e ... 5 - 2 Wa r n i n g s a n d C a u t i o n s .
Page 98: Preventative Maintenance Schedule
P r e v e n t a t i v e m a i n t e n a n c e s c h e d u l e No specific maintenance schedule is required for the FLX since there are no moving parts.
Page 99: Maintenance Screen
M a i n t e n a n c e S c r e e n The Maintenance screen and maintenance screen options are used for diagnostic, troubleshoot- ing, and maintenance operations. Main screen displays the following: • Current Date and Time – The date and time are local to operator interface. •...
Page 100 Useful during installation and troubleshooting. • Service ID – ID tag used as a snapshot of current system I/O configurations. Used by Conair to determine available upgrade options and service calls. • Change Date/Time – Used to change operator interface date and/or time.
Page 101: Card Wire Numbers
The Wire colors button can be used to open a screen to reference the colors and use of either the base input card the conductors used in Conair cable for connection. or base output card. M a i n t e n a n c e l...
Page 102: Service Id
S e r v i c e I D ID tag used as a snapshot of current system I/O configurations. Used by Conair to determine available upgrade options and service calls. NOTE: If Remote I/O Panel is configured, the service ID will consist of two lines. The first line is for the main PLC and the second line (with prefix “EX”) will be for the Remote I/O panel.
Page 103: Date/Time
D a t e / Ti m e The date and time are used locally at each operator interface. The date and time are used for the alarm summary and alarm history. Each operator interface date and time will need to be set. To set date and time: From the Maintenance screen, select Change Date/Time.
Page 104: Calibrate Touch Screen
C a l i b r a t e To u c h S c r e e n The Calibrate Touch screen feature allows the user to calibrate the touch screen in event the screen is not accurate to touch. To calibrate the screen: From the Maintenance screen, select Calibrate Touchscreen.
Page 105: Troubleshooting
S E C T I O N Tr o u b l e s h o o t i n g B e f o r e B e g i n n i n g ..... . . 6 - 2 A Fe w Wo r d s o f C a u t i o n .
Page 106: Before Beginning
B e f o r e B e g i n n i n g You can avoid most problems by following the recommended installation, operation and maintenance procedures outlined in this User Guide. If you have a problem, this section will help you determine the cause and tell you how to fix it.
Page 107 A Fe w Wo r d s o f C a u t i o n ( c o n t i n u e d ) WA R N I N G : D e v e l o p a n d f o l l o w p r o c e d u r e s f o r s a f e o p e r a t i o n a n d m a i n t e n a n c e o f t h e s y s t e m .
Page 108: Identifying The Cause Of A Problem
I d e n t i f y i n g t h e C a u s e o f a P r o b l e m The T section covers problems directly related to the operation and mainte- ROUBLESHOOTING nance of the FLX.
Page 109: Operator Interface Alarms
O p e r a t o r I n t e r fa c e A l a r m s Alarm Possible cause Solution Pump Overload at {pump Indicates a pump overload. Check pump overload. name} Check overload wiring. Material Alarm at {device The number of load cycles exceeds Check location where material is...
Page 110 O p e r a t o r I n t e r fa c e A l a r m s ( c o n t i n u e d ) Alarm Possible Cause Solution The operator interface does not Verify that the controller is in Run Controller not in Run Mode or Comms lost...
Page 111: Understanding The Operator Interface Led Lights
U n d e r s t a n d i n g t h e O p e r a t o r I n t e r fa c e L E D L i g h t s Label Description LED Color...
Page 112: Ethernet Communication
E t h e r n e t C o m m u n i c a t i o n The Ethernet connector contains two LEDs. A yellow LED in the upper right, and a bi-color green/amber LED in the upper left. The LEDs represent the following statuses: LED Color Description Yellow solid...
Page 113: Battery Replacement
B a t t e r y R e p l a c e m e n t A battery is used to keep time when the unit is without power. Typical accuracy of the G306A time keeping is less than one minute per month drift. The battery of a G306A unit does not affect the unit’s memory, all configurations and data is stored in non- volatile memory.
Page 114: Controller Connections Overview
C o n t r o l l e r C o n n e c t i o n s O v e r v i e w C o n t r o l l e r C o n n e c t i o n s L E D s Description Normal Other States...
Page 115 C o n t r o l l e r C o n n e c t i o n s L E D s ( c o n t i n u e d ) Description Normal State Other States TxD/RxD Data FLASHING...
