Published Manual Number/ECN: MATSHUTLDE/2018103A

• Publishing System: TPAS2

• Access date: 03/06/2018
• Document ECNs: Latest

Technical Reference
Mark IV and V
Microprocessor Shuttle
Controller

PELLERIN MILNOR CORPORATION POST OFFICE BOX 400, KENNER, LOUISIANA 70063-0400, U.S.A.
 Table of Contents
MATSHUTLDE/18103A

Page Description Document

1 Limited Standard Warranty BMP720097/2008272A
2 How to Get the Necessary Repair Components BIUUUD19/20081231
3 Trademarks BNUUUU02/2017285A
4 Shuttle Modifications to Support an Encoder MSOPD475AE/2002304N
8 Important Owner/User Information - Machines with a Keypad BICM3K01/20030620
10 About the User Controls - Machines with a Keypad BICPUK01AB/20030625
13 Definitions of Terms and Abbreviations BIUUUK05SU/20050112

19 1. Programming
20 Programming the Mark IV and V Shuttle Controller MSOPD432CE/2003264

41 2. Operating
42 Running the Mark IV and V Shuttle in Automatic Systems MSOPD440CE/199705BV
57 Operation of Specialized Shuttles MSOP0930AE/199436BV
59 Manually Operating the Mark III, IV, and V Shuttle MSOPD441CE/199449BV

67 3. Troubleshooting
68 Mark II, III, IV and V Shuttle Error Messages MSTS0901CE/2002384V

73 4. Supplemental Information
74 Hardware Components of Serial Microprocessor Controllers BICMDF01/20050112
83 Summary of Milnor Allied Interface Capability, Shuttle BICALC13SX/20031016
88 How to Upgrade Microprocessor EPROM Chips BICMUM01SU/20040817
 PELLERIN MILNOR CORPORATION
LIMITED STANDARD WARRANTY
We warrant to the original purchaser that MILNOR machines including electronic
hardware/software (hereafter referred to as “equipment”), will be free from defects in material and
workmanship for a period of one year from the date of shipment (unless the time period is specifically
extended for certain parts pursuant to a specific MILNOR published extended warranty) from our
factory with no operating hour limitation. This warranty is contingent upon the equipment being
installed, operated and serviced as specified in the operating manual supplied with the equipment,
and operated under normal conditions by competent operators.

Providing we receive written notification of a warranted defect within 30 days of its discovery, we
will at our option repair or replace the defective part or parts, FOB our factory. We retain the right to
require inspection of the parts claimed defective in our factory prior to repairing or replacing same.
We will not be responsible, or in any way liable, for unauthorized repairs or service to our equipment,
and this warranty shall be void if the equipment is tampered with, modified, or abused, used for
purposes not intended in the design and construction of the machine, or is repaired or altered in any
way without MILNOR's written consent.

Parts damaged by exposure to weather, to aggressive water, or to chemical attack are not covered by
this warranty. For parts which require routine replacement due to normal wear such as gaskets,
contact points, brake and clutch linings, belts, hoses, and similar parts the warranty time period is 90
days.

We reserve the right to make changes in the design and/or construction of our equipment (including
purchased components) without obligation to change any equipment previously supplied.

ANY SALE OR FURNISHING OF ANY EQUIPMENT BY MILNOR IS MADE ONLY UPON

THE EXPRESS UNDERSTANDING THAT MILNOR MAKES NO EXPRESSED OR IMPLIED
WARRANTIES OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR USE OR
PURPOSE OR ANY OTHER WARRANTY IMPLIED BY LAW INCLUDING BUT NOT
LIMITED TO REDHIBITION. MILNOR WILL NOT BE RESPONSIBLE FOR ANY COSTS OR
DAMAGES ACTUALLY INCURRED OR REQUIRED AS A RESULT OF: THE FAILURE OF
ANY OTHER PERSON OR ENTITY TO PERFORM ITS RESPONSIBILITIES, FIRE OR
OTHER HAZARD, ACCIDENT, IMPROPER STORAGE, MIS-USE, NEGLECT, POWER OR
ENVIRONMENTAL CONTROL MALFUNCTIONS, DAMAGE FROM LIQUIDS, OR ANY
OTHER CAUSE BEYOND THE NORMAL RANGE OF USE. REGARDLESS OF HOW
CAUSED, IN NO EVENT SHALL MILNOR BE LIABLE FOR SPECIAL, INDIRECT,
PUNITIVE, LIQUIDATED, OR CONSEQUENTIAL COSTS OR DAMAGES, OR ANY COSTS
OR DAMAGES WHATSOEVER WHICH EXCEED THE PRICE PAID TO MILNOR FOR THE
EQUIPMENT IT SELLS OR FURNISHES.

THE PROVISIONS ON THIS PAGE REPRESENT THE ONLY WARRANTY FROM MILNOR
AND NO OTHER WARRANTY OR CONDITIONS, STATUTORY OR OTHERWISE, SHALL
BE IMPLIED.

WE NEITHER ASSUME, NOR AUTHORIZE ANY EMPLOYEE OR OTHER PERSON TO

ASSUME FOR US, ANY OTHER RESPONSIBILITY AND/OR LIABILITY IN CONNECTION
WITH THE SALE OR FURNISHING OF OUR EQUIPMENT TOANY BUYER.

BMP720097/2008272A

1
 How to Get the Necessary Repair Components

BIUUUD19 (Published) Book specs- Dates: 20081231 / 20081231 / 20081231 Lang: ENG01 Applic: UUU

How to Get the Necessary Repair Components

This document uses Simplified Technical English.
Learn more at http://www.asd-ste100.org.

You can get components to repair your machine from the approved supplier where you got this
machine. Your supplier will usually have the necessary components in stock. You can also get
components from the Milnor® factory.
Tell the supplier the machine model and serial number and this data for each necessary component:
• The component number from this manual
• The component name if known
• The necessary quantity
• The necessary transportation requirements
• If the component is an electrical component, give the schematic number if known.
• If the component is a motor or an electrical control, give the nameplate data from the used
component.
To write to the Milnor factory:
Pellerin Milnor Corporation
Post Office Box 400
Kenner, LA 70063-0400
UNITED STATES

Telephone: 504-467-2787
Fax: 504-469-9777
Email: [email protected]
— End of BIUUUD19 —

PELLERIN MILNOR CORPORATION

2
 BNUUUU02 / 2017285A BNUUUU02 0000158094 A.3 7/13/17 1:53 PM Released

Trademarks BNUUUU02.R01 0000158093 A.2 7/13/17 1:11 PM Released

These words are trademarks of Pellerin Milnor Corporation and other entities:
Table 1 Trademarks
AutoSpot™ GreenTurn™ Milnor® PulseFlow®
CBW® GreenFlex™ MilMetrix® PurePulse®
Drynet™ Hydro-cushion™ MilTouch™ Ram Command™
E-P Express® Linear Costa Master™ MilTouch-EX™ RecircONE®
E-P OneTouch® Linear Costo™ Miltrac™ RinSave®
E-P Plus® Mentor® MultiTrac™ SmoothCoil™
Gear Guardian® Mildata® PBW™ Staph Guard®

End of document: BNUUUU02

Pellerin Milnor Corporation

3
 MSOPD475AE/2002304N

SHUTTLE MODIFICATIONS TO SUPPORT AN ENCODER

The shuttle software was modified to add support for an encoder system that
tracks the movement of the shuttle along the rail. This software requires a 186 processor
board (08BSPET or 08BSPE1T) and 186 shuttle software (WUCOSHH) 98111 or later
for non-quad UART 186 and (WUCOSHJ) 20003 for quad UART 186 processors. The
8/16 board #2 must be a high-speed board with WUHSPDBDA software 98002 or later.
The shuttle also must be Miltrac receive and discharge. Miltrac software must be version
9400F or later.

The encoder system consists of 3 photo eyes mounted on the Shuttle representing the
OOPS, Count and Home inputs. The photo eye grounds an input when it sees its
respective target mounted on or between the rails. As the shuttle moves along the rail, the
microprocessor sees a series of inputs by the “Count” prox switch. This input is used to
increment and decrement a counter to keep track of the Shuttle’s position. The shuttle
counts up when it moves left and counts down when it moves right. The OOPS target is
a fail-safe input located and the far ends of the rail system. If the Shuttle ever makes
these inputs, the Shuttle will switch directions and proceed to its intended load or
discharge station without need of human intervention.

NEW MILTRAC CONFIGURE DECISION

A configure decision “STATION NUMBER” was added for each device in Miltrac
version 9400F. This number is only used if the device discharges to or receives from a
shuttle equipped with an encoder. Enter the load or discharge station number for this
device. Miltrac sends this number to the shuttle so that the shuttle knows what count
value to look for. See the COUNTS AT LOAD STATION and COUNTS AT
DISCHARGE STATION configure decisions below.

NEW SHUTTLE CONFIGURE DECISIONS.

The following configure decisions were added.

SHUTTLE HAS AN This enables encoder operation in the

ENCODER 0=NO 1=YES shuttle.

NUMBER OF LOAD Enter the number of load stations that the

STATIONS [0-15] shuttle receives goods from. This decision
only appears if the encoder decision is set
to 1 (Yes).

NUMBER OF DISCHARGE Enter the number of discharge stations that

STATIONS [0-15] the shuttle transfers goods to. This decision
only appears if the encoder decision is set

4
 to 1 (Yes).

A new program menu item was added to configure the station counts. To access it, select
program menu item 3

PROGRAM 3 MENU
STATION COUNTS

The following configure decisions appear under the STATION COUNTS selection.
When setting counts, select an appropriate count for the home target, and then base the
station counts off of this. Counts increment as the shuttle moves left and decrement as the
shuttle moves right and there is 1 count per inch.

COUNTS AT HOME Enter the counts for the home target. When
STATION the shuttle sees the home target, it resets its
counts to the number configured here.

COUNTS AT RESET Optionally, a reset target may be added to

POINT the rail. Whenever the shuttle passes this
target, it resets its counts to the number
configured here. Most systems do not use
this input. So enter a 0.

COUNTS AT LEFT Enter the counts that the shuttle sees when
OOPS TARGET it is in front of the left oops target.

COUNTS AT RIGHT Enter the counts that the shuttle sees when
OOPS TARGET it is in front of the right oops target.

COUNTS AT LOAD XX = the load station number. This

STATION XX decision appears for each load station.
Enter the counts that the shuttle sees when
it is in front of the station.

COUNTS AT DISCHARGE XX = the discharge station number. This

STATION XX decision appears for each discharge station.
Enter the counts that the shuttle sees when
it is in front of the station.
STOP OFFSET COUNTS Always enter a 0 for this decision unless:
(The shuttle will stop when it is the
configured number of counts away from
the desired counts. This was done to allow
for a longer decel time.)

5
SLOW DOWN DISTANCE Always program a 1 for this decision.
When the shuttle is within its configured
“Slow Down Distance” counts for the
desired position, it turns on the SLOW
SPEED output.
ALT DECEL TIME Use a default value of 0 unless:
When the slow down output comes on, the
alt decel output stays on for the configured
time and then turns off. This was done to
provide an alternate acel and decel time
when running fast.

OPERATION

When the shuttle receives a get ready command from Miltrac, it also receives the
station number of the device that it needs to move to. Using the counts configured in the
shuttle, it moves towards the station. When the shuttle is within its configured “Slow
Down Distance” counts for the desired position, it turns on the SLOW SPEED output.
This signals the inverter to switch to a second speed. Usually, normal speed is set to 60
Hz and slow speed is set to 20 Hz. It is very important that any device the Shuttle will
be stopping at has a target mounted 12- 14 inches before the actual device target. This
target is better known as the “slow down” target. Keep in mind that some devices are
approached from both directions.

Whenever the shuttle returns home, it also slows down when it is within the
configured “Slow Down Distance” counts from the home target. However, the shuttle is
looking for the home input and will only stop when this input is made, regardless of the
counts. If the counts are incorrect (for example, on initial power up) and the shuttle sees
the home target while moving at high speed, it will stop, reverse direction for 4 seconds,
then move back towards the home target at slow speed. This ensures that the shuttle
always stops at the same spot when it reaches home.

HELPFUL INFORMATION FOR ENCODER SETUP

To help decipher what the actual/desired counts are while in operation, press the “2”
button on the keypad. This will toggle the current display thus showing the Actual
Counts denoted by ACNT and the Desired counts denoted by DCNT.

The display you want to see when toggling the “2” button.

OOPS ACNT DCNT SS FS

0 005 011 4 2

6
The OOPS represents the number of times the OOPS input was made since Shuttle power
up. The SS and the FS can be ignored.

When choosing your initial count values, keep in mind that when the shuttle moves left it
increments the current count and moving right always decrements the current count. The
Shuttle facing the Dryers justifies the movements, left or right.

INPUTS

TRAVERSE COUNTER 2MTA4-8

RESET COUNTER 2MTA4-11
HOME 1MTA4-15
OOPS 1MTA4-4

OUTPUTS

SLOW SPEED 2MTA5-7 & 5-16

7
 BICM3K01 (Published) Book specs- Dates: 20030620 / 20030620 / 20030620 Lang: ENG01 Applic: CM3

Important Owner/User Information—Machines with a Keypad

Take the following important steps before placing this machine in operation:
1. Ensure safety of laundry personnel.
2. Protect against data loss.
3. Customize data (configure, formula, and productivity data).

1. Ensure Safety of Laundry Personnel

Ensure that all personnel who will operate or maintain this machine read the safety manual
before permitting them access to the machine. Ensure that all user manuals are available to the
appropriate personnel and that all precautions explained in the safety and other user manuals are
observed.

2. Protect Against Data Loss

Follow the safeguards listed below to protect against data loss caused by human tampering,
electromagnetic interference (EMI), physical damage to the data storage medium, or loss of
power to random access memory (RAM).
1. Keep the Run/Program keyswitch set to run (R) and secure the keys. Users must
understand proper use of this control. See "ABOUT THE USER CONTROLS. . ." (see Table
of Contents).
2. Keep all electric box doors closed and locked. Secure the keys.
3. Leave machine power on for 48 hours before customizing data. This fully charges the
microprocessor battery, which will then supply power to the RAM for 90 days even if
machine power is off.
4. Replace the battery board every five years. A capacitor on the processor board can supply
power to the RAM for several hours with the battery removed.
5. Keep electronic back-up data and/or a printed record of all field-programmed data (e.g., wash
formulas, configure values, step names, chemical names) in case of data loss. See the
instructions for downloading and printing this data if the machine has this capability.
6. For machines that accumulate productivity data (e.g., count of loads processed), transcribe
any needed data frequently, as described in the instructions for data accumulation.

3. Customize Data

3.1. When to Customize Data

• When commissioning the machine
• When restoring a machine to service after a lengthy shutdown
• When required by error message
• After replacing the CPU board
• After upgrading software (replacing EPROMs)
• After adding or removing optional equipment

3.2. What Customizing Requires—Verify configuration. Program formulas and clear

productivity data, if applicable. See the programming and operating sections in this manual for
instructions.

PELLERIN MILNOR CORPORATION

8
 Important Owner/User Information—Machines with a Keypad

3.3. Data Accessibility—Configure and formula data can only be altered while the keyswitch is
in the program position (data is keyswitch-protected). Producitvity data, because it is
accumulated in the run mode, cannot be keyswitch-protected and is accessible to anyone. Data is
accessible to the extent described in the following table:
Table 1: Data Type and Accessibility
Ways Data Can Be
Used and Altered
Data can be read
Data can be over-written
Data can be up/downloaded
Data can be cleared
Type of Data Machines Data Applies To Contents after clearing
Configure Data dryer (includes gains) Yes Yes Yes Yes example values
shuttle, single-stage press Yes Yes No Yes zeros
two-stage press, Cobuc, Linear Yes Yes No No n.a.
Costo, discharge sequencer
washer (and textile)-extractor, Yes Yes Yes No n.a
centrifugal extractor
Formula Data step, chemical washer (and textile)-extractor Yes Yes Yes Yes example values
names
formulas washer (and textile)-extractor, Yes Yes Yes Yes empty
centrifugal extractor, dryer
Productivity Data washer (and textile)-extractor, Yes No No Yes empty
centrifugal extractor, dryer

3.4. If Data Becomes Corrupt—If the microprocessor senses that data is unusable or unreliable,
an error message will appear (usually at power-up), possibly preventing machine operation. The
consequences and appropriate actions for each error message are explained in the troubleshooting
instructions. Follow these instructions exactly to ensure that corrupt data is completely
eliminated and replaced with valid data. Failure to do so may result in unsafe operation or
machine damage.
— End of BICM3K01 —

PELLERIN MILNOR CORPORATION

9
 About the User Controls—Machines with a Keypad

BICPUK01 (Draft) Book specs- Dates: 20030625 / 20030625 / 20030625 Lang: ENG01 Applic: CSU

About the User Controls—Machines with a Keypad

User controls are of two types—electro-mechanical controls (switches, buttons, and status lights)
and microprocessor interface controls (display, keypad, keyswitch and printer/download
connection). Controls are mounted on one or more nameplates on the machine or a separate
electric box.
Note 1: Do not attempt to use your machine merely by referring to the descriptions of controls. Read the
operating, programming and troubleshooting instructions throughout this and the operator manual.

1. Electro-Mechanical Controls
Electro-mechanical controls vary with machine model and are explained in the machine-specific
operator manual furnished with the machine.

2. Microprocessor Interface Controls

These controls, shown in Figure 1, include the keyswitch, display and keypad located on the main
nameplate (position on nameplate varies), and the printer/download connection, located on its
own nameplate. These controls permit the user to pass data to and from the microprocessor
controller.
Figure 1: Microprocessor Interface Controls
1. Keypad 2. Printer Download Connection

3. Keyswitch

4. Display

Legend
1. User input to microprocessor controller.
2. Connection for serial printer.
3. Allows the user to modify configuration and programming.
4. Output from control system to user.

PELLERIN MILNOR CORPORATION

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 About the User Controls—Machines with a Keypad

Display or Action Explanation

P,n Turn the keyswitch clockwise to program (P) then press and
release the Next key.

R,n Turn the keyswitch counterclockwise to run (R) then press and
release the Next key.

^ Press and release the key shown.

^/& A slash between symbols means use either key shown. The up
and down arrow keys are often shown this way (i.e., scroll up or
down the menu choices).

6,^,5, Typical example of a word entry (spells out “POLY”). In word

(alphanumeric) data fields, press the up or down arrow key to
^,4,^, move right or left to the next character position. Press each key
9 until the desired characters appears (e.g., press 6 until “P”
appears). A comma between symbols means press and release
each key sequentially.

1,5,5 Typical example of a number entry (enters the value 155). In

numeric data fields, the cursor automatically advances to the
next character position when each numeral is entered.

4+5+6 A “+” between symbols means press and hold each key in the
order shown until all keys are depressed at the same time, then
release all keys.
hold 8 + 1 Key(s) must be held depressed for the intended action to occur.
Action will stop when key(s) is (are) released.
<xx> This is an alternative way of depicting word and number entries
<response> when the exact values are determined by the user. <xx> means
enter a two digit number. <response> means enter the value
<password>
prompted for by the display. <password> means enter the
password (or numeric passcode).

0 Press and release the “Stop” button (0).

1 Press and release the “Start” button (1).

2.1. Keyswitch—This key-operated switch provides security for all field-programmed data in
memory. With the keyswitch set to “run” (R) this data cannot be changed. The key cannot be
removed in the “program” (P) position.
CAUTION 1 : DATA LOSS HAZARD—Improper use of the keyswitch may corrupt program
data.
• Return to the run mode only when the display says OK Turn Key to Run.
• Only power off or on with the keyswitch at run.
• Do not leave the key accessible to unauthorized personnel.

2.2. Display—This two-line device displays messages and data entry screens. Messages inform the
user as to the machine's operating status or alert the user to conditions that must be satisified
before operation can continue.

PELLERIN MILNOR CORPORATION

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 About the User Controls—Machines with a Keypad

Data entry screens prompt the user to enter data at the keypad. As keys are pressed, the data
appears in the data input field on the display. A blinking cursor always shows where the next
character will be entered.

2.3. Keypad—The 12-key keypad is used for programming, making selections (e.g., selecting
formulas in a washer-extractor), responding to display messages, certain normal operating
procedures, and manual operation. Applicable procedures are explained in the remainder of this
manual and depicted using symbols to indicate pressing keys on the keypad. These symbols are
explained above.

