MicroPulse Dryer - Softrol Support
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MicroPulse Dryer
1100 Northpoint Parkway
Acworth, GA 30102
770.974.2700
www.softrol.com
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Contents
1. Introduction
2. Front Panel Display
3. Start a Formula
4. Setups Defined
5. Loading the Defaults
6. The RAM Vocabs
7. Learning to Program
8. Defining Instructions
9. Password Levels and Access Rights
10. Maintenance Prompts
11. Key Press
12. Override Displays
13. Copying Memory Contents
14. Hardware Overview
15. Error Fault Lists
16. Default Operations and Formulas
17. Schematic
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Introduction to the microPulse Dryer Controller
The Softrol MicroPulse Dryer Controller is the most advanced, state-of-the art
dryer controller in the industry. Its software, specifically designed, provides safe
and efficient control and easy formula programming. The controller automatically
gathers production data to give clear indication of dryer department efficiency. It
is also communications ready, making it possible to transfer production data to a
PC workstation via PulseNet, our proprietary plant Floor Networking System. Its
modular design allows quick troubleshooting procedures and allows for easy
expansion by simply adding modules as needed.
The MicroPulse Dryer Controller consists of two units. The main control
enclosure houses the microprocessor and provides the points of connection
between the controller and the machine(s). It includes all the input and output
modules necessary to actuate the machine and to completely control all the
machine processes.
The second enclosure is the Front Panel Display (FPD). The FPD is typically
mounted on the front of the machine, and the operator uses it to communicate
with the controller. Its operation is easy. Once the machine has been loaded,
the operator presses the [YES] key and then selects the desired formula.
Password protected access allows key personnel to program new formulas and
operations.
The MicroPulse Dryer Controller Front Panel is constructed of corrosion-resistant
materials. Its operator-friendly interface reduces the learning curve and speeds
up the creation and editing of formulas. The programming mode can only be
entered via high-level user passwords for security. There are 128 different
formulas and 64 operations that can be programmed and referenced by either
name or number. The MicroPulse Dryer Controller keeps in its memory
information about the loads processed (including date and time stamping of each
load), load time, formula executed, formula time, and unload time.
The MicroPulse Dryer Controller has two basic operating states: Normal
Operating Mode and Password Protected Mode.
In the Normal Operating Mode, the MicroPulse Controller will execute
programmed formulas, control all aspects of machine operation, monitor and
record pertinent machine and process information, and monitor all user-defined
operation parameters (i.e., Machine Setups).
The Password Protected Mode allows personnel access to one of seven levels of
protected menus via a password. These different levels allow specific users to
perform a variety of tasks including programming the controller, specifying userdefined Machine Setups, as well as many other advanced control functions.
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VFD
Display
LED
Indicators
Key
Pad
Manual Push
Buttons and
Indicator Lights
The Front Panel Display (FPD) on the MicroPulse Dryer control has a 4 line by
20-character vacuum florescent display (VFD), 3 light emitting diodes (LED)
indicators for time, inlet and outlet temperature displays. 16 key pad for data
entry, and 16 pushbuttons for manual operation.
Key Pad Description
Press the [YES] key to display the formula selection menu. The [YES] key also
restarts the formula after it has been paused. In the programming mode, the
[YES] key is used to answer setup and programming questions. In the
vocabularies mode, the [YES] key moves the cursor left.
The [NO] key pauses the formula. In the vocabularies mode, the [NO] key
moves the cursor right.
The [UP] and [DOWN] arrow keys are used to scroll while in programming,
formula advancement, and a various list of choices.
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The numerical keys are used to program and setup the machine along with
formula starting without the use of scrolling.
The [ENT] key is used to accept choices while in programming, machine setup,
and formula starting.
The [CLR] key can be used to pause an operator signal or maintenance alarm for
the programmed time in the customer Silent Alarm setups. Pressing the [CLR]
key will not silence safety alarms. The [CLR] key is also used in setups and
programming to clear the value being programmed setting the value to “0”.
Light Emitting Diode (LED) Indicators
The time indicator represents different times depending on the mode of
operation.
Formula Execution Mode
During this mode, the time indicator represents in minutes and seconds
the time remaining in the formula. This time is the sum of all step times
programmed in the formula. The time decreases as the formula proceeds.
The time is held while the formula is paused or waiting to satisfy.
Unload Mode
The time display shows the increasing timer while the machine is waiting
to be unloaded.
Load Mode
The time display shows the increasing timer while the machine is waiting
to be loaded.
Programming Mode
The time displays show the hexadecimal number corresponding to the
current menu location. Please note. The Load/Unload time does not
increase while in the password protected programming mode.
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The Inlet temperature indicates the current temperature of the inlet air supply to
the drying chamber. The display will be in either Celsius or Fahrenheit.
The Outlet temperature indicator represents different displays depending on the
mode of operation.
Formula Execution Mode
During this mode, the outlet temperature indicator represents the air
temperature at the outlet of the drying chamber. The display will be in
either Celsius or Fahrenheit.
Programming Mode
The outlet temperature indicator provides information about previous edits
performed on the formula or operation. A “0” in the display indicates that
the formula or operation has not been edited since it was created. The
editing password level is indicated if the formula or operation has been
edited.
Manual Pushbuttons and Indicator Lights
At Dry Position PB 1
This PB has to do with tilt and the light on means the dryer is not tilted but rather
horizontal which is the dry tilt position.
Blowers On PB 2
This PB indicates that the blower motors are on. The indicator light illuminates
when the blower motors are on.
Main Fan PB 3
This PB indicates that the main fan motor is on. The indicator light illuminates
when the main fan motor is on.
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Burner Fan PB 4
This PB indicates that the burner fan motor is on. The indicator light illuminates
when the burner fan motor is on.
Function PB 5
This PB when in conjunction with other PB’s, (Unload Front, Load Front,
Open/Close Door) allows manual movement of the machine.
Pilot RQX PB 6
This PB indicates that the controller has requested the Pilot to be lit. The
indicator light illuminates when the pilot is being lit.
Main Fuel PB 7
This PB indicates that the main fuel valve is opened. The indicator light
illuminates when the main fuel valve is open.
Recirculation Enabled PB 8
This PB on equipped machines indicates that the recirculation flap is closed. The
indicator light illuminates when the recirculation flap is opened.
Rotate CW PB 9
This PB rotates the basket forward (clockwise) during loading and unloading.
The indicator light illuminates when the basket is rotating in the forward direction.
Dryer Horiz PB 10
On equipped machines, this PB will lower the front/rear of the machine into the
run position. The indicator light illuminates while the machine is being placed
into the run position
Unload Front PB 11
On equipped machines, this will raise the rear of the machine into the unloading
position. The indicator light illuminates when the rear of the machine is in the
unload position.
Close Door PB 12
Pressing and holding this PB in conjunction with the function button will close the
Dryer’s front door. These buttons must be held in until the door is closed. If not,
the door will return to the open position. The indicator light illuminates when the
door is fully closed and the control sees the door closed switch.
Rotate CCW PB 13
This PB rotates the cylinder reverse (counter clockwise) during loading and
unloading. The indicator light illuminates when the cylinder is rotating in the
reverse direction.
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Unload Rear PB 14
On equipped machines, this will raise the front of the machine into the unloading
position. The indicator light illuminates when the front of the machine is in the
unload position.
Load Front PB 15
On equipped machines, this will raise the front of the machine into the loading
position. The indicator light illuminates when the machine is in the load position
Open Door PB 16
This will open the machines front door. The indicator light illuminates when the
door is fully opened.
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Starting a Formula
To execute a formula you must load the machine, close the door and return to
horizontal before running a formula.
Waiting for Dryer
to Receive Load!!
Depress [YES] Key to
Select Formula
Press the [YES] key.
Formula Number 0
Use arrow key to select
ENTER=accept 0=exit
Enter the desired formula number or using the arrow keys, scroll to the desired
formula number to be executed. For example to execute formula number 100
press [1][0][0].
Formula # 100
Sheets
Use arrow key to select
ENTER=accept 0=exit
Press [ENT].