Page 116: Operating Mode Switch
C o n t r o l l e r C o n n e c t i o n s O v e r v i e w The operating mode switch is located behind a cover flap. The switch is a push/slide switch with 3 settings and a hold-to-run function. Operating Mode Switch Function Top Position (normal operating...
Page 117: Module Bus Extension (Coupler Mode)
M o d u l e B u s E x t e n s i o n ( C o u p l e r M o d e ) The Bus Extension module is required for output expansion. The RUN LED must be green.
Page 118: Flx Controller Error Codes
F L X C o n t r o l l e r E r r o r C o d e s Signalling of the LED for indication of the node status. After clearing a fault, restart the controller by cycling the power. Fault message of the I/O LED 1st blink sequence: Start of the fault message 2nd blink sequence: Fault code...
Page 119 F L X C o n t r o l l e r E r r o r C o d e s ( C o n t i n u e d ) Fa u l t C o d e 1 : “ H a r d w a r e a n d c o n f i g u r a t i o n fa u l t ” Fault Fault Description Troubleshooting...
Page 120 F L X C o n t r o l l e r E r r o r C o d e s ( C o n t i n u e d ) Fa u l t C o d e 1 : “ H a r d w a r e a n d c o n f i g u r a t i o n fa u l t ” Fault Fault Description Troubleshooting...
Page 121 F L X C o n t r o l l e r E r r o r C o d e s ( C o n t i n u e d ) Fa u l t C o d e 1 : “ H a r d w a r e a n d c o n f i g u r a t i o n fa u l t ” Fault Fault Description Troubleshooting...
Page 122 F L X C o n t r o l l e r E r r o r C o d e s ( C o n t i n u e d ) Fa u l t C o d e 3 : “ I n t e r n a l b u s p r o t o c o l fa u l t ” Fault Fault Description Troubleshooting...
Page 123 F L X C o n t r o l l e r E r r o r C o d e s ( C o n t i n u e d ) Fa u l t C o d e 4 : “ I n t e r n a l b u s p h y s i c a l fa u l t ” Fault Fault Description Troubleshooting...
Page 124 F L X C o n t r o l l e r E r r o r C o d e s ( C o n t i n u e d ) Fa u l t C o d e 5 : “ I n t e r n a l b u s i n i t i a l i z a t i o n fa u l t ” Fault Troubleshooting Fault Description...
Page 125 F L X C o n t r o l l e r E r r o r C o d e s ( C o n t i n u e d ) Fa u l t C o d e 6 : “ F i e l d b u s s p e c i f i c e r r o r s ” Fault Troubleshooting Fault Description...
Page 126 F L X C o n t r o l l e r E r r o r C o d e s ( C o n t i n u e d ) Fa u l t C o d e 1 0 : “ P L C p r o g r a m fa u l t ” Fault Troubleshooting Fault Description...
Page 127 F L X C o n t r o l l e r E r r o r C o d e s ( C o n t i n u e d ) Fa u l t C o d e 1 1 : “ G a t e w a y / M a i l b o x I / O m o d u l e fa u l t ” Fault Troubleshooting Fault Description...
Page 128: Restore Operator Interface Program Using Compact Flash Card
R e s t o r e O p e r a t o r I n t e r fa c e P r o g r a m U s i n g C o m p a c t F l a s h C a r d The HMI database of the FLX Operator Interface (Red Lion G306K and G306A) can be updated via a CompactFlash card.
Page 129 R e s t o r e O p e r a t o r I n t e r fa c e P r o g r a m U s i n g C o m p a c t F l a s h C a r d ( C o n t i n u e d ) Turn power on to the operator interface.
Page 130 S e t t i n g s Vi a C o m p a c t F l a s h These steps allow you to save your FLX-128 configuration and settings to a Compact Flash card installed into the Red Lion HMI.
Page 131: Appendix
We ’ r e H e r e t o H e l p Conair has made the largest investment in customer support in the plastics industry. Our service Additional manuals and prints for experts are available to help with any problem you might have installing and operating your equip- your Conair equipment may be ment.
Page 132: Equipment Guarantee
E q u i p m e n t G u a r a n t e e 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 nor- mal use and service for which it was recommended (except for parts that are typically replaced after normal usage, such as filters, liner plates, etc.).
Page 133: Expansion Box Ip Addresses
E x p a n s i o n B o x I P A d d r e s s e s The IP address of each expansion box is set by using the dip switches located on the Wago 750-871 PLC.

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