2.4. Printer/Download Connection (if so equipped)—Connect a Milnor®-supplied printer

here to print field-programmed data (e.g., formulas) and accumulated data (e.g., count of loads
processed), if applicable. Connect a Milnor®-supplied serial downloader here or interconnect
between machines to copy field-programmed data between devices. Printing and downloading, if
applicable, are explained elsewhere in this manual.
— End of BICPUK01 —

PELLERIN MILNOR CORPORATION

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 Definitions of Terms and Abbreviations

BIUUUK05 (Published) Book specs- Dates: 20050112 / 20050112 / 20050117 Lang: ENG01 Applic: CSU

Definitions of Terms and Abbreviations

append—to write data after previously recorded data, as opposed to overwriting previously
recorded data; useful for applying audit trails in file-by-file backup
archive—long-term on- and/or off-site storage
backup—to copy information from a hard disk onto another data storage medium (e.g.,
minicartridges or diskettes)
bit—smallest amount of data that can be processed by a computer; represents the binary value of
either one or zero
block—number of bytes, an example of a block format is: preamble, data block marker, user
data, block address, CRC, postamble; block sizes vary, but 512 or 1024 user data bytes is most
commonly used
BOT (beginning of tape)—start of backup tape designated by a specific hole pattern on quarter-
inch cartridge tape media
BPI (bits per inch)—number of data bits recorded per inch of tape
byte—one character of information that consists of eight bits
click—to press and release the select button on the mouse while pointing to the choice
command prompt—displayed symbol that indicates where to enter commands
compression—see data compression
configure—to describe the devices, optional features, and programs installed on the computer
CPU (central processing unit)—integrated circuit component, usually an Intel 8088 and its
ancillary devices, that interprets programming instructions and inputs to the microprocessor
and provides outputs to other devices
CRC (cyclic redundancy check)—complex mathematical method used to check that the data
written to tape is error-free
CCW—counterclockwise cylinder rotation, as viewed from the load end; see also CW
checksum—one of several numbers generated by the control that represents the amount of data in
a specific memory area; any change in a checksum indicates that data has changed
configure—microprocessor programming for various software and hardware options on the
machine
control—an electrical enclosure, usually housing a keypad, at which the user commands actions
and programs the machine; also includes all electromechanical devices on the machine
involved with its operation; also referred to as “controller”
CPU—central processing unit; the main computer chip in a microprocessor control system that
processes data, as well as the board on which the CPU chip is mounted
cycle—operations undertaken in a specific order to process goods; a cycle normally ends with the
device ready to accept another load
daisy chain—method of linking two or more serial type microprocessor controls with one four-
conductor shielded cable. All data passes via this cable, regardless of which machines are
communicating.
data—coded representation of information for use in a computer
data block marker—marker that identifies the start of user data in a block
data cartridge—durable tape cassette used to store computer data
data compression—feature that permits increased storage capacities using a mathematical
algorithm that reduces redundant strings of data; can be performed by software or hardware

PELLERIN MILNOR CORPORATION

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Definitions of Terms and Abbreviations

data integrity—validity of recorded information

database—collection of data with a given structure for storing and providing data
DataCare Quality—service and support program for Imation Travan minicartridges
default—value, attribute, or option that is assumed
default password—see Password, default
default value—value used by the microprocessor control if no other value has been set by the
programmer
density—measurement of amount of data stored in a given length of tape; usually expressed in
bits per inch (BPI)
Device Master—Milnor product that regulates the operation, programming, troubleshooting, and
monitoring of specialized conveyors and other devices.
DIP switches—dual in-line package switches; a row of (usually six or eight) miniature switches
in a single housing used to permanently select or configure certain options on microprocessor
boards; on Milnor® microprocessor controls these switches are used most often to specify the
communications address for each machine in a system
directory—list of files stored on a disk that contains information about the file; a named group of
files such as a washer/extractor program directory
discretionary data field—any field in the microprocessor control system that can be updated
through the keyboard or keypad; also, a machine configuration field, such as temperature
units, that is not limited by hardware or equipment in the machine
display—the component by which the machine provides data to the operator; the component may
be one of several types, including vacuum fluorescent or liquid crystal (two lines of 20 alpha-
numeric characters), color graphic liquid crystal (320 pixels by 240 pixels), or CRT monitor of
various resolutions.
download—process of transferring data, usually configuration and programming instructions,
from a machine to another machine or to a memory storage device
double-click—to press and release the select button on the mouse twice in rapid succession while
the pointer is over the intended icon
Drynet dryer/shuttle controller—Milnor product that regulates operation, programming,
troubleshooting, and monitoring of dryers and shuttles
ECC (error correction code)—mathematical algorithm used to correct errors
EW (early warning)—indicator to the drive that the end of the tape is approaching; technically,
the first hole in the EOT hole pattern
edge seek—method of using the recording head to detect the edge of tape and then to reference
the tracks from the edge of tape, thus assuring the tracks are positioned accurately
EOT (end of tape)—end of tape designated by a specific hole pattern on quarter-inch cartridge
tape media
EPROM—erasable programmable read-only memory; the portion of some Milnor®
microprocessor control systems used to store the fixed instructions (software) that determine
how the machine functions
erase—to remove previously-written data by randomizing the magnetic orientation of the media
error—loss of magnetic signal strength to a degree that data is uninterpretable
FRPI (flux reversals per inch)—number of flux changes per inch of tape; this may be equal to
the number of bits per inch stored, depending on the recording code in use
FTPI (flux transitions per inch)—same as FRPI
field—area in a window used to input data
PELLERIN MILNOR CORPORATION

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 Definitions of Terms and Abbreviations

file—one or more recorded blocks of data

file-by-file backup—method of backup in which each file is stored separately and sequentially;
extremely useful if you need to restore or interchange a single file
filename—name used by a program to identify a package of information; e.g., Mildata stores
production data in files named CBWproc.db and process.db
flux transition—change in the magnetic state which can be interpreted to represent a data bit on
tape
form factor—physical size of a device; e.g., the width of a data cartridge drive (if the drive is a
5-1/4" form factor this means that the drive is the same size as a 5-1/4" diskette drive and uses
the same fixing points; the same principle applies with the 3.5" format, where a 3.5" diskette
drive may be exchanged for a 3.5" data cartridge drive in your computer)
format—form in which data is written to the tape; it defines things such as the number and
position of tracks, number of bits per inch and the recording code to be used
formula—instructions used by the machine control to operate motors, valves, and other
components during a standard cycle
formula code—see Code, formula
full height—height of a full-height diskette drive (approximately 3.25")
GB (gigabyte)—1024 Megabytes (MB); 1,073,741,824 bytes
GCR (group code recording)—data encoding method often used on data cartridge drives;
combines high data density with relative ease of decoding
goods—articles processed or conveyed by a machine
HSM (hierarchical storage management)—system of ranking and storing information across a
variety of device types
half height—height of a half-height diskette drive (approximately 1.6")
hardware—electronic boards that control the machine
headers—blocks of data written at the beginning of cartridges or files that contain specific
identification information
help—feature that displays a window with assistance and information
home—the specific position along the shuttle path to which the shuttle returns upon power up; or
after discharge, load, or error correction; belt is at receive level 0
icon—pictorial representation of an program; double clicking the icon activates the program
Infinite Disk—software product manufactured by Cheyenne for compressing, moving, and
backing up data
initialize—to re-tension and read or write header blocks before a data cartridge is used
input, direct—signals that enter the processor board directly; direct inputs are provided by
switches on the machine, including limit switches, the Signal Cancel button, and the
Run/Program keyswitch
input, standard—signals to the microprocessor controller that certain standard conditions exist;
these inputs enter the processor board through the standard input/output board(s); include Bag
Ready, Load Conveyor Ready, and remote customer and goods codes, etc.
installation—process of putting a copy of a program onto a working disk and preparing it for use
interchange—to remove a data cartridge from one drive and read the data on another data
cartridge drive
interface—hardware and software used to establish communication between a host and device
internet downloading—receiving data from the internet

PELLERIN MILNOR CORPORATION

15
Definitions of Terms and Abbreviations

KB (kilobyte)—memory storage unit; 1024 bytes; used when referring to storage space
LP (load point)—physical location on the tape where data recording starts; this location is
physically marked by the location of a punched hole
Linear COSTA—Milnor® controller to store and track multiple cakes on a belt conveyor
load—the amount of goods, measured by weight or pieces, that a machine normally handles
during a cycle
loading device—in a system, this is the device which loads another device; example: a shuttle
may be the loading device for a dryer
loading direction—the direction the goods are loaded into or onto a device
MB (megabyte)—memory storage unit; 1024 kilobytes or 1,048,000 bytes; used when referring
to storage space or filesize
MFM (modified frequency modulation)—recording code used on floppy-interface QIC drives;
it is the most efficient self-clocking code, but requires "good" electronics to decode
Mentor—personal computer-based software system for operating, programming, and monitoring
the Milnor® CBW® tunnel washer
menu—list of functions or operations that can be selected
Mildata—control unit that passes batch codes between the various system components and
controls the routing of goods based on machine availability and the batch code
Miltrac—PC-based controller that coordinates and tracks the transfer of batches throughout the
system
minimize—to reduce a window to an icon so that the program is still running, but is not visible
on the computer screen
MMP (Milnor Machine Programmer)—Milnor-produced Windows Machine Programmer for
newer machines including extractors; washer-extractors; textile, dye, and outerwear machines;
and single stage presses
MMQ—minutes, minutes, and quarter minutes (e.g., 043 = 4 minutes and 45 seconds); see also
SS and SSS
MTBF (mean time before failure)—expected component life before the first failure
MTTR (mean time to repair)—estimated time to repair a failed component
model—designation of machine without regard to options; for most devices, the model includes
some dimensional representation of the effective machine size
modem—device that converts digital data from a computer to a telephone signal that can be sent
to another computer
motor contactor box—enclosure containing the high voltage motor contactors
multimedia files—computer files containing audio, video, or graphics
Multitrac—Milnor supplied software/hardware package that includes Miltrac, Online
Communicator, Drynet, and Device Master
off track retry—method of improving data recovery under error conditions; it is often possible to
recover a data error by moving the head slightly off the track center and re-reading the block
Online Communicator—Milnor product that collects production data for troubleshooting and in
conjunction with the separate Mildata product
open—to start a program and make it available for use
operating system—software that controls the processing of programs and manages data on the
permanant storage device (hard drive)
overwrite—method of overwriting data on a tape without first erasing it

PELLERIN MILNOR CORPORATION

16
 Definitions of Terms and Abbreviations

password—three-character code entered to access or change values in certain display pages, used
to prevent unauthorized programming. The instructions for changing the password are
contained in a separate document sent only to the owner of the machine. See also Minipass
permanent press—a fabric or finish which is heat-set after the article is manufactured to
minimize wrinkling and to retain creases
PE (phase encoding)—method of coding data; it has the advantage of being very reliable and
easy to decode, but it is not particularly efficient in data density
port—connector on the computer to which device cables are attached; ports can be parallel or
serial; the Mildata system uses serial port COM1 to communicate with machines and parallel
port LPT1 to send information to the printer
port designation—four-character name assigned to each port, e.g., COM1, COM2, LPT1
postamble—section of recorded data used to synchronize the data decoding electronics to the
data stream; it occurs at the end of the data block
preamble—section of recorded data used to synchronize the data decoding electronics to the data
stream; it occurs at the start of the data block
program mode—mode which allows programming of wash formulas, dry cycles, and other
discretionary data; see also Run mode
prompt—message that appears on the screen asking for information or a decision from the user;
alternatively, a DOS prompt is a letter followed by a greater-than sign, e.g., C:\>.
QIC (Quarter-Inch Cartridge Drive Standards, Inc)—international trade association
comprised of manufacturers of QIC tape drives, media, and critical components with primary
charters to identify market needs; educate users, OEMs, system integrators, resellers and
dealers; and provide a forum for technical discussions leading to the generation of
development standards for compatibility among manufacturers' systems
RLL (run length limited)—family of codes used to encode data; number of zero or one bits is
limited to a certain value; GCR is an RLL code
random access—feature that allows access to any particular block by going directly to it; disk
devices are random access devices
read after write—method of ensuring that data written to tape is correct by immediately reading
the tape on a read head placed just after the writing head
reference burst—multiple flux transitions written at the beginning of the tape to indicate the
center line of the tape; this allows the read head of the drive to align itself correctly and
improves the data integrity of the drive
remote—system or program accessed through a telephone line
restore—to retrieve information from a tape drive in order to replace data that was lost from a
hard disk
retension—to wind the tape from the beginning of tape (BOT) to the end of tape (EOT), or EOT
to BOT; a critical step when first inserting a data cartridge into the drive; ensures that the tape
in the cartridge is correctly tensioned and will give you the optimum head-to-tape contact for
error-free performance
run mode—mode of operation that allows devices to run automatically; see also Program mode
SCSI (small computer systems interface)—bus interface that enables many different kinds of
devices, such as disk drives, CD-ROM drives, and tape drives, to interface with the host
computer
save—to store information on disk
search—method of finding a particular data file without having to read all the preceding data;
often done at a different speed than reading and writing; usually applies to start/stop drives

PELLERIN MILNOR CORPORATION

17
Definitions of Terms and Abbreviations

select—to highlight or choose an item in a menu

sequential device—device that reads each data block sequentially, as opposed to a random access
device
serial—sequential transmission of one data unit at a time; e.g., serial ports pass one bit at a time
setting—choice that defines characteristics of a program
shutdown—to select the shutdown selection in the Start menu before the computer is powered
off so that data is not lost
software—fixed information contained in EPROMs (programming by Milnor®) or on disk files
that determines how a machine or computer operates
SS (SSS)—seconds, i.e., “SS” means two digits (usually 00-99 seconds), “SSS” means three
digits (usually 000-255 seconds); see also MMQ
start/stop—data cartridge feature that allows stopping and starting before and after each data
block written or read from tape
streamer—data cartridge drive that writes or reads blocks without stopping between blocks
Tape-It—software product manufactured by PG Soft
tape mark—unique data block used to separate data files or volumes of data
third height—one-third the height of a full-height drive, or approximately 1 inch
three-wire circuit—circuit that provides control power for all machine functions; any of several
safety devices in the three-wire circuit will open the circuit and stop machine operation if a
malfunction is detected; once open, the three wire circuit can only be closed by manual
intervention and then only if the condition that opened the circuit is rectified
toggle switch—one of several types of hand-operated switches with a single operating lever that
can be moved to two or more positions (e.g., the Master switch)
track—linear area of media on which data are written
Travan—high capacity minicartridge technology developed by Imation Corporation (formerly a
division of 3M Company)
trickle charge—process of slowly and continuously charging a microprocessor backup battery
during machine operation to maintain a full charge
underrun—action that occurs when a streaming drive runs out of data to be written to tape; it
stops and repositions the tape; this occurs when the processor is too slow to keep up with the
streamer
user data—data recorded by the user; user data is differentiated from other information recorded
by either the drive or formatter
verify—to compare the data read to data written; verification provides an additional confidence
check
volume—logical division of data; consists of a number of files
volume label—data block written at the front of a volume to identify it
VERTSTO—Milnor multi-tiered, non-translating, elevating or non-elevating intermediate
conveyor for storing pressed cakes between other cake-moving devices in the CBW® system
window—an area of the screen in which information is displayed; each program is its own
window and often contains windows inside of windows
Windows Dryer Programmer—Milnor-supplied software that, when installed on a personal
computer, gives the customer flexibility with programming newer Milnor Dryers; included
with the Mildata system
— End of BIUUUK05 —

PELLERIN MILNOR CORPORATION

18
Programming 1

19
 MSOPD432CE/2003264 (1 of 21)

ÈROGRAMMING
P
THE MARK IV AND V SHUTTLE CONTROLLER
The Program Menu and How To Access It
Ê
The Available Modes in the Program Menu
Ë
0=OK Turn Key To Run (permits safe return to run mode)
1=Configure (tells controller which models and options it is controlling)
2=Clear All Memory (Voluntarily)

To Access the Program Menu

Ë
With shuttle power on and shuttle WAITING FOR LOADING
not moving, display= DEVICE TO GET READY
Disables the three-wire circuit THREE WIRE DISABLED Operator alarm will sound. Do not press
Display= PUSH START TO GO to silence the alarm at this time, see
NOTE under “For Safe Return . . .” below.
Accesses the program menu PROGRAM 0 MENU Underline indicates cursor position. Select
OK TURN KEY TO RUN one of two program modes by number, or
select before returning to run mode.
<x> Selects program mode x, where PROGRAM 1 MENU See “The Available Modes in the Pro-
<x> is the program mode number CONFIGURE SHUTTLE gram Menu” in this section.
—example:

Ë For Safe Return to Run Mode From Program Menu

Selects program mode 0 if it is PROGRAM 0 MENU This display must appear before turn-
elsewhere. Display= OK TURN KEY TO RUN ing keyswitch to run.

NOTE: After is accessed and Configure (program mode 1) is accessed, it is permissible to press to
silence the operator alarm. The control always returns to the program menu from any accessed program mode.

, If was not pressed, returns to the run mode.

If was pressed, display= PUSH STOP TO EXIT

CONFIGURE
Returns to run mode from above display.

Returns the shuttle on-line. INITIALIZATION IN

PROGRESS

20
PROGRAMMING
THE MARK IV AND V SHUTTLE CONTROLLER MSOPD432CE/2003264 (2 of 21)

To Access a Program Mode

Ë
With a program selected—example: PROGRAM 1 MENU Program mode 1 selected.
CONFIGURE SHUTTLE

Accesses the selected program. NUMBER OF STORAGE Program mode 1 accessed.

BELTS ? 0 See “The Configure Deci-
sions” in this section.

How To Avoid Data Loss in the Shuttle Controller!

Ê
For Shuttle Controller
PROGRAM 0 MENU
Never , unless the display says OK TURN KEY TO RUN
Otherwise, the controller requires clearing CLEAR MEMORY NOW
the entire memory and prompts PRESS 4 + 5 + 6

+ + Clears all configure codes CLEARING MEMORY

while the display= **PLEASE WAIT**
Display then returns to PROGRAM 0 MENU
OK TURN KEY TO RUN
Do not use the above procedure to voluntarily delete configure codes. See “2=Clear All Memory
(Voluntarily)” in this section for proper procedure.

Never turn power off while in program mode.

Otherwise, the controller requires deleting the entire memory as explained above.

Reconfigure whenever memory is cleared.

See “1=Configure (and Why It Is Necessary)” in this section.

21
PROGRAMMING
THE MARK IV AND V SHUTTLE CONTROLLER MSOPD432CE/2003264 (3 of 21)

1=Configure (and Why It Is Necessary)

Ê
Because the microprocessor can control several different models, it is necessary to “configure” each machine
to match its specific hardware (number of belts, load-end photo-eyes, allied loading, allied discharge, the Mildata®
system, etc.). Such decisions are discrete to the specific machine and must never be changed unless options are later
added or removed. However, other configure decisions, such as Clear Belt Time or Extra Discharge Run Belt Time
may be subsequently changed if desired.
Because the shuttle is a goods moving device (not a processing device), configuration is the only programming
procedure necessary or possible.

When To Reconfigure and What Configure Codes To Use—Reconfigure at installation and

Ë
any time a configure error occurs. Although certain codes are discretionary, most configure codes must
match those shown on the metal configure nameplate, unless optional equipment has been added to or re-
moved from the machine.

How Shuttle Photo-eyes Work—Several configure decisions require an understanding of shuttle photo-
Ë
eyes. Photo-eyes on Milnor® shuttles are always physically identified (e.g., on the electrical schematics) as “load
end” or “discharge end,” with respect to forward
loading and forward discharging. The “physical”
load-end photo-eye is always located on the receiv-
ing end of the belt for forward loading, and the
“physical” discharge-end photo-eye is always lo-
cated on the discharge end of the belt for forward
discharge (see FIGURE 1). If a shuttle must reverse-
load or reverse-discharge—i.e, run the belt in reverse
to receive goods from a device on what is normally
its discharge end, or discharge to a device on what is
normally its load end—the “physical” discharge-end
photo-eye will automatically function as the “logi-
cal” load-end photo-eye, and the “physical” load-end
photo-eye will automatically function as the “logi-
cal” discharge-end photo-eye.
Physical discharge-end photo-eyes are always
furnished. Physical load-end photo-eyes are only
supplied on shuttles two or more cakes long and on
reverse discharging shuttles.

ÎFIGURE 1 (MSOPD432CE)
ÎIdentifying Shuttle Photo-eyes

22
PROGRAMMING
THE MARK IV AND V SHUTTLE CONTROLLER MSOPD432CE/2003264 (4 of 21)

How Miltrac and Allied Interfaces Work—Several configure decisions require an understanding of
Ë
the two basic types of the shuttle interfaces: Miltrac and allied. A shuttle must communicate with both the device it
receives from and the one it discharges to when coordinating goods transfer and passing batch data. When all or
most devices in the system are Milnor® machines, the devices usually communicate electronically via a Miltrac
controller (older systems used the Milnet® network) which serves as a “traffic cop” for the entire system. However,
any non-Milnor® (allied) device must communicate with its neighboring devices electro-mechanically, via inputs
and outputs (allied interface). Shuttle inputs and outputs are described in “RUNNING THE MARK IV AND V
SHUTTLE IN AUTOMATIC SYSTEMS” (see Table of Contents). Two Milnor® machines in a non-Miltrac sys-
tem can also utilize an allied interface. Allied interfaces impose certain requirements as explained in this section.

How To Access the Configure Mode, Enter Data, and Exit

Ë
When the PROGRAM 1 MENU = NUMBER OF STORAGE This is the first configure decision.
display= CONFIGURE SHUTTLE BELTS ? 0
Silences operator alarm if desired.

<value> Enters the value for the current decision, where <value> is the one-, two-, or three-
digit number for the currently displayed decision. See “The Configure Decisions” in this
section.
Accepts the displayed value, and advances to the next decision.

, , , etc. Advances through each decision, retaining the previously entered value.
After advancing past the last configure decision, the display returns to the program menu.
When, and only when, the display= PROGRAM 0 MENU proceed as follows:
OK TURN KEY TO RUN

, If was not pressed, returns to the run mode.

PUSH STOP TO EXIT
If was pressed, display=
CONFIGURE
Returns to run mode from above display.

23
PROGRAMMING
THE MARK IV AND V SHUTTLE CONTROLLER MSOPD432CE/2003264 (5 of 21)

The Configure Decisions

Ê
Why the Sequence of Configure Decisions Will Vary—The following describes all possible
Ë
configure decisions and presents them in the most common order of appearance. Many configure decisions only
appear if certain values were entered in previous configure decisions, and a few configure decisions will appear in
a different order than shown here depending on the values entered in other decisions.
A NUMBER OF STORAGE 1-4 allowed Enter the total number of storage belts (number high multi-
BELTS 1 plied by number wide).
B NUMBER OF BELTS 1-2 allowed Enter 1 for a standard shuttle and 2 for a two-wide shuttle.
PER LEVEL 1 Valve cannot be greater than the Number of Storage Belts.
C NUMBER OF CAKES 1-4 allowed Enter the number of goods positions (cakes) on a belt.
PER BELT 1 If A is 1 or 2, then 1-4.
If A is 3 or 4, then only 1 is allowed.
Configure decision D appears only if A or C is greater than 1.
D IGNORE COMPATIBILITY 0-1 0=No, if the shuttle should wait until it is full of compatible
0=NO 1=YES 0 goods before leaving that loading station.
1=Yes, if the shuttle should return home and wait for second
cake from another device regardless of single cake or com-
patibility.
NOTE: The shuttle can be released from waiting for load
by configuring for Time Out Waiting For Load.