Sheets
INITIAL HEAT
Step # 1
Line # 2
T=0:26
S=4:56
After the formula execution, the MicroPulse Dryer controller will start timing how
long it takes to unload the machine. The display will read.
Sheets
Waiting for Dryer
To Unload!!
Press [YES] Key Continue
Press the [YES] key.
Sheets
Waiting For Dryer
To Unload!!!
T=25:46 Step =0:00
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The display shows the last formula to be executed. Formula number 100:
Sheets. The display shows how long the formula ran during that execution.
T=25:46.
Resetting the MicroPulse
To be able to execute another formula, the control must be reset to the Waiting to
Load display. There are two ways to do this. The first way being opening the
rear door and tilting to the unload rear position, and then closing the rear door.
The second way to reset the display to the Waiting to Load screen, enter a valid
level 1 to 7 password. Now press the [ENT] + [NO] simultaneously to reset the
display.
MicroPulse Tilting Machines
To unload a tilting machine, press the [Unload Rear] or [Unload Front] button
depending on the unload location. After the machine is fully tilted, the [Unload
Rear] or [Unload Front] button depending on the unload location, will remain
illuminated.
To rotate the load from the basket, the operator can press and hold the
[Function] button and either the [Rotate CW] button or the [Rotate CCW] button
depending on the direction preferred.
After the unloading is complete, close the rear door. This resets the display to
the Waiting to Load screen.
Advancing in a Formula
To advance in a formula, enter a valid level 1-7 password. Using the [UP] arrow
key, scroll forward to the desired step in the formula.
Reversing in a Formula
The MicroPulse Dryer Controller will not allow you to scroll backward in a
formula. If the advanced programming functions are not used to control formula
flow and you need to go backwards in a formula, you must cancel the formula,
restart the formula, then advance to the desired step in the formula.
Canceling a Formula
To cancel a formula, pause the program by pressing the [NO] key. Enter a valid
level 1-7 password. Press the [YES] and the [NO] keys simultaneously twice to
reset to the “Waiting to Load” display.
Adding and Subtracting Time During Formula Execution
For Safety purposes, the freeze timer (Level 8) is disabled during formula
execution although the freeze timer may be used after the formula has
completed.
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Setup Procedure
The machine setups tailor the operation to suit individual preferences and
applications. These parameters are global meaning they affect all formulas.
Some of these parameters (maximum temperature, for example) can also be set
locally to override the global parameters and only effect the current formula.
Local parameters are normally used in special circumstances and are controlled
through the Advanced Functions. Please refer to the Advanced Functions for
information. Use the following sequence to set up the user programmable
features.
From the “Waiting to Receive Load” display, enter a valid level 7 password
(please refer to Passwords).
1=Setups
3=Maint.
5=Totals
Selection?
2=Program
4=Diagnos
6=Clock
0=exit
Select 1=Setups
1=Machine Setup
2=Maintenance Setup
3=Clear Ram Vocabs
4=Passwords
0=exit
Select 1=Machine Setup
The current setting is shown on the display. The Programmable Functions
section describes all of the questions in detail.
Note: Use the [YES] or [NO] keys and the numbers on the keypad to change the
answer to the setup questions. Some questions require the operator to enter a
value.
Press the [ENT] key to accept the answer.
Press only the [ENT] key to accept the default or keep the previously
programmed value.
You cannot go backwards through the questions. If you need to change the
answer to a previous question, press the [ENT] key to accept the current values
to the remaining questions then restart the procedure.
Press the [CLR] key to clear the numeric value of the current question.
After all setups are complete pressing the [CLR] key will accept the changes.
The MicroPulse does not store any of the changes in memory until the last setup
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question is answered and the [CLR] key is pressed. If the power is lost during
the setup procedure, the changes will not take effect.
Metric System
This indicates whether the user desires the Level and Temperature prompts to
be in Inches/Deg F or Millimeters/Deg C. If Metric Selected, prompts in the Setup
routine will change to MM and Deg. C where appropriate. Answer YES for Metric
or NO for English.
Heat Overtime Error
This time in MM:SS is the longest possible time that is desired for the heat to be
on during one formula execution. If the heat is on for a time greater than this set
time, formula execution will be halted and the Heat Overtime Error will be
displayed. This setup is intended to eliminate any conditions that would allow
excessive heat cycles.
Inlet Temp Hi
This is the highest temperature limit that the drying chamber inlet will attain. If
the inlet temperature reaches this level, formula execution will be halted and the
Inlet Temp Hi error message will be displayed. This setup is intended to prevent
load damage due to high temperature.
Inlet Temp Lo
This is the lowest temperature limit that the drying chamber inlet will attain. If the
inlet temperature reaches this level, formula execution will be halted and the Inlet
Temp Lo error message will be displayed. This setup is a useful tool to help
diagnose a bad or faulty RTD.
Outlet Temp Hi
This is the highest temperature limit that the drying chamber outlet will attain. If
the outlet temperature reaches this level, formula execution will be halted and the
Outlet Temp Hi error message will be displayed. This setup is intended to
prevent load damage due to high temperature.
Outlet Temp Lo
This is the lowest temperature limit that the drying chamber outlet will attain. If
the outlet temperature reaches this level, formula execution will be halted and the
Outlet Temp Lo error message will be displayed. This setup is a useful tool to
help diagnose a bad or faulty RTD.
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Main Fan Vacuum Lo
Measured in inches, this is the minimum suction pressure of the Main Fan that
will be required for a safe formula execution. If the suction pressure of the Main
Fan drops below this setting, formula execution will be halted and the Main Fan
Vacuum Lo error message will be displayed. This may indicate the lint filter
requires cleaning.
Note: Vacuum pressures are not usually installed and that the setups should
have certain values if not installed to prevent errors.
Main Fan Vacuum Hi
Measured in inches, this is the maximum suction pressure of the Main Fan that
will be required for a safe formula execution. If the suction pressure of the Main
Fan exceeds this setting, formula execution will be halted and the Main Fan
Vacuum Hi error message will be displayed. Default setting 11.00”.
Makeup Air Vacuum Lo
Measured in inches, this is the maximum suction pressure of the Makeup Air
Blower that will be required for a safe formula execution. If the suction pressure
of the Makeup Air Blower falls below this setting, formula execution will be halted
and the Makeup Air Vacuum Lo error message will be displayed. Default setting
0.00”.
Makeup Air Vacuum Hi
Measured in inches, this is the maximum suction pressure of the Makeup Air
Blower that will be required for a safe formula execution. If the suction pressure
of the Makeup Air Blower exceeds this setting, formula execution will be halted
and the Makeup Air Vacuum Hi error message will be displayed. Default setting
11.00”.
Integral #1 Timer
This setup is referred to as the RESET. The Integral #1 Timer is a value in
seconds of how often the Outlet temperature integral is calculated. The initial
setting for reset should be the lowest number of resets per minute. Increase the
resets per minute in small increments, allowing the system to settle down before
making additional changes. When the system starts to oscillate, back the setting
off enough to re-establish system equilibrium.
Integral #2 Timer
The Integral #2 Timer is a value in seconds of how often the Inlet temperature
integral is calculated. The initial setting for reset should be the lowest number of
resets per minute. Increase the resets per minute in small increments, allowing
the system to settle down before making additional changes. When the system
starts to oscillate, back the setting off enough to re-establish system equilibrium.
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Derivative #1 Timer
This is a value in seconds of how often the Outlet temperature derivative is
calculated. This is sometimes called Rate. The Rate’s function is to reduce or
eliminate overshoot. It is based in time, which must be tuned to work with the
overall system response time. The initial setting for the rate should be at the
highest resets per minute possible. Decreasing the seconds in the setup
increases the resets per minute. Increase the resets per minute in small
increments. After each adjustment, observe the approach of the actual outlet
temperature to the programmed set point. If it overshoots, continue to increase
the reset rate in small increments. Continue adjusting the resets per minute,
lowering it until the outlet set point is controlled and stable. If at some point the
system becomes very sluggish or may not be able to reach the new set point,
then too much rate has been adjusted into the control system. The number of
resets per minute of rate must be decreased to reduce the “dampening effect”.