ËDecisions E and F: How and When To Release a Partially Loaded Cake Shuttle
(if Decision A or C is greater than 1)
Use the Miltrac system to release a par-
tially loaded multi-cake shuttle when the A: Number Of Storage Belts
Both=1 Either>1
next cake is not compatible with already C: Number Of Cakes Per Belt
loaded cake(s) (see Miltrac manual). Use E: Time Out Waiting For Load No Yes
Decisions E and F (regardless of compati-
bility) where early release will increase sys- F: Max Wait Time For 2nd Cake xx minutes
tem efficiency by reducing how often the For the combination of values for receives re- receives last cake
device(s) served by the shuttle are idle (e.g., Decisions A, C, E, and D shown above, a cake or ceives or xx minutes
the shuttle declares itself loaded (free to loose last after it receives
how often the tunnel must hold while wait- leave the loading position) when it . . . goods cake prior cake
ing to receive or discharge).

E TIME OUT WAITING FOR 0-1 0=No. Shuttle will wait until it is loaded with maxi-
LOAD 0=NO 1=YES 0 mum number of cakes.
1=Yes. Shuttle will declare itself loaded and desire to dis-
charge after F has expired. Miltrac “handshaking” may in-
fluence this decision. See the Miltrac manual.

24
PROGRAMMING
THE MARK IV AND V SHUTTLE CONTROLLER MSOPD432CE/2003264 (6 of 21)

Configure decision F only appears if E=1.

F MAX WAIT TIME MM 01-99 minutes Enter the maximum time (in minutes) the shuttle will be
FOR 2nd CAKE 01 allowed permitted to wait between the receipt of cakes, before de-
claring itself loaded.

Ë Decisions G, I, W, and X: Controlling Belt Run Time During Discharge

A combination of photo-eye input and the configure values for Decisions G, I, W, and X controls belt run time
during discharge. As the operating characteristics of the system become more evident, these values can be
fine-tuned to shorten discharge time and improve system efficiency. Decisions G, I, W, and X influence belt
run time as follows:
How Long Belt Runs or Stops
Number
of Runs Runs Stops Runs
Goods for Each Cake for Each Cake Between After Last
Positions (Forward Discharge) (Reverse Discharge) Cakes Cake

Loose Clear Belt Time or time to clear discharge- Reverse Discharge Run Belt Time or time to clear
goods end photo-eye*, whichever is longer discharge-end eye*, whichever is longer not
or + + applicable
one cake Extra Discharge Run Belt Time Extra Discharge Run Belt Time
Time (within Clear Belt Time) for this cake Time (within Clear Belt Time) for this cake to Time for
to block discharge-end photo-eye* block discharge eye* devices Extra
Two or + + to talk Discharge
more Time (within Disch Eye To Be Time (within Discharge Eye To Be and belt Run Belt
cakes Blocked=Error time) for this cake to clear Blocked=Error time) for this cake to clear eye* to elevate Time
eye* + (if
+ Time (within newly reset Clear Belt Time) for next applicable
Time (within newly reset Clear Belt Time) cake to block eye* )
for next cake to block eye*

G CLEAR BELT TIME (S) 01-99 seconds

01 allowed
Where time for discharge is not critical, command
sufficient time for the belt to make half of a complete
revolution. If necessary, shorten this time so that the
belt runs approximately as long as it would under
photo-eye control (see FIGURE 2). This time is also
used to initialize belts when the shuttle is first pow-
ered up.

ÎFIGURE 2 (MSOPD432CE)
ÎHow Belt Runs Under Photo-eye Control
During Discharge

25
PROGRAMMING
THE MARK IV AND V SHUTTLE CONTROLLER MSOPD432CE/2003264 (7 of 21)

Ë Decision H: Controlling the Pile of Goods on a Loose Goods Shuttle

This decision helps control how

goods pile up on the storage belt. En-
ter a longer delay time to cause a
larger pile at the discharge end of the
belt or a shorter delay time to cause a
larger pile at receiving end (see FIG-
URE 3).
ÎFIGURE 3 (MSOPD432CE)
ÎEffect of Delay Time Before Run Load Belt
on Pile of Goods

H DELAY TIME BEFORE 00-99 seconds Enter the delay time (in seconds) before running the belt to
RUN LOAD BELT (S) 00 allowed load.

I EXTRA DISCHARGE 00-20 seconds

RUN BELT TIME (S) 00 allowed
Allow both eyes blocked. This value may be
used in place of a longer Clear Belt Time to ensure
that a trail of loose goods following the cake or pile
completely discharges, even if not seen by the photo-
eye. Compare “Condition 1” and “Condition 2” in
FIGURE 4. Assigning a Clear Belt Time that runs the
belt for distance D accommodates the overall worst
case. However, a better approach is to assign a Clear
Belt Time yielding distance A and an Extra Discharge
Run Belt Time yielding distance C, as this provides
the same protection while reducing the overall Run
Belt Time for Condition 2 by distance E. NOTE: The
belt still runs for distance D when Condition 1 pre- ÎFIGURE 4 (MSOPD432CE)
Î ffect of Commanding
E
vails, since the photo-eye causes the belt to run for Extra Discharge Run Belt Time
distance B, and the Extra Discharge Time causes the
belt to continue running for distance C.

J YOU’RE FINISHED 0-1 0=No, if you do not want to receive this input.
RECEIVING INPUT 0 1=Yes, if you have a multi-cake shuttle receiving from an
extractor and the system requires this input to complete
the transfer.

26
PROGRAMMING
THE MARK IV AND V SHUTTLE CONTROLLER MSOPD432CE/2003264 (8 of 21)

Ë Decisions K and L: A: Number Of Storage Belts Any =1 >1

When To Allow C: Number Of Cakes Per Belt >1 =1
Both Photo-eyes Blocked K: Load End Eyes Yes* Yes No No*
As previously explained, physical dis- L: Allow Both Eyes Blocked Yes/No Yes/No
charge-end photo-eyes are always furnished, * K set to this value automatically. (see (see
but physical load-end photo-eyes are only on below) below)
long shuttles (two or more cakes long) and Do not
on reverse-discharging shuttles. Decision K allow
must agree with hardware. Decision L de- both eyes
pends on cake size. Allow both eyes blocked blocked
only if cake(s) or loose goods cannot physi- Allow
cally fit without blocking both eyes as both
shown at right. eyes
blocked

Configure decision K only appears if A=1 and C=1, but the control automatically inserts a value for K in any
other instance (see table above).
K LOAD END EYES 0-1 0=No, if shuttle does not have physical load-end photo-eye.
0=NO 1=YES 0 1=Yes, if shuttle is equipped with physical load-end photo-
eye.
Configure decision L only appears if K=1 or if K=1 automatically (see table above).
L ALLOW BOTH EYES 0-1 0=No. Do not allow both eyes blocked.
BLOCKED 0=NO 1=YES 0 1=Yes. Allow both eyes blocked.
M CO-SLIDE TYPE 0-1 Is this a Co-slide type shuttle? A Co-slide must load allied.
0=NO 1=YES 0 This may be manual or semi-automatic (relay logic) load-
ing (see next decision).
Configure decision N only appears if M=0.
N CO-LO-SLIDE TYPE 0-1 Is this a Co-lo-slide type shuttle? See explanation in “Deci-
0=NO 1=YES 0 sions M Through V . . .” in this section.
Configure decisions O and P only appear if N=1. For proper discharge, the extension belt must be running when
the storage belt starts and remain running after the storage belt stops. Determine the optimum time between exten-
sion belt start and storage belt start and between storage belt stop and extension belt stop through field trials.
O EXTEND BELT RUN 2-20 seconds For discharging, enter the time (in seconds) desired to run
BEFORE DISCH (S) 02 the extension belt before the storage belt starts running.
This time is added to Clear Belt Time (F).
P EXTEND BELT RUN 2-20 seconds For discharging, enter the time (in seconds) desired to run
AFTER DISCH (S) 02 the extension belt after the storage belt stops running.

27
PROGRAMMING
THE MARK IV AND V SHUTTLE CONTROLLER MSOPD432CE/2003264 (9 of 21)

Configure decision Q only appears if M=0, and N=0.

Q COSLIP TYPE 0-1 Is this a Coslip type shuttle? See explanation in “Deci-
0=NO 1=YES 0 sions M Through V . . .” in this section.

ÏDecisions M Through V: Special Purpose Loose Goods Shuttles

Decisions M through V enable various special loose goods applications. Each application requires specific
hardware capability, and some applications require a specific loading and/or discharge interface (Miltrac or al-
lied).
Features that Determine Configure Values Configure Decisions
Type of Hardware Type of Interface • Type names used in the configure decisions
are aliases; not actual model designations.

• In this table, type decisions are shown bold with

Miltrac subordinate decisions indented. No more than one
type applies.
or
• Selecting any shuttle type supresses further type
Allied decisions. A loose goods shuttle may have none of
the hardware features shown here, in which case
none of the types shown here apply (as shown
on the last line of the table).

Extend High Speed Extend 8" Loading Discharge • Only the subordinate decisions for the selected type
30" (762) Extension (203) to appear.
to Load Belt Discharge
see below M: Co-slide Type?

Yes No either Allied Miltrac T: SEMI-AUTO LOADING? (see NOTE 1)

U: SEMI-AUTO LOADING COMPLETED DELAY
Yes V: EXTEND BELT TO DIS?
Miltrac Miltrac N: Co-lo-slide Type? (see NOTE 2)
No Yes No or or
Allied Allied O: EXTEND BELT RUN BEFORE DISCH
P: EXTEND BELT RUN AFTER DISCH
No No Yes Miltrac Miltrac Q: Coslip Type?
or Allied or Allied
Miltrac R: Coflo Type?
Yes No Yes Miltrac or
Allied S: COFLO LOADING JOG ON TIME
S2: COFLO LOADING JOG OFF TIME
No No No Miltrac Miltrac A loose goods shuttle which can not be configured for
or Allied or Allied here.
NOTE 1: An example of semi-automatic loading is shown at right. This
application uses relay logic to automatically reverse load goods
from a de-stoning station back to the shuttle.
NOTE 2: Co-lo-slide has a storage (top) belt and an extension (bottom)
belt that extends and runs at high speed to eject the goods dropped
from the storage belt.

28
PROGRAMMING
THE MARK IV AND V SHUTTLE CONTROLLER MSOPD432CE/2003264 (10 of 21)

Configure decision R only appears if M=0, N=0, and Q=0.

R COFLO TYPE 0-1 Is this a Coflo type shuttle? See explanation in “Decisions M
0=NO 1=YES 0 Through V . . .” in this section.

Ë Configuring a loose goods shuttle to handle two cakes from an extractor B

1. Decision R (Coflo Type) must be set to 1 and Decision C (Number of Cakes per Belt) must be set to 2.
2. Decision J (You’re Finished Receiving Input) must be set to 1.
3. The Discharge Finished output (1MTA13-8 and 13-18) must be wired to the You’re Finished Receiving
input on the shuttle (1MTA38-4). If there is more than one extractor, the Discharge Finished outputs should
be wired in parallel to the input on the shuttle.
The shuttle will transfer the two loads to a dryer as one load. The data passed is the data from the second
cake except for weight which is added up for the two loads.

Configure decisions S and S2 only appear if R=1. To control the discharge of goods on the Coflo belt, the belt
will run intermittently during loading, starting, and stopping for the times specified in S and S2 below.
S COFLO LOADING JOG 00-250 tenths Enter the desired jog on time (in 10ths of a second) when
ON TIME (10ths) 000 of a second loading.
S2 COFLO LOADING JOG 00-250 tenths Enter the desired jog off time (in 10ths of a second) when
OFF TIME (10ths) 000 of a second loading.
Configure decision S3 and S4 only if M=1 and C>1
S3 MIDDLE EYE 0-1 0=No. The shuttle can take up to 4 cakes
0=NO 1=YES 0 1=Yes. The shuttle requires a middle eye and acts like the 2-
B
long Coflo (see “Operation of Specialized Shuttles,” see
Table of Contents).
S4 LOAD EYE CLEAR 00-250 tenths Enter the length of time (in 10ths of a second) the load eye
TIME (1/10 SEC) 000 of a second should be clear before the belt stops running. For the last
cake, the shuttle stops when the discharge eye blocks.
Configure decisions T and V only if M=1.
T SEMI-AUTO LOADING 0-1 0=No. Operator loads shuttle then signals “Loading Com-
0=NO 1=YES 0 pleted.” No tells the shuttle to get all loading information
from the 3rd and 4th 16/8 boards.
1=Yes. Shuttle loads automatically from allied belt. Yes
tells the shuttle to look for a 5th 16/8 board which con-
tains all the signals for semi-automatic loading.

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PROGRAMMING
THE MARK IV AND V SHUTTLE CONTROLLER MSOPD432CE/2003264 (11 of 21)

Configure decision U only appears if T=1. This decision accommodates different types of allied loading devices and
interfaces, which may signal “Loading Completed” before all goods have completely transferred to the shuttle.
U SEMI-AUTO LOADING SS 2-20 seconds Enter the required time (in seconds) to delay the “Load-
COMPLETED DELAY 02 ing Completed” signal from the shuttle.
V EXTEND BELT TO DIS ? 0-1 Does the shuttle belt extend to discharge?
0=NO 1=YES 0
Configure decision V2 only appears if C>2 and R=1. C
V2 BELT DOES NOT EXTEND 0-1 0=No. The belt should extend to load or discharge.
0=NO 1=YES 0 1=Yes. The belt should not extend to load or discharge.
Use this option to control a belt that takes more than 1
load of loose goods.
Configure decision W only appears if A=1 and C=1.
W REVERSE DISCHARGE 05-25 seconds Where time for discharge is not critical, command suffi-
RUN BELT TIME (S) 05 allowed cient time for the belt to make half of a complete revolu-
tion. If necessary, shorten this time so that the belt runs
approximately as long as it would under photo-eye con-
trol (see FIGURE 5).
Configure decision X only appears if C=2 or greater.
X DISCH EYE TO BE SS 04-15 seconds
BLOCKED=ERROR 04 allowed

Enter the maximum time (in seconds) the discharge eye can be blocked before an error is declared. Determine the
required time (see FIGURE 5).

The shuttle must count multiple cakes. If the photo-eye

stays blocked for this configured time, the shuttle assumes
that it cannot distinguish between the individual cakes (usu-
ally the result of cakes that have spread apart and are touch-
ing) and signals an error.

ÎFIGURE 5 (MSOPD432CE)
ÎDetermining Disch Eye To Be
Blocked=Error Time

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 PROGRAMMING
THE MARK IV AND V SHUTTLE CONTROLLER MSOPD432CE/2003264 (12 of 21)

Ë Decision Y: Controlling Cake Spacing

on a Long Cake Mover
(if Decision B is 2 or greater)
Multiple cakes on a belt must be spaced far enough
apart for reliable photo-eye input (see Disch Eye To Be
Blocked Error) and still accommodate the belt’s full cake ca-
pacity. This value is the time in tenths of a second for the belt
to run after a cake clears the load-end photo-eye, which de-
termines spacing between cakes (see FIGURE 6).
ÎFIGURE 6 (MSOPD432CE)
ÎEffect of Time After Trailing Edge In
Tenths on Cake Spacing

Y TIME AFTER TRAILING 02-99 tenths Enter time as explained above for each cake where [x] is
EDGE(x) IN 10ths 02 of a second cake number (up to four cakes).
Z ALLOW BOTH EYES 0-1 0=No. Do not allow both eyes blocked. Prompts an error
BLOCKED 0=NO 1=YES 0 message if both eyes are blocked.
1=Yes. Allow both eyes blocked.
C Z2 IGNORE EYE ERROR 3 0-1 0=No. Eye Error 3 appears when the discharge end eye
0=NO 1=YES 0 blocks and then clears while loading.
1=Yes. Eye Error 3 never appears.

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PROGRAMMING
THE MARK IV AND V SHUTTLE CONTROLLER MSOPD432CE/2003264 (13 of 21)

ËDecisions AA and BB: Determining the Number of Receive and Discharge Levels
The following table explains by example, how receive and discharge levels work.
Non-Elevating Shuttles Elevating Shuttles
Non-Elevating Shuttles have one receive Elevating shuttles have as many loading
and one discharge level, no matter how and discharge levels as any belt must align
many belts. Note that the belts and levels with. In example 6 below, any COSHA belt
are completely independent. Do not count must align with only one belt on the loading
belts on the shuttle to determine levels. device (COSAT) but each COSHA belt
must align with dryers on two levels.

AA NUMBER OF RECEIVE 1-4 levels Enter the number of different receive levels (as
LEVELS ? 1 explained above) the shuttle must go to.

BB NUMBER OF DISCHARGE 1-4 levels Enter the number of different discharge levels (as
LEVELS ? 1 explained above) the shuttle must go to.

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PROGRAMMING
THE MARK IV AND V SHUTTLE CONTROLLER MSOPD432CE/2003264 (14 of 21)

Ë Decisions CC and DD: Ë Decisions EE and FF: Determining if Belt(s)

Enabling the Shuttle Elevator Must Elevate To Load or Discharge
Decision CC must match the hard- (if Decision B is greater than 1)
ware. If the shuttle can elevate, the time If a multi-belt shuttle receives from or discharges to another
required to move the shuttle belt(s) from shuttle with the same number of belts, cakes will normally transfer
full down to full up (see FIGURE 7) must across matching belts (see FIGURE 8). Thus, the shuttle need not
be determined by field trials and entered elevate to transfer the second or higher cakes. When the shuttle
in Decision DD. Use this time when the receives from or discharges to any other device, it must elevate
shuttle is first powered up and is testing between cake transfers.
the maximum and minimum of its elevat-
ing range. If it cannot test these points in
the time entered here, an error will occur.

Î IGURE 7 (MSOPD432CE)
F ÎFIGURE 8 (MSOPD432CE)
ÎTiming Vertical Travel ÎWhen Belts Must Elevate To Load/Discharge

CC ELEVATOR INSTALLED 0-1 0=No, if the shuttle cannot elevate.

0=NO 1=YES 1 1=Yes, if the shuttle can elevate.
Configure decision DD only appears if CC=1.
DD TIME TO REACH 5-99 seconds Enter the time in seconds required to raise the shuttle belt(s)
BOTTOM-TOP (SS) 05 (see FIGURE 7). The controller doubles this time to accomo-
date up and down movement.
Configure decisions EE and FF only appear if A is greater than 1 and CC=1.
EE 2ND BELT ELEVATE TO 0-1 0=No. Do not elevate 2nd or higher belts to receive a cake.
LOAD 0=NO 1=YES 0 1=Yes. 2nd or higher belts must elevate to receive a cake.
FF 2ND BELT ELEVATE TO 0-1 0=No. Do not elevate 2nd or higher belts to discharge a cake.
DISCH 0=NO 1=YES 0 1=Yes. 2nd or higher belts must elevate to discharge a cake.

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PROGRAMMING
THE MARK IV AND V SHUTTLE CONTROLLER MSOPD432CE/2003264 (15 of 21)

Ë Decision GG: Checking for Peripheral Failure

As a permanent setting, always set this decision to 1 (Yes). Only set to 0 (No) temporarily, if requested by
the Milnor® factory, during troubleshooting.

GG CHECK FOR PERIPHERAL 0-1 0=No. Do not check for malfunctioning boards.
FAILURE 0=NO 1=YES 0 1=Yes. Check for malfunctioning boards.

Ë Decisions HH through MM: Accommodating Allied Loading

• Decision HH—This decision specifies allied loading (must match the hardware). If HH=1, then Decisions
JJ, KK, LL, and MM appear (permitting the shuttle to accommodate pecularities of various allied control-
lers) as follows:
• Decisions JJ and KK—If the allied device tells the shuttle to accept a load when in fact there is none, a
time limit must be imposed to stop the belt if the discharge-end eye is not blocked when the useful load-
ing time has expired. Decisions JJ and KK provide for such a time limit. This only applies to one-long
(accomodate one cake, lengthwise) shuttles, because they use this signal to start the belt. Two-long or
longer cake shuttles use the load-end photo-eye to start the belt and are not affected.
• Decision LL—This decision provides for delaying the loading completed input from the shuttle to the allied
device, in case the allied controller would otherwise receive the loading completed input signal from the
shuttle too early to properly respond or before all goods have transferred.
• Decision MM—With allied loading, data that controls the permissible combinations of cakes on a multi-
cake shuttle are unavailable from Miltrac, so Decision MM provides for specifying which batch codes
(formula, dry code, destination, customer, and goods code), if any, must match the first cake when addi-
tional cakes are being loaded.
C
Configure decision HH does not appear if M=1, instead, the control automatically makes HH=1 in this instance.
HH ALLIED LOADING 0-1 0=No. If shuttle loads via the Miltrac system.
0=NO 1=YES 0 1=Yes. If shuttle loads from allied device.

Configure decision JJ only appears if HH=1 and C=1. However, it will not appear if M=1 and T=0.
JJ LIMIT LOAD RUN BELT 0-1 0=No. No time limit when loading.
TIME 0=NO 1=YES 0 1=Yes. Turn off belt after X seconds if a cake has not
been identified, where “X” is the time entered in deci-
sion KK below.

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PROGRAMMING
THE MARK IV AND V SHUTTLE CONTROLLER MSOPD432CE/2003264 (16 of 21)

Configure decision KK only appears if JJ=1.

KK MAX TIME TO RUN BELT 20-99 seconds Enter maximum time (in seconds) allowed to run belt before
FOR LOADING (SS) 08 the shuttle controller declares no cake. If time runs out and
cake still does not block discharge-end eye, the shuttle will
initialize and go to Home position.
Configure decision LL only appears if HH=1.
LL ALLIED LOADING SS 00-10 seconds Enter the time desired (in seconds) to delay the loading com-
COMPLETED DELAY 00 pleted signal from the shuttle to the allied device.
Configure decision MM only appears if HH=1, and B and/or C are greater than 1.
MM COMPATIBILITY FDDCG 0-1 (each) Enter the compatibility code desired for each type of
0=N/A 1=MATCH 00000 data (0=match not required, 1=match required).
F=Formula
D=Dry Code
D=Destination code
C=Customer code
G=Goods code

Ë Decision NN: Applying the Single Cake Code on a Multi-Cake Shuttle

Decision NN specifies whether a “single cake” code issued by the loading device (which tells the shuttle to
declare itself loaded when it receives the first cake) should be ignored. The single cake signal is usually only
pertinent when processing (e.g., drying). The integrity of this data is preserved and passed to the receiving device
even if the shuttle is configured to ignore this signal. Thus, if the shuttle receives two or more cakes, the first of
which has the single cake code assigned, it will pass only the first cake to the dryer, along with the appropriate
codes (including the single cake attribute). Generally, the system will function more efficiently if the shuttle
ignores the single cake signal.

Configure decision NN only appears if HH=1, B and/or C are greater than 1.

NN DISARMED SINGLE 0-1 0=No, if single cake decision is required at the shuttle.
CAKE 0=NO 1=YES 0 1=Yes, if it is desired to ignore single cake.

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THE MARK IV AND V SHUTTLE CONTROLLER MSOPD432CE/2003264 (17 of 21)

Ë Decisions OO and PP: Configuring Reverse Loading Conditions

(if Decision HH=0)
Depending on the physical layout of the system, a shuttle may have to receive from a device on what is
normally its discharge end (shuttle runs its own belt in reverse) or receive from what is normally the load end of
its loading device (loading device runs its belt in reverse). With the Miltrac system (or older Milnet® network)
loading, the shuttle can be configured to handle these conditions automatically. If the shuttle must run its own
belt in reverse to load, the loading device tells the shuttle which direction to run its belt (Decision OO: Enable
Reverse Loading). If the loading device must run its belt in reverse to load the shuttle, the shuttle tells the loading
device which direction to run its belt (Decision PP: Milnet Reverse Loading).
To properly utilize these features, understand that all devices (even cake shuttles, which look almost the
same on either end) have a physical load end (front) and a physical discharge end (rear). Normal belt direction is
always from front to rear of the device. Reverse loading comes into play only when a belt on any device must
run in reverse (opposite its normal direction) to load the shuttle.

NOTE: See next page for explanation of FIGURE 9.

ÎFIGURE 9 (MSOPD432CE)
ÎTypical Application of Decision OO: Enable Reverse Loading

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PROGRAMMING
THE MARK IV AND V SHUTTLE CONTROLLER MSOPD432CE/2003264 (18 of 21)

OO ENABLE REVERSE 0-1 0=No. Do not enable reverse loading. The shuttle will
LOADING 0=NO 1=YES 0 run its belts forward during loading regardless of
what Miltrac tells it to do.
1=Yes. Enable reverse loading. The loading device tells
shuttle which way to run its belts via Miltrac.
In FIGURE 9, devices A, E, and F are processing devices that can only move goods in one direction. De-
vices A and E (both presses) are configured to tell their receiving devices which direction to run the belts
while loading. Device A specifies forward and device E specifies reverse. Devices B, C, and D are all
shuttles. Devices B and D always run their belts forward and device C (Cosha) runs its belt forward when
receiving from device B, but must run in reverse when receiving from device D. Set Enable Reverse Load-
ing to 1 (Yes) in device C so it runs its belts as directed by device B or D when receiving. Set Enable Re-
verse Loading to 0 (No) in device D (Coelf) so it ignores the instruction from device E to load reverse,
and merely passes this instruction to device C. Since device A tells device B (Coelf) to load forward, the
Enable Reverse Loading decision in device B has no effect.

PP MILNET REVERSE 0-1 0=No. Do not use Milnet® reverse loading. Loading
LOADING 0=NO 1=YES 0 device runs its belt forward, regardless of what the
Miltrac controller tells it to do.
1=Yes. Use Milnet® reverse loading. Via the Miltrac sys-
tem, the shuttle tells its loading device which way it
should run its belt in order to transfer goods to the
shuttle.
Cosha-A receives goods from Cosha-B (see FIGURE
10). But to do so, Cosha-B must run its belt in reverse.
Enable Milnet® reverse loading in Cosha-A, to cause
Cosha-A to control Cosha-B’s belt direction when trans-
ferring goods from B to A. The need for Milnet® reverse
loading in Cosha-B depends on how it is loaded, which
is not shown in this example.

ÎFIGURE 10 (MSOPD432CE)
ÎTypical Application of Decision PP:
Milnet Reverse Loading

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PROGRAMMING
THE MARK IV AND V SHUTTLE CONTROLLER MSOPD432CE/2003264 (19 of 21)

Ë Decisions QQ, RR, and SS: Accommodating Special Discharging Conditions

• Decision QQ—Specifies allied discharging (must match the hardware). If the shuttle discharges to a Miltrac
device, not allied, then Decisions RR and SS appear.
• Decision RR—Should the unload (receiving device) wait until full? This is only pertinent when the shuttle
loads a device (e.g., dryer) with a larger capacity than that of the shuttle. Decision RR provides for either
1) releasing the partially loaded receiving device (e.g., dryer starts processing) after the shuttle has fully
discharged its current load or 2) holding the receiving device until the shuttle gets another load, thereby
fully loading the receiving device. The most efficient choice will depend on the needs of the specific sys-
tem.
• Decision SS—Should the shuttle wait for the Miltrac “start” command before moving to the receiving de-
vice? This decision is hardware-dependent. When a shuttle in one Miltrac system must discharge to a de-
vice in another Miltrac system (a linkmaster application), then the shuttle must wait for the “start”
command for the system to function properly. However, in non-Linkmaster applications, the shuttle
should not wait for “start,” but should be permitted to begin moving on the Miltrac “get ready” command.

QQ ALLIED DISCHARGE 0-1 0=No. Shuttle discharges via a Miltrac device.

0=NO 1=YES 0 1=Yes. Shuttle discharges to an allied device.

Configure decisions RR and S only if QQ=0.

RR HOLD UNLD DEVICE TIL 0-1 0=No. It is not required to hold the unload device after the
FULL 0=NO 1=YES 0 shuttle discharges the first load.
1=Yes. Hold the unload device until it is full.
SS WAIT FOR START 0-1 0=No. Shuttle can start moving when the Miltrac system
BEFORE MOVING 0 gives “get ready” command (no Linkmaster).
1=Yes. Shuttle must wait for the Miltrac “start” command
before moving (Linkmaster).

Ë Decision TT: Restricting Shuttle Movement

By default, the shuttle bed can traverse (move left/right) and elevate (move up/down) simultaneously (thus,
move diagonally) to minimize travel time between the loading and receiving devices. With decision UU, the
shuttle can be restricted to traversing only at receive-level zero. This is normally required only if in its diagonal
movement, the shuttle bed might collide with an object in its path.

Configure decision TT only appears if CC=1 (Elevator Installed?=1).

TT ALWAYS TRAVERSE 0-1 0=No. It is OK for the shuttle bed to move diagonally.
LOW 0=NO 1=YES 0 1=Yes. Shuttle is only permitted to traverse at receive
level zero.

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PROGRAMMING
THE MARK IV AND V SHUTTLE CONTROLLER MSOPD432CE/2003264 (20 of 21)

UU ALWAYS RETURN HOME 0-1 0=No. Shuttle travels to load/discharge station, loads/dis-
0=NO 1=YES 0 charges goods, waits for discharge/load command from
Miltrac then moves to next device. The shuttle returns
Home at power-up, error, or return from manual. This
option requires Miltrac 89101 or later.
1=Yes. Shuttle travels to load/discharge station, loads/dis-
charges goods, then returns Home to reorient itself.

Ë Decisions VV Through XX: Facilitating Communication

These decisions facilitate communication between the shuttle and other controllers/devices. If the shuttle
receives from and discharges to allied devices (non-Miltrac), Decisions VV, WW, and YY are meaningless and can
remain at their current values. Decision ZZ is meaningful only for Mildata® systems.

VV GOODS UNIT 0-1 Enter the appropriate unit of quantity (0=Weight or

0=WEIGHT 1=PIECES 0 1=Pieces) to be displayed when the control prompts for
cake data (occurs when the shuttle is powered up with
goods on it). The quantity unit is not passed to other de-
vices, but the quantity value for each batch is passed. Thus
the same goods unit must be used in all devices in the Mil-
trac system.

WW OUTPUT FLAG WHEN 0-1

EMPTY 0=NO 1=YES 0

0=No. Declared empty output not required.

1=Yes. Declared empty output required.
Decision WW supports a special circuit that aug-
ments Miltrac communication in certain systems
such as that shown in FIGURE 11. The circuit
prevents the Costa from issuing a “desire to dis-
charge” command merely because it has a cake.
This circuit only allows the Costa to issue this
command when 1) the press does not desire to dis-
charge, 2) the Cosha is empty, and 3) a dryer de-
sires a load. In this example, the Cosha must have
Output Flag When Empty enabled to provide the
“shuttle is empty” signal. This output requires a
sixth 8/16 board.

ÎFIGURE 11 (MSOPD432CE)
ÎTypical Application of Decision WW:
Output Flag When Empty

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PROGRAMMING
THE MARK IV AND V SHUTTLE CONTROLLER MSOPD432CE/2003264 (21 of 21)

XX FINISHED UNLOADING 0-1 Software version 88108 or later only

OUTPUT 0=NO 1=YES 0 0=No.
1=Yes. Allows the shuttle to inform the receiving device
that the shuttle is empty and the transfer was
completed. This output requires input/output 3.
YY MILTRAC ADDRESS 000-255 Enter the Miltrac address for the shuttle (see Miltrac
000 manual).
YYY NUMBER OF BYTES IN 00, 11, 24, 30 00=Miltrac system version 89100 or later
NETWORK STRING 00 11=Milnet
24=Miltrac system version 8624 and earlier
30=Miltrac system version 89001 and earlier
ZZ MILDATA ADDRESS 000-255 Enter the Mildata® address for the shuttle (see Mildata®
000 manual).
** LANGUAGE 0-4 Software version 88108 or later only
0 0=English
1=French
2=Dutch
3=Spanish NOTE: All languages are available in
4=Italian the same software.
See “How To Access the Configure Mode, Enter Data, and Exit” in this section for displays when exiting
configure.

2=Clear All Memory (Voluntarily)

Ê
When the PROGRAM 2 MENU = "SKIP" FOR NO CHANGE No cursor appears.
display= CLEAR ALL MEMORY "4+5+6" TO CLEAR
Exits this program without PROGRAM 0 MENU
clearing memory. Display= OK TURN KEY TO RUN

+ + Clears all memory. CLEARING MEMORY then PROGRAM 0 MENU

Configure codes are **PLEASE WAIT** OK TURN KEY TO RUN
cleared voluntarily.

40
 Operating 2

41
 MSOPD440CE/9705BV (1 of 15)

È UNNING THE MARK IV AND V SHUTTLE

R
IN AUTOMATIC SYSTEMS

CRUSH HAZARD—Moving shuttles and shuttle mechanisms will strike or crush

anyone in the shuttle path.
☞ Do not operate the shuttle without owner/user furnished fencing to enclose
shuttle path per the guidelines posted on the shuttle.
☞ Never enter the path of a shuttle or its mechanisms unless power to the shuttle is locked
off and tagged out at wall disconnect.
☞ Know how to use all factory-supplied shuttle safety devices including emergency stop
switches, pull cords, and kickplates.
☞ Be sure all personnel are clear of the shuttle path and mechanisms before operating the
shuttle in manual or automatic mode. Shuttle may move automatically when is
pressed, any time cake data is entered, or any time the Manual/Automatic switch is set
to automatic.

Normal Automatic Operation

Ê
The normal operating mode of most shuttles is fully automatic. Once the Manual/Automatic switch on the
shuttle is set to automatic, a new batch (and its batch codes) passes from the loading device (e.g., the Milnor® press)
to the shuttle each time the loading device discharges, until the shuttle is declared fully loaded. The loaded shuttle
will then wait to transfer the batch(es) and the associated codes to a dryer or other post-wash device.
NOTE: Depending on batch codes and shuttle configuration, the shuttle may be declared fully loaded be-
fore its physical capacity is met (e.g., a 2x2 shuttle may be fully loaded with only one cake).

The Power Up Sequence

Ë
Master Energizes control power, but not COPYRIGHT PELLERIN Copyright statement (ap-
switch on shutle power. The operator alarm MILNOR 1990 pears one or more times dur-
sounds, and the power up displays ing sequence)
appear, as shown at right.
ALL RIGHTS RESERVED Number at lower right is soft-
’COSHA’ 8800G ware date code.
The display then prompts THREE WIRE DISABLED
PUSH START TO GO

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RUNNING THE MARK IV AND V SHUTTLE
IN AUTOMATIC SYSTEMS MSOPD440CE/9705BV (2 of 15)

Energizes shuttle power and silences RETRACTING BELT

the operator alarm. The shuttle retracts
bed (if equipped and not retracted) and
tests for maximum up and down time (if
elevating s RETRACTING BELT INITIALIZATION IN
PROGRESS
When Entering Cake Data Is Not Required
If no photo-eye detects goods, the shuttle RETURNING HOME
returns to the Home position and it
waits for a load.
If goods are detected, and the controller WAITING TO DISCHARGE Where b is belt number and p
can verify the data via checksum, the BELT b-p is goods position (see FIG-
shuttle returns to Home, the display= URE 1).
Home is the position along the shuttle path that the shuttle seeks after power up or recovery from an error con-
dition. At the Home position, the shuttle reorients itself (verifies its position). Home is usually either directly in
front of the primary loading device or at a location central to all loading devices.
When Entering Cake Data Is Required
If goods are detected and the controller DOES POSITION p HAVEFor each goods position,
cannot verify cake data via checksum A CAKE? 0=NO 1=YES 1where p=goods position (see
(see “PROGRAMMING THE MARK II, FIGURE 1). Default=1(yes).
III, IV, AND V SHUTTLE CONTROL- WAITING FOR LOADING If yes, see “When Cake Data
LER” (see Table of Contents)), the DEVICE TO GET READY Must Be Confirmed” in this
controller prompts section. If no, operation con-
tinues as shown below.
After cake data is entered (0 or 1), if the RETRACTING BELT Appears until the belt is fully
shuttle has not fully retracted, display= retracted (if equipped).
If the belt is fully retracted, but the shuttle RETURNING HOME Appears until the shuttle finds
is not at Home position, display= the Home position.
When the shuttle is Home, and cake WAITING TO DISCHARGE Where b is belt number and p
data has been entered, display= BELT b-p is goods position (see FIGURE
1).
or If the shuttle was told that no goods are WAITING FOR LOADING
on the belt, display= DEVICE TO GET READY

Belts and Goods Positions—The controller may ask

Ë *1-3 where
about or reference any one of the goods positions (e.g., Waiting 0—1 0—0 1=belt (b) number
and 3=goods
To Discharge Belt b-p), so it is important to understand the goods BELT 0 position (p)

position numbering sequence. A shuttle may have as many as four

storage belts (b), numbered 0 through 3, starting from the topmost LOAD 1—3* 1—2 DISCHARGE
END BELT 1 END
belt. The shuttle may have up to eight goods positions (p), num-
bered 0 through 7 from the discharge end to the load end and top-
most belt to bottommost belt as in FIGURE 1. On two-wide ÎFIGURE 1 (MSOPD440CE)
shuttles, the belt on the right (when viewed from the load end) is ÎBelt and Position Numbering
Belt 0 and the left belt is Belt 1.

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RUNNING THE MARK IV AND V SHUTTLE
IN AUTOMATIC SYSTEMS MSOPD440CE/9705BV (3 of 15)

The Displays During Normal Operation

Ë
NOTE: Traversing shuttles orient themselves using three types of targets on the shuttle rail: Home, Oops,
and Device. The shuttle seeks the fixed Home target whenever it is powered up or recovers from an error.
The shuttle uses this target to determine which devices are to the right or left of it, so it moves in the correct
direction when a device requires service. The shuttle may seek home when it finishes loading and receiving
if it is so configured (see Always Return Home in “PROGRAMMING THE MARK II, III, IV, AND V
SHUTTLE . . .”) The Oops targets are fixed targets mounted at each end of the rail. These targets indicate
that the shuttle has traversed too far right or left. The Device target is a normally retracted target that extends
downward on command. The target is controlled by the device requiring service which stops the shuttle at
the appropriate device. This device extends the target only after the shuttle has begun moving.

LOAD OPERATION
At Home—While the shuttle is idle WAITING FOR LOADING
and waiting to be loaded, display= DEVICE TO GET READY
Preparing To Load—When the
Miltrac system requests “get ready”
or when the shuttle closes the load
allowed output to tell an allied
discharging device to get ready to FINDING LOAD Appears if position is not the Home
discharge, display= STATION AND LEVEL position.

EXTENDING BELT Appears while shuttle is extending the bed

to load (if equipped).

WAITING FOR LOAD Appears when the shuttle has found the
BELT b-p correct load station and level, and the bed
is in position to accept goods. b-p
indicates which belt and position goods
will be loaded onto (see FIGURE 1).

Loading—If the belt is not equipped LOADING BELT b-p Appears when the load-end photo-eye de-
with load-end eyes, the belt will begin tects goods (if equipped) or the Miltrac
running when Loading Belt b-p controller tells the shuttle that the loading
is displayed. If the shuttle has load-end device is loading goods onto it. b-p indi-
eyes, the belt will not run until the cates which belt and position goods are
photo-eye is blocked and will only stop being loaded onto.
when the photo-eye is clear for trailing
edge time. See “PROGRAMMING LOADING BELT b-p Loading is complete for this belt. b-p ind-
THE MARK II, III, IV, AND V COMPLETE icates which belt and position goods were
SHUTTLE CONTROLLER.” loaded onto.

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RUNNING THE MARK IV AND V SHUTTLE
IN AUTOMATIC SYSTEMS MSOPD440CE/9705BV (4 of 15)

Returning to the Home position— RETRACTING BELT After loading, the shuttle retracts its belt
The shuttle will return Home if it is (if equipped).
configured to Always Return Home
(see Decision UU in “PROGRAM- RETURNING TO LOAD The shuttle moves up and down until it
MING THE MARK II, III, IV, AND LEVEL 0 finds level 0.
V . . .”). If it is not configured to Always
Return Home, the shuttle will retract RETURNING HOME The shuttle returns to the Home position
its belt and wait to load another cake to reorient itself along the shuttle rail.
or discharge as instructed by the system WAITING TO The shuttle has declared itself loaded
controller. and is waiting to be allowed to dis-
DISCHARGE
charge.

DISCHARGE OPERATION
Preparing to discharge—When the Mil-
trac controller requests “get ready”
or when the shuttle closes the load
allowed output to tell an allied load- FINDING DISCHARGE The shuttle has been allowed to dis-
ing device to get ready to load, display= STATION AND LEVEL charge and is now searching for the dis-
charge station and the discharge level.
EXTENDING BELT Appears while shuttle is extending the
bed (if equipped) toward the receiving
device.
Discharging load UNLOADING BELT b-p b-p indicates which belt and position
goods are being unloaded from.
UNLOADING BELT b-p The discharge photo-eye has cleared
COMPLETE and unloading is complete for this belt.
b-p indicates which belt and position
goods were loaded onto.
Returning to the Home position— RETRACTING BELT After unloading, the shuttle retracts its
The shuttle will return Home if it is belt (if equipped).
configured to Always Return Home
(see Decision UU in “PROGRAM- RETURNING TO LOAD The shuttle moves up and down until
MING THE MARK II, III, IV, AND LEVEL 0 it finds level 0.
V . . .”). If it is not configured to Always
Return Home, the shuttle will retract RETURNING HOME The shuttle returns to the Home
its belt and wait to load another cake postion to reorient itself along the
or discharge as instructed by the system shuttle rail.
controller.
When the shuttle is idle and ready to be WAITING FOR LOADING
loaded again, display= DEVICE TO GET READY

NOTE: See “OPERATION OF SPECIALIZED SHUTTLES” for more specific operation information
about two-wide shuttles, two-long Coflos, or two-high Coflos/Coslips.

45
RUNNING THE MARK IV AND V SHUTTLE
IN AUTOMATIC SYSTEMS MSOPD440CE/9705BV (5 of 15)

Interruptions in Normal Shuttle Operation

Ê
Holds Ahead of the Shuttle—Anytime the flow of goods onto the shuttle stops (as might be caused by a
Ë
hold condition in the extractor), the shuttle remains at Waiting For Load. When the flow of goods resumes, the
shuttle resumes operation without manual intervention.

Holds Behind the Shuttle—Anytime the shuttle desires to discharge but cannot because the receiving de-
Ë
vice (e.g., dryer) is not ready, the shuttle waits and displays Waiting To Discharge. As soon as the receiving device
is available, the transfer occurs, and normal operation resumes without manual intervention.

Power Loss or Three-Wire Disabled Condition—If the shuttle loses power or the three-wire circuit
Ë
drops out (as will occur if an emergency stop switch is pressed), the shuttle stops immediately. The shuttle resumes
operation, as explained in “The Power Restoration Sequences” in this section, as soon as the power or three-wire
circuit connection is restored, regardless of how long the shuttle was stopped. See NOTE below.