Derivative #2 Timer
This is a value in seconds of how often the Inlet temperature derivative is
calculated. The Rate’s function is to reduce or eliminate overshoot. It is based in
time, which must be tuned to work with the overall system response time. The
initial setting for the rate should be at the highest resets per minute possible.
Decreasing the seconds in the setup increases the resets per minute. Increase
the resets per minute in small increments. After each adjustment, observe the
approach of the actual inlet temperature to the programmed set point. If it
overshoots, continue to increase the reset rate in small increments. Continue
adjusting the resets per minute, lowering it until the inlet set point is controlled
and stable. If at some point the system becomes very sluggish or may not be
able to reach the new set point, then too much rate has been adjusted into the
control system. The number of resets per minute of rate must be decreased to
reduce the “dampening effect”.
Outlet Kp
Enter a constant from 1-10 for the Outlet temperature calculations. This value
will increase the amount of change of the firing rate motor as it continues to move
away from the set point. The value of this constant should be as small as
possible to yield stability. Increasing the constant allows more changes in the
firing rate.
Inlet Kp
Enter a constant from 1-10 for the Inlet temperature calculations. This value will
increase the amount of change of the firing rate motor as it continues to move
away from the set point. The value of this constant should be as small as
possible to yield stability. Increasing the constant allows more changes in the
firing rate.
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Gas Meter
This setup tells the controller if there is a gas meter being used to measure the
gas flow amount during formula execution.
Type 1
This is a flow meter that uses a 4-20 milliamps communication.
Type 2
This is a flow meter that uses pulsating communications.
K-Factor
If a gas meter is being used, this setting tells the controller the pulses per
inch of the gas meter.
Prompt Weight
This indicates whether the operator wishes to prompt the weight of the load
before the start of each formula.
Low Weight Allowed - If Prompt Weight is answered Yes, enter the Low
Weight Value of valid weight range for the machine.
High Weight Allowed - If Prompt Weight is answered Yes, enter the High
Weight Value of valid weight range for the machine.
ArcNet Node
This allows the user to define if the machine is in an automated system or a
manual system. This must be answered Yes in all automatic systems.
Full Baud Rate
Y/N this is used only when a RS 232 port network is active on the Arcfiber card.
Multidrop Net
Y/N this is used only when a RS 232 port network is active on the Arcfiber card.
LAN Member ID #
This is used only when a RS 232 port network is active on the Arcfiber card.
NOTE: THESE SETUPS ARE ONLY IF ARCNET NODE= YES.
Loading Position
This is the position for a shuttle to load the dryer. Positions are numbered in a
system from 0 to 32. Position 0 is always to the far left of the wash aisle facing
the dryer. The rightmost position is determined for each system and is the last
needed position to the far right of the wash aisle facing the dryer aisle from the
washer's aspect.
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Unloading Position
This is the position for a shuttle or a conveyor to unload the dryer. The unloading
position setup follows the same rules as the loading position for shuttle unloaded
machines.
Machine Class Type
This is the class type of the machine. The valid range is 0 to 94. Certain
machines may be equipped differently than other machines. In addition, certain
processes may be preferred in particular machines. This is accomplished
through using the Class Type. When items to be processed are entered into the
AutoPulse system, they are assigned a Class Type Number for the Dry
Classification. The corresponding items will be processed in a machine with a
matching Class Number. Assigning Machine Class Type 99 will prevent the
machine from automatic operation and is useful when maintenance or testing is
performed on a machine.
Sequence Priority #
The sequence priority establishes the manner in which machines are selected for
loading and unloading. Machines with a sequence priority of zero will rotate
priority according to how long the machines have been waiting to load or unload.
Machines with a sequence priority greater than zero attain a higher priority of
selection than those units with a sequence priority of zero. A sequence Priority
of 1 is the highest priority. The available machine with the smallest non-zero
priority will be selected preferentially. Machines with the same priority will be
handled in a shortest path algorithm, meaning that the machine closest to the
current position of the shuttle will be handled first.
Minimum Weight
This establishes the minimum weight that a machine will accept for a load.
Maximum Weight
This establishes the maximum weight that a machine will accept for a load.
Lo Formula Range 1-3
This establishes the minimum formula number for a formula range 1-3 that a
machine will accept for a load. Three acceptable ranges can be established.
Hi Formula Range 1-3
This establishes the maximum formula number for formula range 1-3 that a
machine will accept for a load.
Belt System
This setup determines whether the dryer will be unloading onto a shared flat belt
conveyor (East/West type) and/or a shuttle belt system. If the dryer is to unload
automatically onto a flat belt conveyor, answer YES. When unloading onto a flat
belt conveyor, unloading position indicates which direction to run the belt when
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unloading the dryer. If the dryer is to unload automatically onto a scissors
shuttle, answer YES.
Send Data Record
This setup works in conjunction with the optional database (GUPPI) program.
Answering (Yes) sends the data record to a printer console or to a CSV file
connected to the database.
Idle At Load Position
This setup determines whether the dryer will be positioned at the horizontal rest
position with doors closed or the accept load position when waiting for a load
from the shuttle. In some climates, it is preferable to have the dryer waiting in the
horizontal door closed position to prevent cold and/or hot air from entering into
climate-controlled environments. If the dryer is to sequence to the Load Position
At Idle, answer YES. Otherwise, answer NO.
Loading Height
This establishes the height that a scissors shuttle should be positioned at to load
the machine. A height of 0 is the lowest height and a height of 99 is the highest
height. If the system does not utilize a scissors shuttle, this setup may be
programmed to 0.
Loading Depth
This establishes the depth that a scissors shuttle should be positioned at to load
the machine. A depth of 0 is the depth of the shuttle when positioned at the
shuttle's southern limit. Depth may increase to a maximum of 99. Depth's
greater than the shuttle's middle limit establish positioning towards the shuttle's
northern limit. If the system does not utilize a scissors shuttle, this setup may be
programmed to 0.
Unloading Height
This establishes the height that a scissors shuttle should be positioned at to load
the machine. A height of 0 is the lowest height and a height of 99 is the highest
height. If the system does not utilize a scissors shuttle, this setup may be
programmed to 0.
Unloading Depth
This establishes the depth that a scissors shuttle should be positioned at to
unload the machine. A depth of 0 is the depth of the shuttle when positioned at
the shuttle's southern limit. Depth may increase to maximum of 99. Depth's
greater than the shuttle's middle limit establish positioning towards the shuttle's
northern limit. If the system does not utilize a scissors shuttle, this setup may be
programmed to 0.
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Loading the Defaults
Default Operations
From the Waiting to Load screen, enter a valid level 6 or 7 password.
1=Setups
3=Maint.
5=Totals
Selection?
2=Program
4=Diagnos
6=Clock
0=exit
Select 2=Program
1=Ops2=Formulas
3=Clr Ops 4=Clr Forms
5=Copy
6=Prompts
Selection? 0=exit
Select 3=Clr Ops
Load Defaults
Use YES/NO Keys
ENTER=accept 0=exit
Select YES then press [ENT]. This loads all default operations for quick
reference.
Default Formulas
1=Ops2=Formulas
3=Clr Ops 4=Clr Forms
5=Copy
6=Prompts
Selection? 0=exit
Select 4=Clr Forms
Load Defaults
Use YES/NO Keys
ENTER=accept 0=exit
Select YES then press [ENT]. This loads all default formulas for quick reference.
Exit out of the control. From the Waiting to Load screen, enter a valid level 7
password.
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Default Vocabs
1=Setups
2=Program
3=Maint.
4=Diagnos
5=Totals
6=Clock
Selection? 0=exit
Select 1=Setups
1=Machine Setup
2=Maintenance Setup
3=Clear Ram Vocabs
4=Passwords
0=exit
Select 3=Clear Ram Vocabs
Clear All Ram Vocabs
Key in Password!!!!
NO=exit
Enter a valid level 7 password and all Ram Vocabs are cleared loading all default
vocabs. Exit out of the control.
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RAM Based Vocabularies
RAM based vocabularies are user-programmable “words” that are used on the
MicroPulse Dryer Controller to display information and operator prompts. The
user may edit the following vocabularies.
1.
2.
3.
4.
Formula Names
Operation Names
Formula Prompts
Maintenance Items
128 Words
32 Words
32 Words
32 Words
16 Characters
16 Characters
16 Characters
16 Characters
To enter the RAM based vocabularies on the MicroPulse Dryer Controller; you
use a universal word editor. This word editor uses the same commands to enter
and edit all vocabulary words. The desired word is entered from the keypad and
then it must be saved. Each individual character in the word is entered using its
ASCII code number. For example, to enter an “A” press [065] on the FPD, which
is the ASCII code number for “A”.
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The ASCII Character Codes
The ASCII Character Codes are used to enter text into the programmable text
(RAM Vocab). The RAM Vocab is used to enter maintenance prompts, text
prompts, operation names, and formula names. Refer to the appropriate section
in the MicroPulse Dryer manual for detailed instructions on entering the character
codes.
032 = (space)
052 = 4
071 = G
090 = Z
109 = m
033 = !
053 = 5
072 = H
091 = [
110 = n
034 = "
054 = 6
073 = I
092 = ¥
111 = o
035 = #
055 = 7
074 = J
093 = ]
112 = p
036 = $
056 = 8
075 = K
094 = ^
113 = q
037 = %
057 = 9
076 = L
095 = _
114 = r
038 = &
058 = :
077 = M
096 = `
115 = s
039 = '
059 = ;
078 = N
097 = a
116 = t
040 = (
060 = <
079 = O
098 = b
117 = u
041 = )
061 = =
080 = P
099 = c
118 = v
042 = *
062 = >
081 = Q
100 = d
119 = w
043 = +
063 = ?
082 = R
101 = e
120 = x
044 = ,
064 = @
083 = S
102 = f
121 = y
045 = -
065 = A
084 = T
103 = g
122 = z
046 = .
066 = B
085 = U
104 = h
123 = {
047 = /
067 = C
086 = V
105 = I
124 = |
048 = 0
068 = D
087 = W
106 = j
125 = }
049 = 1
069 = E
088 = X
107 = k
126 =
050 = 2
070 = F
089 = Y
108 = l
127 =
051 = 3
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Programming The Prompts
The Prompt instruction is a very useful instruction that can be found in the
Advanced Functions in the instruction list of the MicroPulse Dryer control. It
allows the user to supply information the operator. Up to three prompts may be
displayed at once. One or Two prompt instructions may be combined to provide
additional information to the operator. Following is an example of how this
Advanced Function is used.
005:
006:
007:
008:
009:
Tumble Only
Dwell Timer 999 Seconds
Prompt: Check Load!!
Prompt: Is Load Dry?
Signal Until Operator Cancels
Editing User Defined Prompts
To program the user defined prompts, from the Waiting to Load screen, enter a
valid level 6 or 7 password.
1=Setups
3=Maint.
5=Totals
Selection?
2=Program
4=Diagnos
6=Clock
0=exit
Select 2=Program
1=Ops2=Formulas
3=Clr Ops 4=Clr Forms
5=Copy
6=Prompts
Selection? 0=exit
Select 6=Prompts
Line 2 on the LCD will display the current text.
Prompt # 1
Prompt # 1
Use arrows to scroll
ENTER=accept NO=exit
Scroll to the desired prompt and press [ENT]
Prompt # 27
ENT= Character # 10
YES = Left NO = Right
YES + NO = Accept
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The cursor (appears as a flashing line) the character position to be edited. With
the cursor in position, key in the numerical code (see the ASCII reference) for the
desired character. For example if you are programming Unload Dryer. Press
[8][5] then press [ENT]. The U will be shown now press the [NO] key to move the
cursor right.
Urompt # 27
ENT= Character # 85
YES = Left NO = Right
YES + NO = Accept
Continue with this sequence until you have programmed the desired operation
name.
U=[8][5] [ENT] [NO]
n=[1][1][0] [ENT] [NO]
l=[1][0][8] [ENT] [NO]
o=[1][1][1] [ENT] [NO]
a=[9][7] [ENT] [NO]
d=[1][0][0] [ENT] [NO]
space=[3][2] [ENT] [NO]
D=[6][8] [ENT] [NO]
r=[1][1][4] [ENT] [NO]
y=[1][2][1] [ENT] [NO]
e=[1][0][1] [ENT] [NO]
r=[1][1][4] [ENT] [NO]
space=[3][2] [ENT] [NO]
space=[3][2] [ENT] [NO]
space=[3][2] [ENT] [NO]
space=[3][2] [ENT] [NO]
[YES]+[NO]
1=Ops2=Formulas
3=Clr Ops 4=Clr Forms
5=Copy
6=Prompts
Selection? 0=exit
If required, repeat the procedure or exit.
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Learning to Program the MicroPulse Dryer Controller
The normal programming sequence is:
-Load default operations, formulas, and vocabs into the control.
-Program your User Defined Setups.
-Program user defined prompts.
-Program operations.
-Program formulas.
-Setup passwords.
-Edit preventative maintenance prompts and next service intervals.
Formula Planning
Inserting lines of instructions and operations create formulas. To aid in this, with
the MicroPulse Dryer controller you can build operations and inset them into
formulas. Inserting lines of instructions creates operations.
In planning for programming operations, it is necessary to view your formulas
and see which instructions are most used. After determining this, build a set of
operations that most fit your drying needs. The MicroPulse Dryer controller has
default operations ranging from operation numbers 33 to 64. These are for the
user to use to learn to program by or even to use in their formulations. The
MicroPulse Dryer controller also has default formulas ranging from formulas 100
to 128. These are a good for referencing. Examples of each may be found later
in the manual.
Formula Name
Formula Name is always the first instruction of any formula. The formula name
may not be deleted. Editing the formula name enables the corresponding
formula for selection by the operator. Setting the Formula Name to Unused
prevents selection of the formula by the operators.
Formula End
Formula End is always the last instruction of any formula. Inserting instructions
and operations between the Formula Name and the Formula End instructions
creates formulas. Memory usage is dynamic so that formulas take up only the
required amount of memory.
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Operation Name
Operations are programmed just like formulas. An operation is usually a
commonly used set of instructions to carry out a desire sequence like INITIAL
HEAT. Operations may be inserted into formulas like MACROS, and then edited
to suit the exact need of the formula. When editing operations, the OPERATION
NAME is always the first instruction of any operation. Editing the OPERATION
NAME enables the corresponding operation for insertion in formulas.
Operation End
Operation End is always the last instruction of and operation. Inserting
instructions between the OPERATION NAME and the OPERATION END
instructions creates operations. Memory usage is dynamic so that operations
take up only the required amount of memory. OPERATION END is not copied
into a formula when an operation is inserted.
Programming Operations
Since formulas are easier to program with operations, operations need to be
programmed first. Setting up operations will save substantial time later when
formulas are programmed.
Name the Operation
From the Waiting to Load screen, enter a valid level 6 or 7 password.
1=Setups
3=Maint.
5=Copy
Selection?
2=Program
4=Diagnos
6=Clock
0=exit
Select 2=Program
1=Ops2=Formulas
3=Clr Ops 4=Clr Forms
5=Copy
6=Prompts
Selection? 0=exit
Select 1=Ops
Key in Oper. # 0
ENTER= Accept NO = Exit
Scroll or enter the number that you wish to program and press [ENT].
1:001 ?OPERATION?
002 END OPERATION
3-e 5-s 0-exit
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The first line is the active line and all editing operates on the contents of that line.
Line 4 on the LCD lists the editing options that are possible. 3-e is for editing the
top line. 5-s scrolls the LCD screen left and right. Only 20 characters may
display on a line and this option allows more of the line to be viewed. Press [3] to
edit.
Operation # 1
CLR= Set to Unused
ENT= Edit Name
0 = exit
Press the [CLR] key to set too unused. Press the [ENT] key to edit the operation
name.
_
ENT= Character # 00
YES = Left NO = Right
YES + NO = Accept
The cursor (appears as a flashing line) the character position to be edited. With
the cursor in position, key in the numerical code (see the ASCII reference) for the
desired character. For example if you are programming COOLDOWN. Press
[6][7] then press [ENT]. The C will be shown now press the [NO] key to move the
cursor right.