NOTE: It is not usually necessary to load or unload the shuttle before returning it on-line with the
controller. Upon restoring power, the shuttle initializes and resumes normal automatic operation. It
automatically synchronizes with its interfacing devices (e.g., extractor, dryer), providing the shuttle
was not in the middle of loading or receiving goods at power loss. See “The Power Restoration Se-
quences” in this section.

The Power Restoration Sequences

Ê
The intervention required to return the shuttle on-line depends on which of the following conditions occurred:
• Power was lost other than during transfer.
• Power was lost during transfer.
• Three wire was disabled without power loss other than during transfer.
• Three wire was disabled without power loss during transfer.

If Power Was Lost Other Than During Transfer

Ë
Master switch on Energizes control power, but THREE WIRE DISABLED
(or power restored) not shuttle power. The power up PUSH START TO GO
display sequence appears, and the
operator alarm sounds, display=
Energizes shuttle power by clos- INITIALIZATION IN
ing the three-wire circuit, and PROGRESS
silences the operator alarm.
The remaining power up displays appear, and the shuttle resumes normal operation. See “The Power Up Se-
quence” in this section.

46
RUNNING THE MARK IV AND V SHUTTLE
IN AUTOMATIC SYSTEMS MSOPD440CE/9705BV (6 of 15)

If Power Was Lost During Transfer—In the unlikely event that a transfer was in progress when power
Ë
was lost, and goods remain both partially on the shuttle and partially in the loading or receiving device, the following
procedure ensures that all goods are transferred to either the shuttle or the loading or receiving device.
Master switch on Energizes control power, but not THREE WIRE DISABLED
(or power restored) shuttle power. The power up dis- PUSH START TO GO
play sequence appears, and the
operator alarm sounds. Display=
Upon viewing this display, continue recovery by seeing “If Three-Wire Is Disabled (Without Power Loss) During
Transfer” in this section and following steps two through seven.

If Three-Wire Is Disabled (Without Power Loss) Other Than During Transfer—If the
Ë
shuttle was not transferring when an error disabled the three-wire circuit, proceed as follows:
When display= THREE WIRE DISABLED
PUSH START TO GO

CRUSHING AND ENTANGLEMENT HAZARDS—Moving shuttles and shuttle

mechanisms will strike or crush anyone in the shuttle path.
☞ Be sure all personnel are clear of the shuttle path and mechanisms before
operating the shuttle in manual or automatic mode. Shuttle may move auto-
matically when it is pressed, any time cake data is entered, or any time the
Manual/Automatic switch is set to automatic.
Energizes shuttle power, and INITIALIZATION IN
silences the alarm. Display= PROGRESS
The remaining power up displays appear, and the shuttle resumes normal operation. See “The Power Up Se-
quence” in this section.

47
RUNNING THE MARK IV AND V SHUTTLE
IN AUTOMATIC SYSTEMS MSOPD440CE/9705BV (7 of 15)

If Three Wire Is Disabled (Without Power Loss) During Transfer—In the unlikely event that
Ë
a transfer was in progress when the three-wire circuit was disabled, and goods remain both partially on the shuttle
and partially in the loading or receiving device, the following procedure ensures that all goods are transferred to
either the shuttle or the loading or receiving device.

Goods extending past the end of a shuttle belt after a power loss or three-wire disabled
condition can catch on machinery during shuttle movement, causing damage to goods or
machinery. These goods must be moved either onto the shuttle or into the transferring
device before the shuttle is permitted to move automatically.
1. Correct the malfunction that caused the three-wire disabled condition.
2. Set the Manual/Automatic switch on the shuttle to manual.
3. Press at the shuttle controller to enable the three-wire circuit.

CRUSHING AND ENTANGLEMENT HAZARDS—Moving shuttles and shuttle

mechanisms will strike or crush anyone in the shuttle path.
☞ Always operate the shuttle carefully in manual mode. The operator has total
control of shuttle movement immediately after the Manual/Automatic switch
is set to manual.
4. Using the manual controls (switches) on the shuttle, move the goods either completely onto the shuttle or com-
pletely into the transferring device, ensuring that any goods on the shuttle are not hanging over the edge of
the belt where they can catch on machinery. See “MANUALLY OPERATING . . .”
5. Press the nearest and release it. This disables the three-wire circuit, preventing the shuttle from moving
automatically, even after returning to automatic mode, until is pushed.
6. Set the Manual/Automatic switch on the shuttle back to automatic.

CRUSH HAZARD—Moving shuttles and shuttle mechanisms will strike or crush

anyone in the shuttle path.
☞ Be sure all personnel are clear of the shuttle path and mechanisms before
operating the shuttle in manual or automatic mode. Shuttle may move auto-
matically when it is pressed, any time cake data is entered, or any time the
Manual/Automatic switch is set to automatic.
7. Press at the shuttle controller, and the shuttle resumes normal operation.

48
RUNNING THE MARK IV AND V SHUTTLE
IN AUTOMATIC SYSTEMS MSOPD440CE/9705BV (8 of 15)

When Cake Data Must Be Confirmed

Ê
When normal operation resumes following a power loss, morning start up, any error (see “MARK II, III, IV,
AND V SHUTTLE ERROR MESSAGES”), or manual intervention, the controller runs the belt(s) (i.e., initializes)
to determine if any goods are on the belt. If the photo-eye detects goods (i.e., the photo-eye is blocked), the control-
ler prompts the user for certain information, as explained below.

CRUSHING AND ENTANGLEMENT HAZARDS—Moving shuttles and shuttle

mechanisms will strike or crush anyone in the shuttle path.
☞ Be sure all personnel are clear of the shuttle path and mechanisms before
operating the shuttle in manual or automatic mode. Shuttle may move auto-
matically when it is pressed, any time cake data is entered, or any time the
Manual/Automatic keyswitch is set to automatic.

Responding to Prompts for Shuttle Cake Information

Ë
To verify its photo-eye has truly detected goods, the DOES POSITION p HAVE Where p indicates posi-
control prompts A CAKE? 0=NO 1=YES 1 tion. Default=1(Yes).
See NOTE below and
FIGURE 1.
(No) Tells the controller that WAITING FOR LOADING If all goods positions are
, there are no goods for this DEVICE TO GET READY answered No (see NOTE
position. below), then the shuttle is
ready to be loaded.
or
(Yes) Tells the controller that ENTER FORMULA Where XXX is the wash
, or
goods are still on the shuttle FOR POSITION 0 XXX formula. Change number if
and prompts necessary.
Accepts the displayed formula number, and the controller prompts for confirmation of ad-
ditional information: dry code, destination, customer, goods code, weight (or pieces, as deter-
mined by configure), cake number.
When all cake data is entered, the normal power up sequence resumes.

NOTE: If the shuttle has more than one goods position per belt or more than one belt (or both), the
controller prompts for batch codes for each goods position on every belt where goods have been de-
tected. See FIGURE 1 to identify goods positions.

49
RUNNING THE MARK IV AND V SHUTTLE
IN AUTOMATIC SYSTEMS MSOPD440CE/9705BV (9 of 15)

Viewing Data on the Microprocessor Display During Operation

Ê
Cake data (batch codes), inputs, outputs, and Miltrac commands can be viewed while the shuttle is operating
(i.e., the three wire is enabled). All this data is useful for troubleshooting, but cake information is also useful for
determining the status of individual batches.

Ë How To Access, Scroll, and Exit the Data Menu

When display= WAITING FOR LOADING
DEVICE TO GET READY
Displays one of the four types of data each time it is pressed, or scrolls through all menu
choices if held depressed. Pressing , with Miltrac commands displayed, returns to the
normal run display.

Viewing Cake Information

Ë
Hold until
CAKE FM DC DS CC GC
this display appears,
then release. XX XX XX XX XXX XX Goods Code
Constantly (every two seconds)
scrolls through all cake posi- Customer Code
tions (regardless if cake is there
or not) to show associated cake Destination
information. The first position Dry Code
starts at the load end of belt 0
and progresses. Formula

Example 1 1 long 1 wide 2 high shuttle

Cake 00=Position 0 Belt 0
Cake 01=Position 1 Belt 1
Example 2 2 long 1 wide 2 high shuttle
Cake 00=Position 0 Load end Belt 0
Cake 01=Position 1 Discharge end Belt 0
Cake 02=Position 2 Load end Belt 1
Cake 03=Position 3 Discharge end Belt 1

50
RUNNING THE MARK IV AND V SHUTTLE
IN AUTOMATIC SYSTEMS MSOPD440CE/9705BV (10 of 15)

Viewing Inputs
Ë
until Displays 1st 16 inputs (1: A-P). (1) ABCDEFGHIJKLMNOP “+” = input energized
Hold
this display ap- Located on first 16/8 board. -+-+-+-+-+-+-+-+ “-” = input not ener-
gized
pears, then release.
Displays second 16 inputs (2: A-P). Located on 2nd 16/8 board. CAPITAL letters
represent inputs.
Displays third 16 inputs (3: A-P). Located on 3rd 16/8 board.

Displays fourth 16 inputs (4: A-P). Located on 4th 16/8 board.

Displays fifth 16 inputs (5: A-P). Located on 5th 16/8 board.

Displays sixth 16 inputs (6: A-P). Located on 6th 16/8 board.

Displays last 6 inputs (7: A-F). Located on processor board.

ÏTable A: Standard INPUTS for SHUTTLES

Page 1: First 16 Inputs Page 2: Second 16 Inputs
Display
Code Input Name Connector/Pin Input Name Connector/Pin
A Belt 0 Discharge Level Switch 1 1MTA4-1 Discharge End Eye Belt 2 2MTA4-1
B Belt 0 Slack Cable 1MTA4-2 Discharge Level Switch 2 for 2MTA4-2
Belt 0
C Belt 0 Receive Level Switch 1 1MTA4-3 Go Down Before Up 2MTA4-3
D Left Right Oops 1MTA4-4 Receive Level 3 for Belt 0 2MTA4-4
E Receive Level Switch 2 1MTA4-5 Discharge Level 3 for Belt 0 2MTA4-5
F Load End Eye Belt 1 1MTA4-6 First Cake Eye for Belt 0 2MTA4-6
G Discharge End Eye Belt 0 1MTA4-7 Not Used 2MTA4-7
H Discharge End Eye Belt 1 1MTA4-8 Not Used 2MTA4-8
I Belt 0 Receive Level Switch 0 1MTA4-11 Not Used 2MTA4-11
J Belt 0 Discharge Level Switch 0 1MTA4-12 Not Used 2MTA4-12
K Manual Switch 1MTA4-13 Not Used 2MTA4-13
L Three Wire 1MTA4-14 Fully Extended Load 2MTA4-14
M Shuttle Home 1MTA4-15 Extended Too Far 2MTA4-15
N Belt 0 Transfer Station 1MTA4-16 Retracted Too Far 2MTA4-16
O Belt 0 Load Station 1MTA4-17 Fully Extended Unload 2MTA4-17
P Load End Eye Belt 0 1MTA4-18 Fully Retracted 2MTA4-18

51
RUNNING THE MARK IV AND V SHUTTLE
IN AUTOMATIC SYSTEMS MSOPD440CE/9705BV (11 of 15)

ÏTable A: Standard INPUTS for SHUTTLES (cont’d)

Page 7: Last 6 Inputs
Display
Code Input Name Connector/Pin
A Not Used Not Used
B Program Key MTA38-03
C Signal Cancel MTA38-02
D Finished Receiving Input MTA38-05
E Not Used Not Used
F Not Used Not Used

ÏTable B: Optional INPUTS for SHUTTLES

Page 3: Third 16 Inputs Page 4: Fourth 16 Inputs
Display
Code Input Name Connector/Pin Input Name Connector/Pin
A Dry Code 0 3MTA4-1 Customer Code 0 4MTA4-1
B Dry Code 1 3MTA4-2 Customer Code 1 4MTA4-2
C Dry Code 2 3MTA4-3 Customer Code 2 4MTA4-3
D Dry Code 3 3MTA4-4 Customer Code 3 4MTA4-4
E Dry Destination Code 0 3MTA4-5 Customer Code 4 4MTA4-5
F Dry Destination Code 1 3MTA4-6 Customer Code 5 4MTA4-6
G Dry Destination Code 2 3MTA4-7 Go Load Left 4MTA4-7
H Dry Destination Code 3 3MTA4-8 Go Load Right 4MTA4-8
I Single Cake 3MTA4-11 Allied Run Load Belt 4MTA4-11
Backwards
J Input Data Valid 3MTA4-12 Coslide Loading Complete 4MTA4-12
K Discharge Backwards 3MTA4-13 Discharge Right 4MTA4-13
L Go Discharge at Level 1 3MTA4-14 Allied Discharge Complete 4MTA4-14
M Allied Discharge Desired 3MTA4-15 Allied Loading Cancelled 4MTA4-15
N Allied Discharge Allowed 3MTA4-16 Allied Discharge Cancelled 4MTA4-16
O Discharge Left 3MTA4-17 Go Load at Level 1 4MTA4-17
P Desire to Load Shuttle 3MTA4-18 New Customer 4MTA4-18

52
RUNNING THE MARK IV AND V SHUTTLE
IN AUTOMATIC SYSTEMS MSOPD440CE/9705BV (12 of 15)

ÏTable B: Optional INPUTS for SHUTTLES (cont’d)

Page 5: Fifth 16 Inputs Page 6: Sixth 16 Inputs
Display Code Input Name Connector/Pin Input Name Connector/Pin
A Dry Code 3 5MTA4-1 Belt 1 Load Station 6MTA4-1
B Dry Code 2 5MTA4-2 Belt 1 Transfer Station 6MTA4-2
C Dry Code 1 5MTA4-3 Belt 1 Slack Cable 6MTA4-3
D Dry Code 0 5MTA4-4 Belt 1 Receive Level 6MTA4-4
Switch 0
E Destination Code 0 5MTA4-5 Belt 1 Discharge Level 6MTA4-5
Switch 0
F Destination Code 1 5MTA4-6 Belt 1 Receive Level 6MTA4-6
Switch 1
G Destination Code 2 5MTA4-7 Belt 1 Discharge Level 6MTA4-7
Switch 1
H Load Left 5MTA4-8 Belt 1 Receive Level 6MTA4-8
Switch 2
I Desire to Load Shuttle 5MTA4-11 Belt 1 Discharge Level 6MTA4-11
Switch 2
J Allied Load Cancelled 5MTA4-12 Belt 1 Receive Level 6MTA4-12
Switch 3
K Load Right 5MTA4-13 Belt 1 Discharge Level 6MTA4-13
Switch 3
L Load Semi-automatically 5MTA4-14 Not Used 6MTA4-14
M Allied Run Load Back 5MTA4-15 Not Used 6MTA4-15
N Go Load at Level 1 5MTA4-16 Not Used 6MTA4-16
O Destination Code 3 5MTA4-17 Not Used 6MTA4-17
P Dry Code on Board 5 5MTA4-18 Not Used 6MTA4-18

53
RUNNING THE MARK IV AND V SHUTTLE
IN AUTOMATIC SYSTEMS MSOPD440CE/9705BV (13 of 15)

Viewing Outputs
Ë
Displays 1st 16 outputs (1: a-p). (1) abcdefghijklmnop “+” = input made
Hold until
this display appears. +-+-+-+-+-+-+-+- “-” = input not made
Displays 2nd 16 outputs (2: a-p).
LOWER CASE letters
Displays last 9 outputs (3: a-i). represent outputs.

ÏTable C: Standard OUTPUTS for SHUTTLES

Page 1: First 16 Outputs
Display Display
Code Output Name Connector/Pin Code Output Name Connector/Pin
a Move Up Belt 0 1MTA5-10 i Manual Allowed 2 2MTA5-10
1MTA5-19 2MTA5-19
b Move Down Belt 0 1MTA5-9 j Signal 2MTA5-9
1MTA5-18 2MTA5-18
c Move Left 1MTA5-8 k I Am Loading 2MTA5-8
1MTA5-17 2MTA5-17
d Move Right 1MTA5-7 l Extend Belt 0 Unload 2MTA5-7
1MTA5-16 2MTA5-16
e Move Belt 1 Rearward 1MTA5-4 m Extend Belt 0 Load/ 2MTA5-4
1MTA5-14 Belt 2 Reverse 2MTA5-14
f Move Belt 1 Forward 1MTA5-3 n Flag 2 Down/ 2MTA5-3
1MTA5-13 Retract Belt 0 Load 2MTA5-13
g Move Belt 0 Rearward 1MTA5-2 o Manual Allowed 1 2MTA5-2
1MTA5-12 2MTA5-12
h Move Belt 0 Forward 1MTA5-1 p Retract Belt 0 Unload/ 2MTA5-1
1MTA5-11 Belt 2 Forward 2MTA5-11

54
RUNNING THE MARK IV AND V SHUTTLE
IN AUTOMATIC SYSTEMS MSOPD440CE/9705BV (14 of 15)

ÏTable D: Optional OUTPUTS for SHUTTLES

Page 2: Second 16 Outputs Page 3: Last 9 Outputs
Display Display
Code Output Name Connector/Pin Code Output Name Connector/Pin
a Dry Code 2 3MTA5-10 a Extend Belt 1 Unload 5MTA5-10
3MTA5-19 5MTA5-19
b Dry Code 3 3MTA5-9 b Retract Belt 1 Unload 5MTA5-9
3MTA5-18 5MTA5-18
c Load Desired 3MTA5-8 c Extend Belt 1 Load 5MTA5-8
3MTA5-17 5MTA5-17
d I Want To Discharge 3MTA5-7 d Retract Belt 1 Load 5MTA5-7
3MTA5-16 5MTA5-16
e Finished Unloading 3MTA5-4 e Semi Auto Load Desired 5MTA5-4
3MTA5-14 5MTA5-14
f Dry Code 0 3MTA5-3 f Finished Unloading 5MTA5-3
3MTA5-13 5MTA5-13
g Dry Code 1 3MTA5-2 g Not Used 5MTA5-2
3MTA5-12 5MTA5-12
h Finished Loading 3MTA5-1 h Not Used 5MTA5-1
3MTA5-11 5MTA5-11
i Destination Code 2 4MTA5-10 i I Am Empty 6MTA5-10
4MTA5-19 6MTA5-19
j Destination Code 3 4MTA5-9 j Move Up Belt 1 6MTA5-9
4MTA5-18 6MTA5-18
k Data Valid 4MTA5-8 k Move Down Belt 1 6MTA5-8
4MTA5-17 6MTA5-17
l Ready To Unload 4MTA5-7 l Not Used 6MTA5-7
4MTA5-16 6MTA5-16
m Discharge Partial Load 4MTA5-4 m Not Used 6MTA5-4
4MTA5-14 6MTA5-14
n Destination Code 0 4MTA5-3 n Not Used 6MTA5-3
4MTA5-13 6MTA5-13
o Destination Code 1 4MTA5-2 o Not Used 6MTA5-2
4MTA5-12 6MTA5-12
p Not Finished Unloading 4MTA5-1 p Not Used 6MTA5-1
4MTA5-11 6MTA5-11

55
RUNNING THE MARK IV AND V SHUTTLE
IN AUTOMATIC SYSTEMS MSOPD440CE/9705BV (15 of 15)

Viewing Miltrac Commands

Ë
This screen is used when troubleshooting with factory assistance.

Hold until DLRL LSDS LCDC SS

this display appears, Shuttle State
X X X X X X XX
then release. (not explained)
Miltrac Discharge Level Discharge-end Command

Miltrac Receive Level Load-end Command

Load-end Status Discharge Status

DL (Miltrac Discharge Level)—where the Miltrac system wants the shuttle to accept discharged goods.
RL (Miltrac Receive Level)—where the Miltrac system wants the shuttle to receive goods.
LS (Load End Status)—what the shuttle is telling the Miltrac system about its load end.
0 Cannot Do Anything 3 I am Finished Receiving
1 Want To Receive 4 I am Finished Receiving (Do Not Hold)
2 Ready To Receive

DS (Discharge End Status)—what the shuttle is telling the Miltrac system about its discharge end.
0 Cannot Do Anything 3 I am Finished Transferring
1 Want To Transfer 4 I am Finished Transferring (Do Not Hold)
2 Ready To Transfer

LC (Load End Command)—what the Miltrac system is telling the shuttle to do with respect to its load end.
0 Do Nothing 4 Start Receiving
1 Get Ready To Receive 5 Finished Receiving
2 Get Ready To Receive Left 6 You are Finished Receiving (Do Not Hold)
3 Get Ready To Receive Right

DC (Discharge End Command)—what the Miltrac system is telling the shuttle to do with respect to its
discharge end.
0 Do Nothing 4 Start Transferring
1 Get Ready To Transfer 5 You are Finished Transferring
2 Get Ready To Transfer Left 6 You are Finished Receiving (Do Not Hold)
3 Get Ready To Transfer Right

SS (Shuttle State)—not explained (factory troubleshooting only).

56
 MSOP0930AE/9436BV (1 of 2)

OPERATION OF SPECIALIZED SHUTTLES

È

Two-Wide Shuttle
Ê
Description—A two-wide shuttle (any model designation) can be thought of as two single-high shuttles bolted
Ë
together and operated by the same controller. Each half of the shuttle has separate motors for up/down and left/right;
therefore, each half of the shuttle can move up/down independently. However, it moves left/right as a single unit.
A single microprocessor output controls left/right movement of the entire shuttle. Each belt has separate out-
puts for up and down and separate inputs for Receive and Discharge levels and Slack and Taut Chain.

Operation—At power up, the belts initialize simultaneously, rise to Receive Level 0, and travel home (which is
Ë
designated by belt 0).
When Miltrac tells the shuttle to load, the shuttle stops with belt 0 at the desired load station. The controller
loads belt 0 first (when viewed from the load end, the belt on the right is belt 0). After the shuttle takes the first cake,
it will either return home and wait to move to another device to load belt 1, or it will move right and wait to load a
second cake from that device onto belt 1.