C_
ENT= Character # 67
YES = Left NO = Right
YES + NO = Accept
Continue with this sequence until you have programmed the desired operation
name.
C=[6][7] [ENT] [NO]
O=[7][9] [ENT] [NO]
O=[7][9] [ENT] [NO]
L=[7][6] [ENT] [NO]
D=[6][8] [ENT] [NO]
O=[7][9] [ENT] [NO]
W=[8][7] [ENT] [NO]
N=[7][8] [ENT] [NO]
space=[3][2] [ENT] [NO]
space=[3][2] [ENT] [NO]
space=[3][2] [ENT] [NO]
space=[3][2] [ENT] [NO]
space=[3][2] [ENT] [NO]
space=[3][2] [ENT] [NO]
space=[3][2] [ENT] [NO]
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space=[3][2] [ENT] [NO]
[YES]+[NO]
1:001 COOLDOWN
002 END OPERATION
3-e 5-s 0-exit
Now using the arrow keys, place the active line to the top line.
002 END OPERATION
1-i 2-d 3-e 5-s 0-exit
Line 4 on the LCD list the editing options that are possible. 1-i insert. 2-d delete.
3-e edit. 5-s shift. 0-exit. Press 1-i to insert an instruction. You will see "Run
<time>". Scroll through the operation list using the arrow keys to the
Temperature Control and press [ENT]. Now scroll through the list until you find
Cooldown <temp>. Press [ENT].
Cooldown <temp>.
Key in Temp 0 F
To cooldown the load to 135 Degrees Fahrenheit/Celsius, press [1][3][5].
002: Cooldown 135 F
003: END OF OPERATION
1-i 2-d 3-e 5-s 0-exit
Now using the arrow keys, place the active line to the top line.
003 END OPERATION
1-i 2-d 3-e 5-s 0-exit
Press 1-i to insert an instruction. You will see "Run <time>". Press [ENT].
Run <time>
Key in time 0:00
ENTER= accept
To run a total of five minutes, press [5][0][0]
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002: Cooldown 135 F
003: Run 5:00
004: END OF OPERATION
1-i 2-d 3-e 5-s 0-exit
This operation tells the controller to cool the load down to below 135 Degrees
Fahrenheit/Celsius or run a total of five minutes attempting to cooldown to below
135 Degrees Fahrenheit/Celsius.
After you have programmed the operation, press 0-exit then press 1=Ops to
enter another operation and follow this guideline.
Programming Formulas
Name the Formula
From the Waiting to Load screen, enter a valid level 6 or 7 password. Select
2=Program. Select 2=Formulas
Key in Formula # 0
ENTER= Accept NO = Exit
Scroll or enter the number that you wish to program and press [ENT].
1:001 ?formula?
002 END FORMULA
3-e 5-s 0-exit
The first line is the active line and all editing operates on the contents of that line.
Line 4 on the LCD list the editing options that are possible. 3-e is for editing the
top line. 5-s scrolls the LCD screen left and right. Only 20 characters may
display on a line and this option allows more of the line to be viewed. Press [3] to
edit.
Formula # 1
CLR= Set to Unused
ENT= Edit Name
0 = exit
Press the [CLR] key to set too unused. Press the [ENT] key to edit the formula
name.
_
ENT= Character # 00
YES = Left NO = Right
YES + NO = Accept
The cursor (appears as a flashing line) the character position to be edited. With
the cursor in position, key in the numerical code (see the ASCII reference) for the
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desired character. For example if you are programming Sheets. Press [8][3]
then press [ENT]. The S will be shown now press the [NO] key to move the
cursor right.
S_
ENT= Character # 83
YES = Left NO = Right
YES + NO = Accept
Continue with this sequence until you have programmed the desired formula
name.
S=[8][3] [ENT] [NO]
h=[1][0][4] [ENT] [NO]
e=[1][0][1] [ENT] [NO]
e=[1][0][1] [ENT] [NO]
t=[1][1][6] [ENT] [NO]
s=[1][1][5] [ENT] [NO]
[YES]+[NO]
1:001 Sheets
002 END FORMULA
3-e 5-s 0-exit
Now using the arrow keys, place the active line to the top line. Line 4 on the LCD
lists the editing options that are possible. 1-i insert. 2-d delete. 3-e edit. 4-m
macro shows only Operation Names no instructions. 4-n returns display to
normal viewing Operation Names and instructions. 5-s shift display. 0-ex exit.
002 END FORMULA
1-i 2-d 3-e 4-m 5-s 0-ex
Press 1-i. This gives us another list of options. From here we can insert an
operation from our operations that was programmed, insert an instruction from
the same list that was available in programming operations list, or insert an entire
formula. Here we will choose 1= Ins. Operation.
1 = Ins. Operation
2 = Ins. Instruction
3 = Ins. Formula
0=exit
Using the arrow keys, scroll through the operations list until you reach the
desired operation to be inserted. We will use an operation that we have
programmed named INITIAL HEAT. Following will be an example of what is
entered into the control.
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001: INITIAL HEAT
002: Inlet Temperature 600.F
003: Outlet Temperature 200.F
004: Run Time 3:00
005: END OF FORMULA
Using the arrow keys, scroll until the active line is on top.
005: END OF FORMULA
1-i 2-d 3-e 4-m 5-s 0-ex
Press 1-i. Scroll though the operations list until you reach the desired operation
to be inserted. We will use an operation we programmed named HI TEMP HEAT
CYCLE. Following will be an example of what is entered into the control.
006: HI TEMP HEAT CYCLE
007: Recirculation On
008: Inlet Temperature 600.F
009: Outlet Temperature 200.F
010: Run Time 14:00
011: END OF FORMULA
In our HI TEMP HEAT CYCLE operation that we have placed into the formula,
we have decided that we want to dry for 16:00 minutes instead of 14:00 minutes.
Using the arrow keys, scroll until the active line (010 Run Time 14:00) is on top.
010: Run Time 14:00
011: END OF FORMULA
1-i 2-d 3-e 4-m 5-s 0-ex
Now press 3-e and enter the desired run time [1][6][0][0].
Run Time
Key in time 16:00
The HI TEMP HEAT CYCLE operation in this formula will now be entered into the
control as follows.
006: HI TEMP HEAT CYCLE
007: Inlet Temperature 600.F
008: Outlet Temperature 200.F
009: Run Time 14:00
010: END OF FORMULA
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Using this same procedure, you can edit any of the operations for any of the
formula. This does not change the operation in your list of operations, only in the
formula that you are programming. After we have entered operations into our
formula we can press 4-m to see what operations that we have in our formula.
INITIAL HEAT
HI TEMP HEAT CYCLE
END FORMULA
1-i 2-d 3-e 4-n 5-s 0-ex
To return to the normal viewing press 4-n.
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Defining Instructions
Run Time
Time programmed in MM:SS (MM:SS > 0 Constitutes a step. A value from 0 to
99:99 can be entered.
Cylinder Rotations
Rotate CW Time
Describes the forward rotation time in ### seconds (0 to 998) for the
reversing action of the dryer basket. If set at 999, the dryer basket will
rotate forward only.
Rotate CWW Time
Describes the reverse rotation time in ### seconds (0 to 998) for the
reversing action of the dryer basket. If set at 999, the dryer basket will
rotate reverse only.
Dwell Timer
Describes the dwell time to occur between forward and reverse rotation
time in ### seconds (0 to 998) for the reversing action of the wash motor.
If set at 999, then dryer will not rotate however if a temperature instruction
is programmed in the same step, the basket will rotate automatically.
Temperature Control
Inlet <temp>
The inlet temperature is a programmed in Fahrenheit 0 to 600 or Celsius 0
to 350. This instruction is the maximum inlet temperature desired. This
instruction needs to be reprogrammed after every run time. It is not
retentive.
Outlet <temp>
The outlet temperature is a programmed in Fahrenheit 0 to 600 or Celsius
0 to 350. This instruction is the desired outlet temperature at the outlet of
the dryer or the exhaust duct. This instruction needs to be reprogrammed
after every run time. It is not retentive.
Note: Programmed Inlet and outlet temp should remain the same in each
step of the formula unless there is very compelling reasons to change
them. Changing them resets the PID firing rate control loop.
Cooldown <temp>
The cooldown temperature is a programmed in Fahrenheit 0 to 600 or
Celsius 0 to 350. This instruction is used to cool the temperature to the
programmed value. It is not retentive.
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Max Valve <pos.>
Max Valve Position is a limit. Setting it will not let the control ask for more
firing rate than the set point. The maximum valve position is
programmable from 0 to 4095. This instruction controls the amount of gas
entering the burner. The amount of gas entering the burner is called the
fire rate. It controls the amount of heat available to the dryer. If the
position is set to 0, the valve is closed. If the position is set to 4095, the
valve is full open. This instruction IS retentive. The position will remain
the same unless another instruction is programmed.
Algorithm Options
Inlet <time><temp>
This instruction is programmed in Fahrenheit 0 to 600 or Celsius 0 to 350.
It is also programmed in minutes and seconds from 0 to 99:99. This
instruction instructs the controller to record the time when the inlet
temperature is below the programmed temperature value. If the elapsed
time exceeds the programmed time, the step is cancelled. This algorithm
is used to declare dry.
Outlet <time><temp><temp>
This instruction is programmed in Fahrenheit from 32 to 240 or 0 to 115
Celsius for the high temperature and programmed in Fahrenheit from 32
to 240 or 0 to 115 Celsius for the low temperature. It is also programmed
in minutes and seconds from 0 to 99:99. This instruction measures the
rate of the outlet temperature rise. This cancels the remainder of the
current step if the outlet temperature rises from the low to the high within
the time selected. On a steam dryer, the outlet temperature can be
stopped or one temperature achieved by setting the high and the low
temperature values to the same number and setting the time to 99:99
which will end the formula.
Hum. #1 <set><time>
This instruction is set from 0 to 255 and for a specified time from 0 to
99:99 minutes and seconds. The lower the set point, the dryer the goods.
This measures the humidity sensor #1 for the specified set value and time.
It is usually a good idea to have at least 2:00 minutes in the humidity time.
Aux. #2 <set><time>
This instruction is set from 0 to 255 and for a specified time from 0 to
99:99 minutes and seconds. The lower the set point, the dryer the goods.
This measures a decreasing 4 to 20 mA auxiliary device for the specified
set value and time.
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Discharge Selections
Auto Discharge Front
This instruction is programmed at the end of the formula to instruct the
dryer to automatically discharge the goods from the front.
Auto Discharge Rear
This instruction is programmed at the end of the formula to instruct the
dryer to automatically discharge the goods from the rear.
Note: Auto discharge unlike washer discharge receives rotation instructions at
the end of the formula.
Advanced Functions
Advanced Functions are a set of instructions that allow the user to program
powerful enhancements and decision-making loops into a formula. Total "Flow
Control" of the formula can be based on Operator Input during formula execution.
Complete knowledge of these functions is essential if they are to be successfully
implemented.
Prompt
The Prompt instruction is used to give messages to the operator on the
LCD display. Up to 32 prompts may be programmed by accessing the
Vocab editor in the program menu system of the MicroPulse Dryer
controller. A prompt may be any message up to 16 characters long. To
display a prompt during a formula execution, insert the correct Prompt and
combine it with a signal.
Label
The Label instruction is used to mark a spot in a formula. Up to 16
different labels (Labels 1-16) may be inserted into a formula for reference.
In addition, Label 17 is always the first instruction of a formula and Label
18 is always the last instruction of a formula. Label 19 is always the
Resume label. The Label positions are recorded at formula execution and
are used for references of the branching instructions. (See <Signal
YES/NO>, <Compare Count>, and <GOTO Label>)
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SIGNAL YES/NO
The Signal YES/NO instruction is a flow control instruction, which
branches to Labels based on operator input. The Signal YES/NO
instruction is usually combined with the Prompt instruction to display a
message to the operator. The operator's response to the message must
be framed as YES or NO. Depending on the response, formula execution
is altered according to the desired action needed. Consider the following
dryer loop:
006: ********* Label 1 *********
007: HI TEMP HEAT CYCLE
008: Inlet Temperature 600.F
009: Outlet Temperature 200.F
010: Run Time 14:00
011: Tumble Only
012: Dwell Timer 999 Seconds
013: Run Time 0:00
014: Prompt: Check Load !!
015: Prompt: Is Load Dry ?
016: Signal [Yes] = Resume [No] = Label 1
017: Run Time 0:00
018: COOLDOWN
019: Cooldown When Temp > 135.F
020: Run Time 5:00
021: END OF FORMULA
Label 1 is inserted on line 6 of the formula. This is the temperature
adjustment and main drying portion of the formula. Prompts are
programmed for the operator to “Check Load!! and Is Load Dry?” The
display will show:
Display 1: Check Load !!
Display 2: Is Load Dry ?
Display 3: Blank
Display 4: [ENT]+[YES]or[NO]
Line 16 of the formula will direct flow of the formula based on the
acceptance of the dryness. If the load is dry, then GOTO Label 19
(RESUME FORMULA) is executed and the Cooldown operation begins. If
the load is not dry, then GOTO Label 1 (line 6) is executed and the
temperature is adjusted and the Hi Temp Heat Cycle operation is reexecuted. Note the loop will be repeated as long as the operator continues
to answer NO.
COUNT# Adjust
This instruction operates on one of the five available counters. Counters
#1 through #5 are initialized to zero at the initial formula execution. Each
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MICROPULSE DRYER
of the five counters may be independently changed in the formula. These
counters may be used to direct flow of the formula based on their values.
A counter can be Incremented or set to Zero. The maximum value of a
counter is 99.
COMPARE COUNT #
This instruction is used to program formula flow control based on the
contents of the counters. Counters may be compared to values from 0 to
99 and counters may be compared to other counters. The compare is
always framed as: COUNTER COMPARED TO VALUE - Is Counter X
greater than Value (value can be 0 - 99), or COUNTER COMPARED TO
COUNTER - Is Counter X greater than Counter Y. If the statement is true,
then a branch is executed to the indicated label. In the formula, the
instruction appears as: Cnt #1 > 1 GOTO 1 (If counter #1 is greater than 1,
then GOTO Label 1), and Cnt #1 > Cnt #2 GOTO 1. The Compare
Count# instruction can be used in the above formula (see Signal YES/NO)
to limit drying to 3 adjustments in the following way:
006: ********* Label 1 *********
007: Increment Counter 1
008: HI TEMP HEAT CYCLE
009: Inlet Temperature 600.F
010: Outlet Temperature 200.F
011: Run Time 14:00
012: IF Counter 1 > 2 GOTO Label 2
013: Tumble Only
014: Dwell Timer 999 Seconds
015: Run Time 0:00
016: Prompt: Check Load !!
017: Prompt: Is Load Dry ?
018: Signal [Yes] = Resume [No] = Label 1
019: Run Time 0:00
020: ********* Label 2 *********
021: COOLDOWN
022: Cooldown When Temp > 135.F
023: Run Time 5:00
024: END OF FORMULA
The Operator will be prompted to check the dryness of the load two times
and a maximum of three Hi Temp Heat Cycles can be executed. Counter
1 is incremented (line 7) in the adjustment step each time it is executed.
After execution of the step, Counter 1 is checked to see if three
adjustments have been made (line 12). The dryness check is bypassed by
branching to Label 2 (line 20).
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GOTO LABEL #
The GOTO Label# instruction causes an unconditional branch to the
indicated label. This can be used to make even more powerful flow control
formulas. The GOTO Label# can be used to add a new message to the
Supervisor indicating that problems with the dryer is occurring. The
supervisor can then decide whether to try to dry the load again or continue
running the formula.