When Miltrac tells the shuttle to discharge, the shuttle stops with belt 0 at the desired discharge station. After
the shuttle has discharged the first cake, it will move right (facing load end) to position belt 1 at the discharge station.
After completely loading or discharging, the shuttle returns Home.

If a situation arises where the shuttle returns home and only belt 1 has a load, an error (Cake Must Be Manually
Unloaded) requiring manual unloading will occur.

Two-Long Coflo
Ê
Description—A two-long Coflo (see Coflo description in “PROGRAMMING THE MARK IV AND V SHUT-
Ë B
TLE CONTROLLER,” “Decisions M Through V: Special Purpose Loose Goods Shuttles”) differs from a regular
Coflo because it loads two loose goods loads from one belt and discharges those same loads as a single load.

Operation—At power up, the shuttle operates as described in “RUNNING THE MARK IV AND V SHUTTLE B
Ë
IN AUTOMATIC SYSTEMS.” However, when initializing, a two-long Coflo looks for a new input, First Cake
Eye. During loading of the first load, the belt runs until this eye (typically located in the middle of the belt) is
blocked. While loading the second load, the belt runs until the discharge-end eye is blocked. The shuttle returns to
the home position, then the goods are discharged as a single load.

NOTE: Multi-cake Coflo/Coslip shuttles are typically used to receive goods from an extractor. The output,
You’re Finished Receiving (11MTA14-1, 2) from the extractor grounds the input Finished Receiving
(MTA38-5) on the shuttle to notify the shuttle when the extractor finishes discharging.

57
OPERATION OF SPECIALIZED SHUTTLES MSOP0930AE/9436BV (2 of 2)

Two-High Coflo/Coslip
Ê
B
Description—A two-high Coflo/Coslip (see Coflo and Coslip description in “PROGRAMMING THE MARK
Ë
IV AND V SHUTTLE CONTROLLER,” “Decisions M Through V: Special Purpose Loose Goods Shuttles”) dif-
fers from a regular Coflo or Coslip because it loads and discharges from two belts (levels) rather than just one.

Operation—At power up, the shuttle operates as described in “RUNNING THE MARK IV AND V SHUTTLE B
Ë
IN AUTOMATIC SYSTEMS.” However, two-high Coflos and Coslips transport two batches of goods, each batch
on one of the two shuttle belts. When Miltrac tells the shuttle to load, the shuttle stops with belt 0 at the desired load
station. Miltrac loads belt 0 first. After the shuttle takes the first cake, it will either return home, move to position
belt 1 to receive a second cake from that device, or move to another device to load belt 1. When Miltrac tells the
shuttle to discharge, the shuttle stops with belt 0 at the desired discharge station. After the shuttle has discharged the
first cake, it will move to position belt 1 at the discharge station and discharge the second cake. After completely
loading or discharging, the shuttle returns home. If a situation arises where the shuttle returns home and only belt 1
has a load, an error with occur.

NOTE: Multi-cake Coflo/Coslip shuttles are typically used to receive goods from an extractor. The output,
You’re Finished Receiving (11MTA14-1, 2) from the extractor grounds the input Finished Receiving
(MTA38-5) on the shuttle to notify the shuttle when the extractor finishes discharging.

58
 MSOPD441CE/9449BV (1 of 8)
B
È ANUALLY OPERATING THE MARK III, IV,
M
AND V SHUTTLE
The shuttle can be operated manually from either the manual controls on the shuttle itself (see descriptions of the
controls in the operator manual) or the bare manual menu accessible at the shuttle controller. Though the shuttle can be
operated manually from either, the controls at the shuttle are for making subtle movements or for manual goods handling.
The shuttle controller, however, is better for moving the shuttle longer distances or in situations that do not require
manually handling goods. By actuating outputs in bare manual, most microprocessor outputs can be tested.
While bare manual modes 00-13 allow actuating outputs for manual operation or output testing, bare manual
mode 13 (test inputs) allows microprocessor inputs to be viewed and tested without returning to automatic operation,
a function particularly useful when troubleshooting.

The Bare Manual Menu and How To Access It

Ê
The Available Modes in the Bare Manual Menu
Ë
00=Return to Automatic 03=Run Belt 2-3 06=Loading 09=Dry Code 12=Belt 1
01=Moving Shuttle 04=Extend-Retract 07=Discharge 10=Dry Destination Up/Down
02=Run Belt 0-1 05=Extend-Retract 1 08=Data Pass 11=Signal-Manual 13=Test Inputs

CRUSH HAZARD—Moving shuttles and shuttle mechanisms will strike or crush

anyone in the shuttle path.
☞ Do not operate the shuttle without owner/user furnished fencing to enclose
shuttle path per the guidelines posted on the shuttle.
☞ Know how to use all factory-supplied shuttle safety devices including emergency stop
switches, pull cords, and kickplates.
☞ Always operate the shuttle carefully in manual mode. The operator has total control of
shuttle movement immediately after the Manual/Automatic keyswitch is set to manual.

To Access the Bare Manual Menu

Ë
When the display= WAITING FOR LOADING This is the run mode. It is possible to
DEVICE TO GET READY enter bare manual from other dis-
plays, but Milnor® recommends entry
from this display.
Accesses bare manual **MANUAL OUTPUTS**
+ 00 RETURN TO AUTO
Selects Moving Shuttle **MANUAL OUTPUTS**
, (example) 01 MOVING SHUTTLE

59
MANUALLY OPERATING THE MARK III, IV,
AND V SHUTTLE MSOPD441CE/9449BV (2 of 8)

Accesses the selected 1=RIGHT 2=LEFT This is the Moving Shuttle sub-menu.
mode (example) 3=UP 4=DOWN See “Bare Manual: 01=Moving Shut-
tle” in this section.

Ë For Quick Return to Run Mode From Any Bare Manual Mode
Turns off any output if **MANUAL OUTPUTS** The last-selected mode is displayed.
it is on and returns to 01 MOVING SHUTTLE
bare manual menu
Selects **MANUAL OUTPUTS**
,
00 RETURN TO AUTO
Returns to run mode WAITING FOR LOADING Shuttle ready for normal automatic op-
DEVICE TO GET READY eration.

Careless operation of the shuttle in bare manual mode can result in extensive damage to
equipment and/or goods. In bare manual mode, the operator is fully responsible for all
shuttle movement.
☞ Do not direct the shuttle too far left/right or taut/slack.
☞ Do not run goods onto the floor.
☞ Do not extend the bed into equipment.

Bare Manual: 00=Return to Automatic

Ë
When the **MANUAL OUTPUTS** = WAITING FOR LOADING Shuttle ready for normal auto-
display= 00 RETURN TO AUTO DEVICE TO GET READY matic operation

60
MANUALLY OPERATING THE MARK III, IV,
AND V SHUTTLE MSOPD441CE/9449BV (3 of 8)

Bare Manual: 01=Moving Shuttle

Ë
When the **MANUAL OUTPUTS** 1=RIGHT 2=LEFT
=
display= 01 MOVING SHUTTLE 3=UP 4=DOWN

Controller ignores all inputs. The oops switch and associated relays (not controlled by the microprocessor)
must prevent the shuttle from going too far left/right or taut/slack chain. The operator must make sure these
circuits are operating to prevent damage to the shuttle. Outputs can be actuated simultaneously (e.g., Right
and Up); however, the software prevents simultaneously actuating opposing outputs (e.g., Right and Left or
Up and Down).

NOTE: Once an output is turned on, press the same button to turn it off.

Turns Right output on/off.

/
Turns Left output on/off.
/
Turns Up output on/off.
/
Turns Down output on/off.
/
Turns all outputs off and returns to bare manual menu.

Bare Manual: 02=Run Belt 0-1

Ë
Display= **MANUAL OUTPUTS** B0 1=FORWD 2=BACKWD
, =
02 RUN BELT 0-1 B1 3=FORWD 4=BACKWD

Controller ignores photo-eyes. It is possible to run the goods on to the floor. Outputs can be actuated
simultaneously; however, the software prevents simultaneously actuating opposing outputs (e.g., B0 Forwd
and B0 Backwd or B1 Forwd and B1 Backwd).

Turns move belt 0 forward (B0 Forwd) output on/off.

/
Turns move belt 0 rearward (B0 Backwd) output on/off.
/
Turns move belt 1 forward (B1 Forwd) output on/off.
/
Turns move belt 1 rearward (B1 Backwd) output on/off.
/
Turns all outputs off and returns to bare manual menu.

61
MANUALLY OPERATING THE MARK III, IV,
AND V SHUTTLE MSOPD441CE/9449BV (4 of 8)

Bare Manual: 03=Run Belt 2-3

Ë
Display= **MANUAL OUTPUTS** B2 1=FORWD 2=BACKWD
, =
03 RUN BELT 2-3 B3 3=FORWD 4=BACKWD

Controller ignores photo-eyes. It is possible to run the goods on to the floor. Outputs can be actuated
simultaneously; however, the software prevents simultaneously actuating opposing outputs (e.g., B2 Forwd
and B2 Backwd or B3 Forwd and B3 Backwd).

Turns belt 2 forward (B2 Forwd) output on/off.

/
Turns belt 2 reverse (B2 Backwd) output on/off.
/
(Optional) Turns belt 3 forward (B3 Forwd) output on/off.
/
(Optional) Turns belt 3 reverse (B3 Backwd) output on/off.
/
Turns all outputs off and returns to bare manual menu.

Bare Manual: 04=Extend-Retract 0

Ë
Display= **MANUAL OUTPUTS** EXTND 1=UNLD 2=LOAD
, =
04 EXTEND-RETRACT 0 RETRT 3=UNLD 4=LOAD

Controller ignores all inputs. It is possible to extend the bed into equipment. Outputs can be actuated
simultaneously; however, the software prevents simultaneously actuating opposing outputs (e.g., Extnd
Unld and Retrt Unld or Extnd Load and Retrt Load).

Turns extend belt 0 unload (Extnd Unld) output on/off to extend in the unload direction.
/
Turns extend belt 0 unload (Extnd Unld) output on/off to extend in the load direction.
/
Turns retract belt 0 unload (Retrt Unld) output on/off to retract in the unload direction.
/
Turns retract belt 0 unload (Retrt Unld) output on/off to retract in the load direction.
/
Turns all outputs off and returns to bare manual menu.

62
MANUALLY OPERATING THE MARK III, IV,
AND V SHUTTLE MSOPD441CE/9449BV (5 of 8)

Bare Manual: 05=Extend-Retract 1

Ë
Display= **MANUAL OUTPUTS** EXTND 1=UNLD 2=LOAD
, =
05 EXTEND-RETRACT 1 RETRT 3=UNLD 4=LOAD

Controller ignores all inputs. It is possible to extend the bed into equipment. Outputs can be actuated
simultaneously; however, the software prevents simultaneously actuating opposing outputs (e.g., Extnd
Unld and Retrt Unld or Extnd Load and Retrt Load).

Turns extend belt 1 load (Extnd Unld) output on/off to extend in the unload direction.
/
Turns extend belt 1 load (Extnd Load) output on/off to extend in the load direction.
/
Turns retract belt 1 unload (Retry Unload) output on/off to retract in the unload direc-
/ tion.
Turns retract belt 1 unload (Retry Load) output on/off to retract in the load direction.
/
Turns all outputs off and returns to bare manual menu.

Bare Manual: 06=Loading

Ë
Display= **MANUAL OUTPUTS** 1=DESIRED 2=SM DESRD
, =
06 LOADING 3=LOADING 4=FINISHED
Turns load desired (Desired) output on/off.
/
Turns semi auto load desired (Sm Desrd) output on/off.
/
Turns shuttle is loading (Loading) output on/off.
/
Turns finished loading (Finished) output on/off.
/
Turns all outputs off and returns to bare manual menu.

63
MANUALLY OPERATING THE MARK III, IV,
AND V SHUTTLE MSOPD441CE/9449BV (6 of 8)

Bare Manual: 07=Discharge

Ë
Display= **MANUAL OUTPUTS**
, = 1=DESIRED 2=READY
07 DISCHARGE 3=FINISHED 4=SM FINI
Turns I want to discharge (Desired) output on/off.
/
Turns ready to unload (Ready) output on/off.
/
Turns finished unloading (Finished) output on/off.
/
Turns semi auto finished unload (Sm Fini) output on/off.
/
Turns all outputs off and returns to bare manual menu.

Bare Manual: 08=Data Pass

Ë
Display= **MANUAL OUTPUTS** 1=PARTIAL LOAD
, =
08 DATA PASS 2=DATA VALID
Turns discharge partial load (Partial Load) output on/off.
/
Turns Data Valid output on/off.
/
Turns all outputs off and returns to bare manual menu.

Bare Manual: 09=Dry Code

Ë
Display= **MANUAL OUTPUTS** = 1=DRY# 0 2=DRY# 1
,
09 DRY CODE 3=DRY# 2 4=DRY# 3
Turns dry code 0 (Dry# 0) output on/off.
/
Turns dry code 1 (Dry# 1) output on/off.
/
Turns dry code 2 (Dry# 2) output on/off.
/
Turns dry code 3 (Dry# 3) output on/off.
/
Turns all outputs off and returns to bare manual menu.

64
MANUALLY OPERATING THE MARK III, IV,
AND V SHUTTLE MSOPD441CE/9449BV (7 of 8)

Bare Manual: 10=Dry Destination

Ë
Display= **MANUAL OUTPUTS** 1=DEST# 0 2=DEST# 1
, =
10 DRY DESTINATION 3=DEST# 2 4=DEST# 3
Turns destination code 0 (Dest# 0) output on/off.
/
Turns destination code 1 (Dest# 1) output on/off.
/
Turns destination code 2 (Dest# 2) output on/off.
/
Turns destination code 3 (Dest# 3) output on/off.
/
Turns all outputs off and returns to bare manual menu.

Bare Manual: 11=Signal-Manual

Ë
Display= **MANUAL OUTPUTS** 1=SIGNAL 2=MANUAL1
, =
11 SIGNAL-MANUAL 3=MANUAL2 4=IM EMPTY
Turns Signal output on/off.
/
Turns manual1 (Manual 1) allowed output on/off.
/
Turns manual2 (Manual 2) allowed output on/off.
/
Turns I am empty (Im Empty) output on/off.
/
Turns all outputs off and returns to bare manual menu.

Bare Manual: 12=Belt 1 Up/Down

Ë
Display = **MANUAL OUTPUTS**
, = 1=BELT 1 - UP
12 BELT 1 UP/DOWN 2=BELT 2 - DOWN
Turns move up belt 1 (Belt 1-Up) output on/off.
/
Turns move down belt 1 (Belt 1-Down) output on/off.
/
Turns all outputs off and returns to bare manual menu.

65
MANUALLY OPERATING THE MARK III, IV,
AND V SHUTTLE MSOPD441CE/9449BV (8 of 8)

Bare Manual: 13=Test Inputs

Ë
Display= **MANUAL OUTPUTS** See tables of listed inputs in “RUNNING THE
,
13 TEST INPUTS MARK II, III, IV, AND V SHUTTLE . . .”

Displays 1st 16 inputs (1: A-P) (1) ABCDEFGHIJKLMNOP “+” = input energized
Located on 2nd 16/8 board +-+-+-+-+-+-+-+- “-” = input not ener-
gized
Displays 2nd 16 inputs (2: A-P). Located on 2nd 16/8 board.

Displays 3rd 16 inputs (3: A-P). Located on 3rd 16/8 board.

Displays 4th 16 inputs (4: A-P). Located on 4th 16/8 board.

Displays 5th 16 inputs (5: A-P). Located on 5th 16/8 board.

Displays 6th 16 inputs (6: A-P). Located on 6th 16/8 board.

Displays last 6 inputs (7: A-F). Located on Processor Board.

Returns to bare manual menu.

66
Troubleshooting 3

67
 MSTS0901CE/2002384V

MARK II, III, IV, AND V SHUTTLE ERROR MESSAGES

È
The following messages can result from an error condition (e.g., improper procedure, microprocessor compo-
nent failure, mechanical malfunction) or while correcting an error condition.

Power Up Error Messages

Ê
CLEAR MEMORY NOW Indicates configure data is corrupt (possibly as a result of turning power off while in
PRESS 4 + 5 + 6 the program mode). RECOVERY: Reconfigure machine, as shown below.

Enables clearing configure memory.

Clears entire configure memory. CLEARING MEMORY See “PROGRAMMING

+ + **PLEASE WAIT** THE MARK IV AND V
SHUTTLE CONTROL-
LER” to restore config-
ure data.
PROGRAM 0 MENU The keyswitch was incorrectly in the position at power up, but the control has
OK TURN KEY TO RUN determined that configure data is good. RECOVERY: Turn keyswitch to run.

THREE WIRE DISABLED At power up, this message appears following the power up displays.
PUSH START TO GO RECOVERY: Press to close the three-wire circuit (which provides power to
the shuttle). may be pressed at any time during the power up displays, thus si-
lencing the operator alarm and overriding this message. If fails to clear this
message, see “Operational Error Messages” in this section.
CHECK I/O BOARD x The controller detects a failed or missing control circuit board, where x is the board
PRESS SIGNAL CANCEL number (see schematic manual). A “missing” board can result from configuring for
an option not available (e.g., allied loading) or installing a new board or software
that was configured for an option not on this machine. The shuttle uses only I/O
boards, which are defined from #1 - #6. RECOVERY: Press to reset the con-
troller and access the program menu. Review configure decisions to ensure that all
configured options are available on that shuttle model and with the microprocessor
boards available. If everything is configured correctly, replace the failed board.
Automatic operation can resume when the problem is resolved.

68
MARK II, III, IV, AND V SHUTTLE ERROR MESSAGES MSTS0901CE/2002384V

Operational Error Messages

Ê

SHOCK HAZARD—High voltage electricity is present in electrical device on this

machine whenever external power is supplied, even if all power switches are
off. Contact with high voltage electricity will kill or seriously injure you.

☞ Lock off and tag out power at wall disconnect before opening any electrical control box
or accessing any other electrical component.
☞ Always employ the services of a licensed, qualified electrician when troubleshooting the
electrical system.
THREE WIRE DISABLED The three-wire relay, which provides control circuit power to the machine, became
PUSH START TO GO de-energized. If the three-wire contact opens, even momentarily, the machine stops
and displays Three Wire Disabled. This message will remain even if the contact
only opened momentarily, and will reappear if the Master switch is turned off and
then on again. RECOVERY: These messages can only be cleared if the cause of
the error is corrected, then the relay is energized by pressing . The relay is held
energized by its own normally open contacts along with motor overloads, etc.

NOTE: If three wire was disabled because the switch that monitors the chain tension was made (i.e., taut
chain error), the Taut Chain Fault light illuminates (see the descriptions of controls in the operator manual
for full explanation). RECOVERY: 1) Turn the keyswitch from normal operation to manual enable; 2) Press
Enable Down button until the bed is lowered from the taut chain switch; 3) Press the Reset button (Taut Chain
Fault light extinquishes); 4) Ensure operation of level switches; 5) Resume normal operation as follows:

Closes the three-wire circuit and may prompt for cake information.

<responses> Confirms cake data, where <responses> are as explained in “RUNNING THE MARK IV
AND V SHUTTLE IN AUTOMATIC SYSTEMS.”

CHECK I/O BOARD x See explanation in “Power Up Error Messages” in this section.
PRESS SIGNAL CANCEL
ERROR - CHECK CHAIN The shuttle failed to run the hoist to its maximum and minimum heights (to verify
PRESS SIGNAL CANCEL they operate) within the configured time. This error condition occurs only when the
shuttle first powers up. RECOVERY: Verify that the hoist is free to move up and
down and that enough time is entered in configure decision G.

69
MARK II, III, IV, AND V SHUTTLE ERROR MESSAGES MSTS0901CE/2002384V

ERROR - RAIL LIMIT The shuttle moved too far left or right, making the oops switch on the traversing
PRESS SIGNAL CANCEL rail and was not able to move away from the switch within five seconds.
RECOVERY: Verify that the circuit is operational. Manually move the shuttle
off of the oops switch:
1. Set the Manual/Automatic switch to manual and, use manual switches at the
shuttle to move the shuttle away from the oops switch.
2. When shuttle is off the oops switch, set the Manual/Automatic switch to
automatic.
3. Resume operation at controller by pressing .
ERROR-NOT RETRACTED The shuttle bed is not fully retracted when moving left/right, up/down, or after in-
PRESS SIGNAL CANCEL itialization. RECOVERY: Verify operation of the Fully Retracted switch. Cor-
rect error, and press .
ERROR - SLACK CHAIN The shuttle descended too far while searching for a level, making the Slack Chain
PRESS SIGNAL CANCEL switch. RECOVERY: Verify operation of the level switches (load and dis-
charge) and engagement of targets. Correct error, and press .
ERROR - TAUT CHAIN The shuttle ascended too far searching for a level, making the Taut Chain switch.
PRESS SIGNAL CANCEL RECOVERY: Verify operation of the level switches (load and discharge) for op-
eration and engagement of targets. Correct error, and press .
ERROR -XFER ABORTED (For Miltrac system loading and/or discharging only) Indicates the transfer was
PRESS SIGNAL CANCEL aborted while in progress. RECOVERY: Verify that goods are not caught be-
tween devices. If goods are caught, use all safety precautions to remove them be-
fore clearing the error. Press to clear the error.
ERROR - EYE ERROR This error depends on shuttle hardware and the location at which the error occurs;
PRESS SIGNAL CANCEL any of the following conditions may cause this error:
1. The shuttle load-end or discharge-end photo-eyes detect goods on a multi-
cake shuttle (>1 cake per belt). This may indicate that goods are hanging from
either end of the shuttle with the potential to catch on machinery and cause
damage.
2. The shuttle is configured as a two-cake belt and the load-end and/or discharge-
end photo-eye detects goods when the shuttle tries to move left/right or up
/down. This may indicate that goods remain hanging from either end of the
shuttle with the potential to catch on machinery and cause damage.
3. The shuttle is configured for two or more cakes per belt and the shuttle knows
it received more than one cake. While discharging, the shuttle cannot find the
second cake (e.g., both/all cakes were discharged at one time because goods
were trailing between cakes, preventing the shuttle from recognizing separate
cakes).

70
MARK II, III, IV, AND V SHUTTLE ERROR MESSAGES MSTS0901CE/2002384V

ERROR - EYE ERROR 4. The shuttle is configured as a two-cake belt and while loading, the discharge-
PRESS SIGNAL CANCEL end photo-eye blocked before the load-end photo-eye cleared. This indicates
that goods may be trailing off the load end of the bed with the potential to
catch on machinery and cause damage.
5. The shuttle load-end and discharge-end photo-eyes detect goods at the same
time. This may indicate that goods are hanging from either end of the shuttle
with the potential to catch on machinery and cause damage.
6. The shuttle overshoot eye is blocked, meaning goods may be hanging off the
front of the shuttle with the potential to catch on machinery and cause damage.

RECOVERY: Correct error, and press .

EXTENDING TOO FAR The shuttle bed extended too far, causing the shuttle to stop.
ADJUST BELT MANUALLY RECOVERY:
1. Verify operation of the Fully Extended switch.
2. Set Manual/Automatic switch to manual, and use manual switches at shuttle
to retract belt.
3. Set Manual/Automatic switch to automatic.
4. Resume operation at the controller by pressing .

RETRACTING TOO FAR The shuttle bed retracted too far, causing the shuttle to stop.
ADJUST BELT MANUALLY RECOVERY:
1. Verify operation of the Fully Extended switch.
2. Set Manual/Automatic switch to manual, and use manual switches at shuttle
to retract belt.
3. Set Manual/Automatic switch to automatic.
4. Resume operation at the controller by pressing .

CAKE MUST BE (For shuttles configured not to elevate the second belt for discharge) A cake is on
MANUALLY UNLOADED Belt 1 and not on Belt 0. RECOVERY:
1. Set the Manual/Automatic switch on the shuttle to manual.
2. Using the manual switches, discharge the goods from Belt 1.
3. Return the Manual/Automatic switch to automatic.
4. Resume operation at the controller by pressing .

ERROR - NO CAKE (For shuttles having more than one storage position per belt) The shuttle is at-
PRESS SIGNAL CANCEL tempting to discharge a cake, but the discharge eye was not blocked in Belt Clear
Time. RECOVERY: Determine why cake did not block discharge eye in config-
ured Belt Clear Time and correct. Press to clear the error.

ERROR- WAIT TOO LONG (For allied discharge only) The shuttle finished discharging, and the receiving de-
PRESS SIGNAL CANCEL vice failed to acknowledge completion of the discharge within 30 seconds.
RECOVERY: Check circuitry that indicates discharge completion to the
shuttle. Press to clear the error.

71
MARK II, III, IV, AND V SHUTTLE ERROR MESSAGES MSTS0901CE/2002384V

ERROR - TOO MANY DIR (For allied loading only) Right and left inputs that tell the shuttle what direction
PRESS SIGNAL CANCEL to move have been actuated during semi-automatic loading. RECOVERY:
Check circuitry that controls right/left inputs for correct operation. Press to
clear the error.

72
Supplemental Information 4

73
 BICMDF01 (Published) Book specs- Dates: 20050112 / 20050112 / 20050118 Lang: ENG01 Applic: CAU CM2 CM3 CGU CJU CKU
CCN PDU YUU CPU CXU CSU CDU CWU

Hardware Components of Serial Microprocessor Controllers

1. General
Milnor® serial microprocessor controls are designed specifically for Milnor® machines and
systems. Along with certain external electromechanical relay logic and sensing devices, they
control all machine and system functions. Not every microprocessor controller includes all the
components described in this section.

2. Microprocessor Components
Note 1: This is a list of all components for Milnor® microprocessor controllers. Not every Milnor®
microprocessor controller includes all of the following components.

2.1. Keypad or Keyboard—Depending upon the model and type of machine, the keypad may
have 12, 30, or 58 buttons. The different keypads are not interchangeable.

2.2. Keyswitch—Selects run/program modes. The key may be removed only when the switch is set
to the Run position.
CAUTION 1 : Prevent Unauthorized Programming—To prevent unauthorized
programming, store the programming key so that it is not available to unauthorized personnel.
Improper programming can damage equipment and goods.

2.3. Display—Depending upon the type and model of machine, the display may be either liquid
crystal, vacuum fluorescent, or cathode ray tube (CRT), which is a typical computer monitor.
Different types of displays are not interchangeable.
Liquid crystal graphic display—This display is identified by colored characters and graphics,
usually on a black or white background. It's currently used only on certain washer-extractor
models with the Milnor Mark VI control system.
Liquid crystal text display—This type of display is identified by dark gray characters on a
lighter gray background, or by green characters on a dark gray background.
Vacuum fluorescent display—The bright green characters on a black background make this
display highly visible. This is the most common display for Milnor® washer-extractors, textile
machines, and dryers.
Cathode ray tube (CRT)—The CRT display resembles a television screen in appearance and
function. This type of display is most commonly used in Miltrac™ and Mildata® systems,
which require the display of graphics such as boxes and lines. It is also used on Milnor CBW®
tunnel washers.

2.4. Power Supply—The power supply converts the alternating current at the control circuit
voltage to direct current voltages of 12 volts positive and negative, and 5 volts positive. One or
more of these values are adjustable, depending on the specific power supply used in each
application.
The Milnor™ CBW® system employs two different power supplies to convert alternating current
from the control circuit to direct current for the microprocessor and peripheral boards.

2.4.1. Control Console Power Supply—The power supply referenced as ESPS in the schematic

PELLERIN MILNOR CORPORATION

74
 Hardware Components of Serial Microprocessor Controllers

diagrams is a 40-watt power supply located in the Miltron™ or Mentor™ cabinet. It powers the
peripheral boards located within this cabinet, including the optional load cell interface board and
the analog to digital board for a weighing conveyor, as well as the microprocessor board and the
memory expansion board.
Tip: For maximum reliability and to minimize the chances of the processor board resetting due to low
voltage, adjust the power supply voltage for 80186 processors to 5.10 VDC at the processor
board.

In systems operated via the Miltron™ controller, this power supply also provides electricity to the
monitor interface board. In Mentor™-controlled tunnel systems, the monitor interface board is
contained within the Mentor™ computer enclosure and powered by the computer power supply.

2.4.2. Tunnel Power Supply—The power supply referenced as PSO in the schematic diagrams is a
120-watt unit which powers the peripheral boards located on the tunnel washer. All three
voltages output by this device are adjustable.
If adjustment is necessary, set the 5 volts output to provide at least positive 4.8VDC at the electric
box on the module farthest from the power supply. This measurement must be made with an
accurate digital voltmeter. Verify that the positive and negative 12 volts outputs are set at positive
and negative 12.00VDC, respectively.
If the 5 volts reading at the peripheral board nearest the PSO power supply is at least positive
5.25VDC, and the voltage at the peripheral board farthest from PSO is positive 4.8VDC or less,
suspect one or more loose connections or inadequate wiring somewhere between the two
peripheral boards.

2.5. Power Supply —The power supply converts the alternating current at the control circuit
voltage to direct current voltages of 12 volts positive and negative, and 5 volts positive. One or
more of these values are adjustable, depending on the specific power supply used in each
application.
• The 12 volts positive is used to power all boards other than the microprocessor board. This
value is not adjustable.
• The 12 volts negative is used by the analog to digital (A/D) board. This value is not
adjustable.
• The 5 volts output powers the microprocessor. This value is adjustable and very sensitive. For
devices using microprocessors other than the 80186, the power supply must be adjusted to
provide actual voltage of 4.95VDC to 5.10VDC at the microprocessor board. Use an accurate
digital voltmeter to measure this value. For devices with 80186 microprocessors, the power
supply voltage should be 5.10VDC at the processor board.
A wire of at least 14AWG (2.5 sq mm) must be connected between the ground points on the
microprocessor and the peripheral boards. This ground wire is installed at the factory if both
enclosures are mounted on the same machine (e.g., washer-extractors). The ground wire must be
provided during installation if the microprocessor enclosure and its associated peripheral board
enclosures are remote from one another (e.g., dryers).
Some machines, including Milnor® dryers, employ a second identical power supply to provide
power for the peripheral boards, which are mounted in an enclosure separate from the
microprocessor enclosure.

PELLERIN MILNOR CORPORATION

75
 2.6. Central Processing Unit (CPU) Board—Also referred to as the microprocessor, the
central processing unit processes data received from the various inputs, stores information, and
responds to each keypad entry with the appropriate action. It may be mounted in an enclosure
separate from its peripheral boards. The CPU board contains EPROMs programmed by the
Milnor® factory with fixed instructions (software) that determine how the machine functions.
Depending upon machine model/type, the processor chip may one of three Intel models: the
8085, the 8088, or the 80186.
Although the EPROMs do not require battery backup, the CPU board utilizes a battery which
normally provides power to retain the user-programmable memory for two to three months
without external power.

2.7. Memory Expansion Board—Increases memory space available to the processor. This
board is used with 8088 CPU boards in some applications.

2.8. Battery—Provides memory retention backup when power is off. The battery is mounted
directly on 8085 CPU boards, and mounted separately for 8088 and 80186 CPU boards. A
capacitor on the 8088 and 80186 CPU boards provides enough power to retain memory for
several hours after the battery has been disconnected. Once fully charged, the battery backup is
reliable for two to three months with no power applied.

2.9. Opto-Isolator Board—Optically isolates inputs to the microprocessor for electronic noise
immunity. Opto-isolators are incorporated into the 8088 and 80186 CPU board; thus this separate
board is only required for machines employing Intel 8085 CPUs.

2.10. Input/Output Board—The 16/8 input-output board contains 16 solid-state signal input
devices and eight output relays. The input devices are capable of faithfully conducting a low VA
12VDC ground signal to the microprocessor. The output relays are socket-mounted SPDT,
12VDC electromechanical relays with contacts capable of faithfully conducting a maximum of
25VA at 110/120VAC (0.2 ampere or 200 milliamperes at 110/120VAC) or 12.5 VA at 24VAC
(0.5 ampere or 500 milliamperes at 24VAC). The output will be either 24VAC or 110/120VAC,
depending on the machine model/type.
These outputs and their power source are intended only to drive another relay with higher contact
ratings, that in turn may drive a pump, valve, solenoid, etc., from a separate power source. Never
use these outputs to directly drive a pump, valve, or solenoid unless the maximum current
required never exceeds the above values. Higher ampere or VA loads will burn out traces on the
printed circuit board or possibly overload and damage the control circuit transformer.
This board has 25 status lights. The amber light flashes when the board is communicating. Each
of the 24 remaining lights represent an input (green lights) or output (red lights) on that board,
and illuminates when the corresponding input or output is made. This board has two rotary dials
which must be adjusted to set the board's address (see Section 4 “Assigning Board Addresses” in
this document). This board also has convenient test points that can be used to test voltage to the
board.
Standard input/output board—used in all devices requiring input/output boards, except those
listed below.
High-speed input/output board—used only in the following devices and configurations: E6N,
J6N, and T6N washer-extractors equipped with and configured for both variable basket speed
and electronic balancing; Milrail configured for high-speed boards, and all configurations of
the M7E centrifugal extractor.

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 Hardware Components of Serial Microprocessor Controllers

2.11. Output Board—A 24-output board contains 24 output relays identical to those described in
Section 2.10 “Input/Output Board”.

2.12. Analog to Digital Convertor Board—Converts analog voltage signals, such as

temperature, to a digital signal that can be utilized by the CPU. Up to a maximum of eight
channels may be provided on a single board. Although seemingly identical, the analog to digital
boards used to sense air temperature in the dryer, water temperature in washer-extractors and
textile machines, water temperature in the tunnel, and weight for a weighing conveyor are all
different. The different types are clearly marked with different part numbers, which are
mentioned in the wiring diagram set and are not interchangeable.
All analog to digital boards have one status light which flashes when the board is communicating.
The board has two rotary dials which must be adjusted to set the board's address (see Section 4
“Assigning Board Addresses”). This board also has convenient test points that can be used to test
voltage to the board.

2.13. Digital to Analog Convertor Board—Converts digital signals from the processor to
analog signals with voltages between 0 and 5VDC (e.g., provides the analog signal to the dryer
gas valve position actuator and dye machine steam position actuator).
This board has one status light which flashes when the board is communicating. The two rotary
dials must be adjusted to set the board's address (see Section 4). This board also has convenient
test points that can be used to test voltage to the board.

2.14. CRT (Video Display) Board—Receives display instructions from the processor and
generates the signals to the video monitor to create the desired displays; used in controllers such
as the Miltron™ and Miltrac™ controllers and Device Master™ systems.
CAUTION 2 : Avoid Component Damage—The CRT board can be installed backwards,
even though the cabinet and bracketry makes this difficult, and labelling on the parent board
states the proper orientation. Use care to orient the board correctly, otherwise microprocessor
components may be damaged.

CBW® systems with the Mentor™ controller use a standard computer video display adapter,
housed within the Mentor™ computer, to transmit signals from the Mentor™ computer to the
video monitor. Thus, Mentor™ systems do not have a separate video display board as described
here.

2.15. Resistor Boards—Although visually similar, resistor boards vary according to the
application. The different types are clearly marked with part numbers, which are mentioned in
the electrical schematic diagrams and are not interchangeable.
For temperature-sensing systems—used with analog to digital boards in washer-extractors and
dye-extractors as part of temperature-sensing system; not required on tunnel systems because
the necessary circuitry is included on other standard CBW® circuit boards.
For modulating gas valves—used with digital to analog boards in the temperature control circuit
of gas dryers; converts 0-5VDC to 4-20 milliamperes for controlling the modulating gas valve.
For modulating steam valves—used with digital to analog boards in temperature control circuit
of older steam dryers; converts 0-5VDC to 4-20 milliamperes for modulating steam valve. See
Section 2.20 “4-20mA Output Board” in this document.

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2.16. Signal Conditioner for Thermocouple—Amplifies and filters the output from a
thermocouple so an analog to digital board can convert the signal to digital values for the
microprocessor.

2.17. Rotation Safety Board—Used in dryers. Reads rotational safety proximity switch to
confirm that the basket is turning.

2.18. Temperature Probe—Two types of temperature probes are used, depending on equipment
type:
Thermistor temperature probe—a temperature-sensitive resistor whose resistance value
changes with respect to temperature; uses include washer-extractors, textile machines, and
tunnel systems.
Thermocouple temperature probe—a closed loop of two dissimilar metals which produces a
voltage with respect to the change in temperature between the two junctions. Thermocouples
are used in dryers.

2.19. Weigh Scale Interface Board—In the electrical circuit, this device is between the
weighing conveyor (CONWA) load cell and the weighing conveyor analog to digital board. It
filters and interprets the signals from the conveyor load cell to the analog to digital board.

2.20. 4-20mA Output Board—Used on newer textile machines and steam dryers with temperature
control. See Section 2.15 “Resistor Boards” in this document.

2.21. 8 Output/16 Input Chemical Flow Meter Board—This board is used with the metered
chemical injection option on textile machines. Eight outputs and eight counters respectively are
assigned to chemical valves and chemical flow meters. Two of the counters are non-isolated
direct inputs to the microprocessor on this board and are capable of counting pulses of 0 to 5VDC
at a frequency of up to 10kHz. The remaining six counters are optically isolated from the
peripheral board microprocessor and are capable of counting pulses from 0 to 12VDC at a
frequency up to 150 Hz.

3. Serial Communications Port

All Milnor® serial microprocessors have a serial port with a nine-pin receptacle and plug to
communicate with other devices via one of several special serial cables. If supported by the
software, downloading and printing of data is accomplished through this port. These actions are
described in the programming section of this manual.
For more information on the various separate serial cables required for these functions, see the
related section in document BICWUC01, if applicable.

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Hardware Components of Serial Microprocessor Controllers

Table 1: Board Application by Device (Part A)

Board Name
Weight Scale Interface •
Rotation Safety • |
Chemical Flow Meter • | |
Thermocouple Signal Conditioner • | | |
Steam Valve (4-20mA) • | | | |
Gas Valve Resistor • | | | | |
Temperature Sensing Resistor • | | | | | |
Opto-isolator • | | | | | | |
CRT • | | | | | | | |
Digital to Analog • | | | | | | | | |
Analog to Digital • | | | | | | | | | |
Output • | | | | | | | | | | |
Input/Output • | | | | | | | | | | | |
CPU • | | | | | | | | | | | | |
| | | | | | | | | | | | | |
Device | | | | | | | | | | | | | |
Number 1 2 1 1 1
CBW System*
Note(s) + 1 9 5
Number 1 2 1
Device Master*
Note(s) 1 1
Number 1 1
Miltrac*
Note(s)
Number 1 2 1
VERTSTO
Note(s)
Number 1 1
Linear COSTA
Note(s) 1
Number 1
Link Master
Note(s)
Number 1 1 2 1 1 1 1
Textile*
Note(s) 4 1
Notes:
* Intel 80186 central processing unit
1 Boards can be added for options
2 Used on steam dryers with temperature control, and all gas dryers
3 Used on washer-extractors with temperature option
4 Analog to digital boards vary according to application. See the descriptions of
these boards elsewhere in this section.
5 Required for weighing conveyors on tunnel washing systems
6 Required for reuse/cooldown and/or overhead fill tanks on tunnel washing
systems
7 Mark I washer-extractor control used Intel 8085 central processing unit
8 Notes 3 and 4 apply
9 One board required per each 8 modules (see also Notes 1, 4, 5, and 6)
10 Two boards required, plus one additional board per module

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Table 2: Board Application by Device (Part B)
Board Name
Weight Scale Interface •
Rotation Safety • |
Chemical Flow Meter • | |
Thermocouple Signal Conditioner • | | |
Steam Valve (4-20mA) • | | | |
Gas Valve Resistor • | | | | |
Temperature Sensing Resistor • | | | | | |
Opto-isolator • | | | | | | |
CRT • | | | | | | | |
Digital to Analog • | | | | | | | | |
Analog to Digital • | | | | | | | | | |
Output • | | | | | | | | | | |
Input/Output • | | | | | | | | | | | |
CPU • | | | | | | | | | | | | |
| | | | | | | | | | | | | |
Device | | | | | | | | | | | | | |
Number 1 2
COBUC
Note(s) 1 1
Number 1 2
COSHA
Note(s) 1
Number 1 2 1 1 1 1 1 1
Dryer
Note(s) 4 2 2 2
Number 1 2 1
Extractor
Note(s) 1 1
Number 1 2 1 1
Press
Note(s) 1 1
Number 1 1 1 1 1 1
W/E (Mark I)
Note(s) 7 1 1 8 1
Number 1 1 1 1 1 1
W/E (Mark II-VI)
Note(s) 1 1 8 1 1
Notes:
* Intel 80186 central processing unit
1 Boards can be added for options
2 Used on steam dryers with temperature control, and all gas dryers
3 Used on washer-extractors with temperature option
4 Analog to digital boards vary according to application. See the descriptions of
these boards elsewhere in this section.
5 Required for weighing conveyors on tunnel washing systems
6 Required for reuse/cooldown and/or overhead fill tanks on tunnel washing
systems
7 Mark I washer-extractor control used Intel 8085 central processing unit
8 Notes 3 and 4 apply
9 One board required per each 8 modules (see also Notes 1, 4, 5, and 6)
10 Two boards required, plus one additional board per module

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 Hardware Components of Serial Microprocessor Controllers

4. Assigning Board Addresses

The input/output board, output board, analog to digital board, and digital to analog board each
have two rotary switches which establish the address for each board. This allows each board to
communicate serially with the microprocessor in its device while sending and receiving its own
messages. In a battery of machines, the rotary switches are identical for each identical peripheral
board in each identical machine (e.g., the first input/output board (I/O-1) in each washer-extractor
has identical rotary switch settings). When a microprocessor must communicate with a higher
level control (e.g., when all dryers communicate with the MilData® system), the higher level
control must know the address of each microprocessor. For 8088 microprocessors, the high level
control knows the address of each device because that information was established during
configuration (e.g., see Miltrac Address configure decision in the programming manual for any
device that communicates with Miltrac).

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Table 3: Rotary Switch Settings
COSHA ¬
COBUC ¬
Device Master ¬
Dryer ¬
Textile ¬
Devices
Linear COSTO ¬
One-Stage Press ¬
Two-Stage Press ¬
Extractor ¬
VERTSTO ¬
Washer-Extractor ¬

Board
SW2 2* 2 2 2 2
Analog to Digital
SW1 1* 1 1 1 1
SW2 3* 3 3 3
Digital to Analog
SW1 1* 1 1 1
SW2 0 0 0 0 0 0 0 0 0
Input/Output #1
SW1 1 1 1 1 1 1 1 1 1
SW2 0* 0 0* 0 0 0* 0* 0 0 0 0
Input/Output #2
SW1 2* 2 2* 2 2 2* 2* 2 2 2 2
SW2 0* 0* 0* 0* 0* 0*
Input/Output #3
SW1 3* 3* 3* 3* 3* 3*
SW2 0 0* 0* 0* 0*
Input/Output #4
SW1 4 4* 4* 4* 4*
SW2 1 1 1 1 1 1 1*
Output #1
SW1 1 1 1 1 1 1 1*
SW2 1* 1* 1* 1 1*
Output #2
SW1 2* 2* 2* 2 2*
SW2 1 1* 1*
Output #3
SW1 3 3* 3*
Notes:
* Optional boards
See schematics for rotary switch positions on tunnel washer system
1
devices.