006: ********* Label 1 *********
007: Increment Counter 1
008: HI TEMP HEAT CYCLE
009: Inlet Temperature 600.F
010: Outlet Temperature 200.F
011: Run Time 14:00
012: IF Counter 1 > 2 GOTO Label 2
013: GOTO Label 1
014: Tumble Only
015: Dwell Timer 999 Seconds
016: Run Time 0:00
017: Prompt: Check Load !!
018: Prompt: Is Load Dry ?
019: Signal [Yes] = Resume [No] = Label 1
020: Run Time 0:00
021: ********* Label 2 *********
022: Zero Counter 1
023: Prompt: Call Supervisor!
024: Prompt: Load Not Dry !!
025: Prompt: Try Again ?
026: Signal [Yes] = Label 1 [No] = Resume
027: COOLDOWN
028: Cooldown When Temp > 135.F
029: Run Time 5:00
030: END OF FORMULA
If three dry adjustments have been made, the formula branches to Label 2
(line 21). The counter is set to zero and the supervisor is prompted for a
decision on whether to adjust dry again or continue without further drying.
If drying is tried again, Counter #1 has been set to zero to allow three
more adjustments. If no further adjustment is needed, the Cooldown
operation is executed.
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Set Parameters
This instruction is not used in the MicroPulse Dryer controller software.
Compare Weight
This instruction is not used in the MicroPulse Dryer controller software.
Compare Sensor #1
This instruction is not used in the MicroPulse Dryer controller software.
Compare Sensor #2
This instruction is not used in the MicroPulse Dryer controller software.
Auxiliary Functions
Enable Recirc.
This instruction enables recirculation.
Signal
This instruction turns on an audible and a visible alarm to notify the wash
operator of a wash condition.
Tumble Only
This instruction allows the basket to rotate without the blower motors
being turned on.
Lint Strip
This instruction is programmed in minutes and seconds from 0 to 99:99. It
is the programmed time needed to strip the lint filter.
Aux. Bypass
This instruction is used to bypass a decreasing 4 to 20 mA auxiliary
device.
Aux Out #1-7
This instruction is programmed in minutes and seconds from 0 to 99:99.
The programmed time will turn on the specified auxiliary output.
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Notes:
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
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____________________________________
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Passwords Levels and Access Rights
The MicroPulse Dryer controllers are setup with an eight-level password system.
Formula programming, manual operations, and maintenance functions are
accessible only after entering the appropriate password. The machine is
programmed with default passwords at the factory but the user can change them
after the machine is entered into service. To change the passwords, a valid level
7 password must be entered. From the Waiting to Load screen enter a valid
level 7 password. Select 1=Setup. Select 1=Machine Setups. Select
4=Passwords. Using the arrow keys, scroll to the password that needs to be
changed or viewed. A password consists of 1 to 6 numbers. Examples are 1 or
080499. Using a six-digit password is recommended. A password control log is
also a recommended practice to keep track of who has each level of password.
Level
Password Code
User
Date
Remarks
1
_____________________________________________________
2
_____________________________________________________
3
_____________________________________________________
4
_____________________________________________________
5
_____________________________________________________
6
_____________________________________________________
7
_____________________________________________________
8
_____________________________________________________
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Default Password Setups
Level
1
2
3
4
5
6
7
8
Default Password
111111
222222
333333
444444
555555
666666
777777
888888
Function
Cancel Steps
Access Totals
Manual Operation
Maintenance
Clock
Cancel Watchdogs
Program
Machine Setups
Freeze Timers
1
x
2
x
x
3
x
x
x
x
x
4
x
x
x
x
x
x
5
x
x
x
x
x
x
6
x
x
x
x
x
x
x
7
x
x
x
x
x
x
x
x
8
x
Cancel Steps
This function is used to skip steps in a formula or to abort a formula that is
executing. To cancel a step, press the [NO] key to pause the formula.
Formula # 1
Step # 2 Line 15
PAUSED! [YES] Starts
T = 1:45 S = 5:00
Advancing in a Formula
Enter a valid password level 1 through 7. Press the [UP] arrow key to advance
the formula to the desired step. The controller will advance to the next run
instruction in the formula.
Formula # 1
Step # 4 Line 63
PAUSED! [YES] Starts
T = 1:50 S = 2:00
Press the [YES] key to resume the formula at the new step.
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Canceling a Formula
If a formula is cancelled, time accumulated for that formula is added to the totals.
Formula # 1
Step # 4 Line 63
HI TEMP HEAT CYCLE
T = 1:55 S = 4:57
To abort a formula, enter a valid password level 1 through 7. Press the [ENT]
and the [NO] keys simultaneously to clear the current formula.
Waiting for Dryer
to Unload!!
Press [YES] Key Continue
Press the [ENT] and the [NO] keys simultaneously to the "Waiting to Load"
display.
Waiting for Dryer
to Receive Load!!
Depress [YES] Key to
Select Formula
Access Totals
This function allows the user to list various statistics such as formula run times
and formula usage. From the "Waiting to Load" display, enter a valid password
level 2 through 7.
1=Setups
3=Maint.
5=Totals
Selection?
2=Program
4=Diagnos
6=Clock
0=exit
Select 5=Totals
1=Review Totals
Blank Line
3+Clr= Clr Run Data
Selection? 0 = Exit
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Pressing 1=Review Totals the LCD will display the following.
1=View Run Time Data
2=View Event History
Blank Line
Selection? 0=exit
Press 1=View Run Time Data to display the number of formula run executions of
the displayed formula since the last time the last time run time data was reset.
The total minutes spent running the displayed formula is also shown.
Formula 1
Total Runs = 14
Tot. MMMMSS= 824
Arrows Scroll 0=exit
Press 2=View Event History to view the last 101 formulas executed. The data for
the most recent is displayed. Use the arrow keys to scroll. The start date, start
time, formula name, run time, heat on time, loading time and the unloading times
are displayed for each formula execution. The time display shows a number for
the formula position. For example, the number 1 means that the date in the
display is for the last run formula. The number 5 means that the data in the
display is for the 5th preceding formula run.
D= 08-04-00 (start date) T= 11:45 (start time)
Formula # 1 (formula name)
R= 36:45 (formula run time)
H= 5:30 (satisfy time)
L= 2:34 (load time)
U= 2:54 (unloading time)
Maintenance
This function allows the user to operate various machine functions manually.
From the "Waiting to Load" display the user can enter a valid password level 3
through 7.
1=Setups
3=Maint.
5=Totals
Selection?
2=Program
4=Diagnos
6=Clock
0=exit
Select 3=Maint.
1=Input/Output Tests
2=Control Tests
3=Maintenance
Selection? 0=exit
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Select 1= Input/Output Tests
The following is a list of inputs and outputs that may be on or off. The outputs
can be toggled on or off by pressing the [YES] key. Use the arrow keys to scroll.
Control Power On Input
Front Door Open Input
Front Door Closed Input
Open Back Door Output
Fan Door Closed Input
Lint System Strip Output
Lower Rear Output
Lift Front ½ Up Output
Lift Rear Up Output
Front Up ½ Input
Rear Up Full Input
Rotate CW Output
Baskets Rotating Input
Burner Fan O/L’s OK Input
Doors Closed Limit Input
Burner Fan Suction Input
Fireye Needs Reset Input
Lint System Pres. OK Input
Fire RQ Off Status Input
Main Fuel Status Input
DC Alarm Output
Request Front Up Input
RQ Back Door Closed Input
RQ Basket CW Rotate Input
Air Blocking Valve Output
Open Front Door Output
Back Door Open Input
Back Door Closed Input
Emerg. Stops OK Input
Warning Bell Output
Lower Front Output
Lift Front Full Output
Dryer Horizontal Input
Front Up Full Input
Baskets O/L’s OK Input
Rotate CCW Output
Main Fan O/L’s OK Input
Turn On Fans Output
Main Fan Suction Input
Fan Aux. Switches Input
Lint System Temp. OK Input
High Temp. Limit OK Input
Allow Fireye Output
Recirc. Valve Output
Spare Input
RQ Back Door Open Input
RQ Dryer Horizontal Input
RQ Basket CWW Rotate Input
Press 0 to exit.
1=Setups
3=Maint.
5=Totals
Selection?