— End of BICMDF01 —

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 BICALC13 (Published) Book specs- Dates: 20031016 / 20031016 / 20031017 Lang: ENG01 Applic: CSX

Summary of Milnor® Allied Interface Capability, Shuttle

A Milnor system machine may need to load from, or discharge to a non-Milnor machine. This
document summarizes allied interface capability for the Milnor system machine equipped with
Mark 5 microprocessor or later controls, as of this writing (see Note 2).
Note 1: Refer to the document “About Milnor® Allied Interfaces for Automated Laundering System
Machines” for a general explanation of allied interfaces. Refer to “Milnor® Allied Interface Specifications
and Signals” for technical information needed to implement an allied interface.

Note 2: The allied interfaces offered by Milnor are continually evolving and the available signals can vary
from one software version (date code) to another. Milnor Tehnical Support can assist in determining data-
passing capacities for specific software versions.

1. How Batch Data Travels Through a System

The types and ranges of batch codes that the devices within an automated laundering system can
handle depend on both the individual device controller and the means of communication used to
pass this data from device to device. Generally, allied interfaces provide less capacity then the
Miltrac controller because they are much more limited by hardware constraints and are developed
on an as-needed basis. You will notice in Table 1 that certain types of codes and code ranges do
not carry over from device to device, or even from the loading to the discharge interface within
the same device. Keep in mind that both down stream and upstream of a given allied interface,
data will most likely be passed not via an allied interface, but rather, by the Miltrac controller or a
similar system controller supplied by another equipment manufacturer. As of this writing, Miltrac
is capable of passing the following codes and code ranges throughout the entire system (among
all Miltrac devices): 256 formula codes, 16 press/extract codes, 16 dry codes, 256 goods code,
1000 customer codes, 64 destination codes, 1000 weight values, 256 cake numbers, and the
following flags: single cake, empty load, low pressure, third pressure, no pressure.

2. Batch Data Signals

This section summarizes the types and number of batch codes for which, as of this writing, batch
data allied interface signals are available. As shown in Table 1, the signals that carry batch data
are divided into two general categories, those that pass multi-digit batch codes (e.g., drycode) in
binary, and must therefore, function in groups and those that pass a single on/off value (e.g., the
“new customer” code).
Both the need for, and the specific use that any type of batch code serves can vary significantly
from one installation to another. Signals traditionally used for certain batch codes can sometimes
be adapted to new types of batch data. The following are the batch codes traditionally associated
with allied interfaces and their traditional definitions.
Formula code—identifies the wash formula used in the tunnel. Although in some systems, the
wash formula may affect post-wash processing, formula codes are passed to post-wash devices
primarily for accounting and record-keeping purposes (see Note 3).
Extract code—Sometimes called press code, this identifies the extract formula, if a Milnor
centrifugal extractor is used, or the press formula, if a Milnor single stage press is used (see
Note 3). Extract codes do not apply to the Milnor two-stage press which does not have
formulas as such, but can be made to vary the pressure of the main bell via the Low, 3rd, and
No Pressure (on/off) signals.
Note 3: Although formula code and extract code are technically different things, they can be thought of as
the same by programming the Milnor centrifugal extractor or single stage press so that the proper extract
formula is invoked by a formula code of the same number. For example, program extract code 05 so that it
is the proper extraction process for batches processed with formula code 05. Then simply pass the formula
code to the extractor or single stage press as the extract code.

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Summary of Milnor® Allied Interface Capability, Shuttle

Dry code—identifies the drying formula to be used in the drying or conditioning equipment.
Cooldown code—identifies the cooldown procedure to be used in the dryer.
Customer code—identifies the customer (commercial laundry) or department (institutional
laundry) the batch belongs to.
Goods code—in older Milnor CBW®'s (with Miltron™ controllers), identifies a subset of a
general class of goods. All batches conforming to the general class are processed using the
same wash formula. But each specific goods code within that class causes variations in
processing, essentially extending the range of available wash formulas. Although in some
systems, the goods code may affect post-wash processing, goods codes are passed to post-
wash devices primarily for accounting and record-keeping purposes.
Destination code—identifies a storage location within the laundry to send the load.
Weight—the dry, soiled weight of a batch, as measured by a weighing device, such as a weighing
type load conveyor, upstream of the tunnel. Although in some systems, weight may affect
post-wash processing, weights are passed to post-wash devices primarily for accounting and
record-keeping purposes.
Cake Number—in older Milnor CBW®'s (with Miltron™ controllers), this is an identification
number associated with each batch. The Miltron automatically assigns the numbers 000 to 255
in sequence and starts over at 255. As indicated in Table 1, allied signals are not currently
available on any machine for passing this code.
New formula—indicates that the batch being transferred was processed using a different formula
than the previous batch (see Note 4).
New customer—indicates that the batch being transferred belongs to a different customer than
the previous batch (see Note 4).
Note 4: The intent of both of these signals is to provide a means of segregating batches with different
formula, goods, and/or customer codes, in post-dry. They are typically used in systems that are not capable
of passing (or do not need to pass) formula, goods, or customer codes. Depending on the specific situation,
the signal would be actuated by the washer whenever the formula, goods, and/or customer code changes. In
the Milnor dryer controller, the “new customer” signal causes the customer code to increment by one (e.g.,
from 07 to 08). In such a system, the value of the customer code is irrelevant, but changing it signals
downstream devices not to combine these loads.

Single cake—also called “small load” or “little load”, this signal tells a shuttle to deliver, and a
multi-cake dryer to accept this cake (load) by itself. This is usually done when the cake that
follows belongs to a different customer and the goods should not be intermingled.
Empty load—also called “empty pocket” or “pass-empty”, this signal tells the receiving device
that it will not receive any goods with the batch data it is receiving. Empty pockets are
sometimes used in the tunnel to perform a cleaning process or to segregate goods from
incompatible baths.
Low (main) pressure—tells the Milnor two-stage press to use the lowest main bell pressure (see
Note 5).
3rd (main) pressure—tells the Milnor two-stage press to use a lower than normal main bell
pressure (see Note 5).
No (main) pressure—tells the Milnor two-stage press to use no main bell pressure (see Note 5).
Note 5: If the Low, 3rd, and No pressure signals are all off, the press will use standard (high) main bell
pressure.

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Table 1: Batch Data-passing Capacity for Milnor® Allied Interfaces
Non-Numeric: One signal passes a single
Data Numeric: Groups of signals pass multi-digit batch codes in binary (number
on/off value (X indicates signal is
Format--> of available batch codes shown)
available)
Code Low,
Press/ weight
Name--> Form- Cool- Cust- destin- Cake New New 3rd,
Ex- Dry Goods (tenths Single Empty
ula down omer ation num- form- cust- No
tract code code of cake load
Type of code code code code ber ula omer press-
code units)
Interface ure*
Shuttle
Loading 16 64 16 X X
Discharge 16 16 X
* Low, 3rd, and No Pressure are three separate signals.

3. Operational Signals
A set of generic functions can be defined that encompasses most operational information that
might be needed for any interface. The generic functions are helpful in understanding interfacing
in general, even though it is usually possible to successfully interface any two specific machines
using only a few of these functions. Table 2 lists the generic functions and which corresponding
signals are actually provided on the device(s).
The generic functions only describe the general purpose for a signal. A given signal may have a
more specific meaning pecular to the device. The signal names are taken from the schematics
(may be abbreviated) and may vary from device to device. As shown in Table 2, the generic
functions can be grouped into three categories: directional functions, transfer functions, and
confirmation functions.
Directional functions apply specifically to communication with the shuttle or COBUC and tell
the shuttle / COBUC where it must travel to align with the device it will receive from or
discharge to. These are all inputs to the shuttle / COBUC and include the following:
2nd level—The shuttle/COBUC must elevate to the higher of two possible levels. 2nd level is
usually referred to in the documentation as “level 1” (the first level is level 0).
opposite side—The shuttle must run its belt(s) backwards because the device it is receiving from
or discharging to is on the opposite side of the rail from normal. See Note 6.
Note 6: Although the Mark 5 COBUC controls provide a signal for this function, it is not needed because
the COBUC can only receive and discharge forward.

at left—The shuttle/COBUC must traverse leftward.

at right—The shuttle/COBUC must traverse rightward.
Transfer functions either declare that the device is now in a certain state with respect to transfer,
or request that the other device achieve a certain state. The transfer functions include:
early call—applies only to communication between the tunnel and a Milnor centrifugal extractor.
This function tells the extractor to end the current cycle in preparation for transfer if minimum
extract time has elapsed. The Milnor extractor input is called end extract.
discharge desired—There are actually two possible functions: 1) Allied discharge desired
(loading interface input) which tells the Milnor device that the allied loading device is or soon
will be ready to send a batch to it, and 2) Milnor discharge desired (discharge interface output)
which tells the allied discharge device that the Milnor device is or soon will be ready to send a
batch to it.

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Summary of Milnor® Allied Interface Capability, Shuttle

load desired—There are actually two possible functions: 1) Milnor load desired (loading
interface output), which tells the allied loading device that the Milnor device is or soon will be
ready to receive a batch from it, and 2) allied load desired (discharge interface input), which
tells the Milnor device that the allied discharge device is or soon will be ready to receive a
batch from it.
loading mode—tells the receiving device to perform the actions that facilitate receiving. In the
centrifugal extractor, the input is called start extractor and causes the load door to open or the
load chute to lower, and the cylinder to turn. In the dryer, the input is called dryer is loading
and causes the load door to open and the cylinder to turn.
discharge allowed—There are actually two possible functions: 1) allied discharge allowed
(loading interface input), which tells the Milnor device that the allied loading device can now
send, and 2) Milnor discharge allowed (discharging interface output), which tells the allied
discharge device that the Milnor device can now send.
load allowed—There are actually two possible functions: 1) Milnor load allowed (loading
interface output), which tells the allied loading device to begin sending, and 2) allied load
allowed (discharge interface input), which tells the Milnor device to begin sending.
Confirmation functions provide information on the completion status of transfer and include the
following:
transfer not completed—not an error condition (see below) but simply the inverse of transfer
completed.
error: cancel transfer—says that an illegal condition was detected when transfer was attempted
and to stop the transfer. Currently, this function is only provided as an allied output/Milnor
input signal.
data valid—tells the Milnor device (in a loading interface) or the allied discharge device (in a
discharge interface) that batch data are set and should now be read. See Note 7.
transfer completed—says that all goods have been transferred. The signal usually passes from
discharging device to receiving device. Hence, this is usually an input signal in a loading
interface and an output signal in a discharging interface. However, the Milnor shuttle is also
capable, via the belt photoeyes, of detecting when it has received a complete load. So if
needed, it can communicate this information (in the opposite direction) to the loading device.
The signal name varies, depending on the device and type of interface. See Note 7.
Note 7: In most cases, an explicit data valid signal is not needed because another operational signal serves
this purpose. Where the data valid signal is not provided, the various tables of non-numeric signals in the
document “Milnor® Allied Interface Specifications and Signals” indicate which signal should be used for
this purpose.

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Table 2: Operational Functions and Available Signals
Function
Directional Functions Transfer Functions Confirmation Functions
Type-->
Function Dis- Trans- Error: trans-
Name--> Oppo- Dis- Load- Load
2nd At Early Load charge fer not cancel data fer
site At left charge ing al-
Type of level right call desired al- com- trans- valid com-
side desired mode lowed
Interface lowed plete fer plete
Shuttle
input: input: input: input: input: output: output: output: input: input: †
go 2nd load left of right desires shuttle desires shuttle cancel data
Loading load re- home of to load is to load- trans- valid
posn. verse home shuttle empty receive ing fer
dir. load
input: input: input: input: output: input: output: input: output: input: output: ††
go 2nd load left of right desires desires ready to allowed not cancel data
Dis-
unload re- home of to load unload to fin- trans- valid
charge
posn. verse home unload from receive ished fer
dir. shuttle load unload
† All shuttles except the COSLIDE provide a "shuttle is loaded" output. The COSLIDE expects a "belt is loaded" input.
†† The shuttle provides a shuttle "finished unloading" output. It also expects an "allied discharge complete" input.

— End of BICALC13 —

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 How to Upgrade Microprocessor EPROM Chips

BICMUM01 (Published) Book specs- Dates: 20040817 / 20040817 / 20040817 Lang: ENG01 Applic: CSU

How to Upgrade Microprocessor EPROM Chips

Milnor® microprocessor software is continually upgraded to improve performance and maximize
efficiency. Depending on the software change, the new software EPROM (Erasable,
Programmable Read-Only Memory) chips may be offered for sale or for no charge to the
customer. When a set of these chips is changed in the field, ensure that the software version being
installed matches the machine hardware, and that the chips are installed in the proper socket
positions and orientation.

1. How to Change EPROMs

WARNING 1 : Electrocution and Electrical Burn Hazards—Contact with high voltage
will electrocute or burn you. Power switches on the machine and the control box do not eliminate
these hazards. High voltage is present at the machine unless the main machine power disconnect
is off.
• Do not attempt unauthorized servicing, repairs, or modification.
• Lock out and tag out power at the main machine disconnect before servicing, or in
accordance with factory service procedures.

1.1. Remove and Replace EPROM Chips

1. Make sure all power to the machine is off.
2. Locate the chips as described in Section 2 “Location of EPROM Chips”. Note the orientation
of the chips as shown in the figure(s) below.
3. Use a chip removal tool or another small flat tool to carefully remove each EPROM chip
from its base. Be sure to note the numerical order of each chip and the orientation to the key
notch on the socket.
4. Install new chips, making sure the key notch on each chip is properly oriented and that all
pins enter the proper holes in the socket, as shown in Figure 1. If necessary, slightly bend the
pins on the EPROM chip to align the pins with the holes in the socket. After inserting each
chip, verify that all pins are seated in the socket.

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 How to Upgrade Microprocessor EPROM Chips

Figure 1: EPROM Chip Identification and Installation

EPROM Chip and Socket Legend
1. Label
2. EPROM chip
3. Key notch
4. EPROM socket

CAUTION 2 : Machine Damage Hazards—Incorrectly installing any EPROM chip may

destroy or damage the chip or cause the machine or the display to operate erratically.
• Match each chip with its corresponding socket. Each EPROM chip will operate in only
one socket, although it may physically fit into others.
• Align each chip so every pin mates with the correct hole in the socket.

1.2. Verify Proper EPROM Chip Installation—After installing new EPROM chips, apply
power to the machine and turn the machine on. If the chips are properly installed, the display will
continue with the normal display sequence when powering up. If the display is blank or appears
unusual, turn the machine off at once and verify that the chips are correctly oriented in the
sockets.

2. Location of EPROM Chips

Depending on machine model and type, the microprocessor may be an Intel 8085, Intel 8088, or
Intel 80186. Each microprocessor board requires at least one EPROM chip for proper operation,
but these chips may be located differently on each type of processor board. The following
information describes the location and arrangement of the EPROM chips on each type of board,
as well as the favored location for checking the voltages required by each type of board.

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 How to Upgrade Microprocessor EPROM Chips

Table 1: Processor Boards and Applications

Processor Part Typical Machine
Number Applications Comments
08BNCMPAD_ System 7 (e.g., 30015M5G)
08BN785A_ 30-inch E-P Plus
08BN788A_ ---see above---
08BH18EP_ 36- and 42-inch E-P Plus 20 MHz; brown output and chemical connectors
08BH18EPA_ ---see above--- 15 MHz; brown output and chemical connectors
08BH18EPB_ ---see above--- 15 MHz; white output and chemical connectors
08BH18EPC_ ---see above--- 11 MHz
08BH18EPD_ 20 MHz; white output and chemical connectors
8085 non-serial
08BSP___ Mark 2 washer-extractors, etc. 8085 serial with 4 EPROMs
08BSPA___ Mark 2 textile machines 8085 serial with 2 EPROMs
replacement for 08BSP_ and uses jumpers on processor board to match EPROM
08BSPAA_
08BSPA_ type
Revisions A through D use same software; revision E
08BSPC_
software is different
tunnel washers (with expanded 8088 serial with 2 EPROMs; same as Rev. E of
08BSPD_
memory board) 08BSPC_
8088 serial with 4 EPROMs; expanded memory added
08BSPDA_
to processor board
08BSPE_ 80186 serial with 1 EPROM and 4 UART chips
08BSPE1_
08BSPE2_ Mark 6 devices (with graphic 80186 serial with 1 EPROM and 1 quad-UART chip
display)
E-P OneTouch (e.g.,
08BT168A_
30015T5E)

2.1. 8085 Processor Boards (except Coin Machines)—See Figure 4. Install EPROM #1
at the end of the row nearest the corner of the board, then #2, #3, and #4. Chip #4 goes next to the
two chips soldered to the board. See Figure 3 for where to check for proper voltages.

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 How to Upgrade Microprocessor EPROM Chips

Figure 2: Replacement Processor Board

08BSPAA_ Legend
A. Jumpers for setting
EPROM capacity
B. EPROM socket 1
C. EPROM socket 2
D. EPROM socket 3
E. EPROM socket 4
F. DIP switch
G. Capacitor
H. Microprocessor

Figure 3: Where to Check Processor Board Voltages

Typical MTA-31 Legend
1. Ground (Earth)
2. Negative 12VDC
3. Positive 12VDC
4. Positive 5VDC

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 How to Upgrade Microprocessor EPROM Chips

Figure 4: 8085 Processor Boards (Except Coin Machine)

Typical 08BSP_ and 08BSPx_ Processor Boards Legend
A. 8085 microprocessor chip
B. EPROMs
C. Soldered chips
D. DIP switch
E. Battery
F. 08BSPB_ processor board

2.2. 8088 Processor Boards without Memory Expansion Board—See Table 2

“EPROM Locations for 8088 Processor Applications” and Figure 6. If the set consists of only
one EPROM, install it in socket A of Figure 6 . If two EPROMs comprise the set, install EPROM
#2 in socket A and EPROM #1 in socket B. Always install the highest numbered EPROM in
socket A. If the set consists of more than two EPROMs, a memory expansion board must be
present in the machine along with the processor board.

Figure 5: Typical 8088 Processor Board without Memory Expansion Board

08BSPC_ Processor Board Legend
A. EPROMs
B. 8088 processor chip
C. MTA31 for voltage
verification

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 How to Upgrade Microprocessor EPROM Chips

Table 2: EPROM Locations for 8088 Processor

Applications
EPROM Location by Socket
EPROMS in Set A B IC-1 IC-2
4 chips 4 3 2 1
3 chips 3 2 1 —
2 chips 2 1 — —
1 chip 1 — — —

Figure 6: 8088 Processor Board and Optional Memory Expansion Board

8088 Processor Board Memory Expansion Board

Legend
1. Connector, memory board
to processor board
.

2. Socket IC1
3. Socket IC2
4. Chassis ground
5. 8088 microprocessor chip
6. Capacitor
7. Highest numbered
EPROM

2.3. 8088 Processor Boards with Memory Expansion Board—See Table 2 and Figure
6. If the EPROM set consists of three or more EPROMs, install the two highest numbered
EPROMs (e.g., #3 and #4 of a four-chip set) on the processor board, with the highest numbered
EPROM (EPROM #4 of a four-chip set) in socket A, and the EPROM with the second highest
number (EPROM #3 of a four-chip set) in socket B. Install the remaining EPROM(s) on the
memory expansion board with the highest numbered of the remaining EPROMs (e.g., EPROM
#2 of a four-chip set) in socket IC-1 on the memory expansion board and EPROM #1 in socket
IC-2.

2.4. 80186 Processor Boards—This processor board (see Figure 7) is used on all Milnor®
system controllers (Miltron™, Mildata®, etc.) equipped with a color monitor. It is also used on
fully-programmable washer-extractors, textile processing machines with software version 95000
and later, and other models. The single EPROM on this board is located in socket IC-2.
Tip: For maximum reliability and to minimize the chances of the processor board resetting due to low
voltage, adjust the power supply voltage for 80186 processors to 5.10 VDC at the processor

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 How to Upgrade Microprocessor EPROM Chips

board.

There are three major revisions of this board, both of which have Milnor part numbers starting
with “08BSPE”. If the seventh character is a number “1,” the board is a later version with a single
four-channel communications chip. If the seventh character of the part number is a letter, the
board is an earlier version with four one-channel communications chips.
The third version of 80186 processor board—with part number “08BSPE2_”—can be configured
via a jumper on the board to operate either a vacuum fluorescent text display, or a flat panel color
graphic LCD display. The jumper controls the serial communications port on MTA30.
Supplement 1
Rules for Replacing 80186 Processor Boards
Processor board “08BSPET” is obsolete. Depending on machine model and build date, this
board can be replaced by either “08BSPE1T” or “08BSPE2T”, but new software is required.
Contact Milnor's service engineering department to determine the appropriate replacement
board and software.
Processor board “08BSPE1T” has been superseded by board “08BSPE2T”(see Figure 9). If
your machine uses a two-line or four-line vacuum fluorescent text display, either “...E1T” or
“...E2T” will work with your existing software. The most important difference between these
two boards is jumper J1 on the “...E2T” board for selecting the flat panel color graphic LCD
display. This jumper must be set to the TXT or NO position for machines with a vacuum
fluorescent display, or in the GPX (graphics) position for machines with a color LCD display.

Figure 7: Obsolete 80186 Processor Board

08BSPE_ Processor Board Legend
1. Chassis ground
2. Capacitor
3. 80186 microprocessor
chip
4. EPROM in socket IC-2
5. ROM socket (empty
except in Japan)

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Figure 8: 80186 Processor Board

08BSPE1_ Processor Board Legend
A. Chassis ground
B. Capacitor
C. Quad-UART chip
D. 80186 microprocessor
E. EPROM
F. Rotary DIP switches for
keypad
G. ROM socket (empty
except in Japan)

Figure 9: 08BSPE2_ 80186 Processor Board

Detail Legend
A. Jumper for selecting
display type

— End of BICMUM01 —

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