2=Program
4=Diagnos
6=Clock
0=exit
Select 3=Maint.
1=Input/Output Tests
2=Control Tests
3=Maintenance
Selection? 0=exit
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Select 2= Control Tests
1=Test Front Panel
2=Board Responses
Selection?
0=exit
Select 1=Test Front Panel
Press all key and buttons one at a time. The time display will show a number
corresponding to the location of the active switch. The LCD will also show the
corresponding number to the location of the active switch. If the [up arrow] key is
being pressed the time and the LCD will displays will show the following.
Time 00:08
P.B./key 8 is pushed
YES + NO = Exit
If no number is displayed, either the switch is faulty or the corresponding
electrical circuit has a bad component. Press [YES] + [NO] to exit.
1=Test Front Panel
2=Board Responses
Selection?
0=exit
Select 2=Board Responses
I/O Rack #1
No Responses
0
Arrows Scroll 0= exit
By using the arrow keys, the user can determine if there is a possible I/O rack
problem. Due to the nature of the electronic timing signals, the I/O racks will fail
to respond to the controller. The controller will repeat the request until the board
responds. If the controller receives four sequential no-responses, an error
message is displayed. An excessive number of repeat requests may indicate a
failing I/O rack or a bad connection. Press [0] to exit.
1=Test Front Panel
2=Board Responses
Selection?
0=exit
Press 0 to exit.
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1=Input/Output Tests
2=Control Tests
3=Maintenance
Selection? 0=exit
Select 3=Maintenance
Using the arrow keys, scroll to examine the preventative maintenance watchdog
schedule of the machine. The LCD (for example only) will display the following.
DRIVE COMPONENTS
Next Service = 26
0= exit
This tells the user that the drive components preventative maintenance schedule
will be due in 26 (26 used for example only) machine hours. Please note that
machine hours accumulate only while the machine is executing a formula. Exit
from the control.
Clock
The clock is used to track when a formula was executed and for reports on the
optional PulseNet module. To set the clock, enter a valid level 3 through 7
password from the Waiting to Load screen.
1=Setups
3=Maint.
5=Totals
Selection?
2=Program
4=Diagnos
6=Clock
0=exit
Select 6=Clock
Date= 00:00:00
Enter New Date
Date= 00:00:00
ENTER= Accept No= exit
Enter the day, month, and year. For example the date is July 4, 2000 press
[0][8][0][4][0][0].
Date= 00:00:00
Enter New Date
Date= 08:04:00
ENTER= Accept No= exit
Press [ENT].
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Time= 00:00:00
Enter New Time
Time= 00:00:00
ENTER= Accept No= exit
The clock is in a 24-hour format also known as European. Enter the hour,
minutes, and seconds. For example, if the time is 3:15:33 PM, press
[1][5][1][5][3][3].
Time= 00:00:00
Enter New Time
Time= 15:15:33
ENTER= Accept No= exit
Press [ENT].
Cancel Watchdogs
This allows the user to cancel maintenance and preventative maintenance
watchdogs. The fault will be displayed on the LCD any time the controller
detects an error condition. The error message will indicate the type of fault.
Machine operation will be halted until a valid level 4 through 7 password is
entered. Refer to troubleshooting for a list of error messages and possible
corrective actions.
Call Maintenance!!
Low Air Pressure!
Enter a valid level 4 through 7 password.
Formula # 1
Step # 4 Line 63
PAUSED! [YES] Starts
T = 1:50 S = 2:00
Setups
This allows the user to enter the user-defined setups. Refer to user-defined
setups. From the Waiting to Load screen, enter a valid level 6 or 7 password.
1=Setups
3=Maint.
5=Totals
Selection?
2=Program
4=Diagnos
6=Clock
0=exit
Select 1=Setups (Please see Setups section)
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Program
This allows the user to enter the 2=Program selection. Refer to Program section.
From the Waiting to Load screen, enter a valid level 6 or 7 password.
1=Setups
3=Maint.
5=Totals
Selection?
2=Program
4=Diagnos
6=Clock
0=exit
Select 2=Program
Machine Setups
This allows the user to setup the user defined watchdog setups. From the
Waiting to Load screen, only a valid level 7 password will allow access. Refer to
Watchdog/Setups section.
1=Setups
3=Maint.
5=Totals
Selection?
2=Program
4=Diagnos
6=Clock
0=exit
Select 1=Setups
1=Machine Setup
2=Maintenance Setup
3=Clear Ram Vocabs
4=Passwords 0=exit
Select 1=Machine Setup
Freeze Timers
This allows the user to freeze the controls timers while not in use by entering a
valid level 8 password all of the control timers are frozen. After the days
production it is good to make sure the formula is finished processing to freeze the
timers. This is for the total reports. This is known as sleeping the machine.
Pressing any key will wake the machine and resume all timers.
9: 9
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Notes:
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
____________________________________
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Maintenance Prompts
Because the maintenance prompts can be customized to suit the individual
needs of the user, responsibility for completing maintenance rests with the user.
There is a total of 32 maintenance prompts for the user.
For the recommended preventative maintenance, please refer to the
manufacturer for details.
Setting up the Preventative Maintenance Program
From the Waiting to Load screen, enter a valid level 7 password.
1=Setups
3=Maint.
5=Totals
Selection?
2=Program
4=Diagnos
6=Clock
0=exit
Select 1=Setup.
1=Machine Setup
2=Maintenance Setup
3=Clear Ram Vocabs
4=Passwords
0=exit
Select 2=Maintenance Setup
Maintenance # 1
MAINTENANCE # 1
Use arrows to scroll
Enter = Accept No = Exit
Press [ENT]. The cursor (appears as a flashing line) the character position to be
edited. With the cursor in position, key in the numerical code (see the ASCII
reference) for the desired character.
For example if you are programming CLEAN MACHINE. Press [6][7] then press
[ENT]. The C will be shown now press the [NO] key to move the cursor right.
CAINTENANCE # 1
ENT= Character # 67
YES = Left NO = Right
YES + NO = Accept
Continue with this sequence until you have programmed the desired operation
name.
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C=[6][7] [ENT] [NO]
L=[7][6] [ENT] [NO]
E=[6][9] [ENT] [NO]
A=[6][5] [ENT] [NO]
N=[7][8] [ENT] [NO]
space=[3][2] [ENT] [NO]
M=[7][7] [ENT] [NO]
A=[6][5] [ENT] [NO]
C=[6][7] [ENT] [NO]
H=[7][2] [ENT] [NO]
I=[7][3] [ENT] [NO]
N=[7][8] [ENT] [NO]
E=[6][9] [ENT] [NO]
space=[3][2] [ENT] [NO]
space=[3][2] [ENT] [NO]
space=[3][2] [ENT] [NO]
[YES]+[NO]
The LCD display will now read as follows:
CLEAN MACHINE
Interval= 0
Key in Interval Hrs.
ENTER = Accept
The next step is to set up the desired maintenance interval. The screen will
show the currently programmed interval in hours. Enter the desired interval
using hours from 1 to 99999. We will enter 80 hours for our example. Press
[8][0][ENT]. The LSD display now reads as follows:
CLEAN MACHINE
Next Service= 80
Password Resets Hrs.
ENTER = Accept
Key in a valid level 7 password to make the interval change take effect. The LCD
display will read as follows:
1=Machine Setup
2=Maintenance Setup
3=Clear Ram Vocabs
4=Passwords
0=exit
If required, Press 2=Maintenance Setup and follow this guideline. If not, exit from
the controller.
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Key Pressing During Formula Execution
While a formula is being executed you can get very useful information by
pressing and holding any of the numeric keys. Following will be examples of
information by pressing these keys.
Pressing the [1] key displays information on the programmed Inlet and Outlet
temperature controls.
Inlet Temp. Control
Control Temp. =
Outlet Temp. Control
Control Temp. =
Pressing the [2] key displays the programmed Cooldown temperature.
Cooldn Temp. Control
Control Temp. =
Pressing the [3] key displays the programmed Inlet Algorithm. If no algorithm is
programmed, the following will be displayed.
Inlet Algorithm
Not Prog. This Step
Pressing the [4] key displays programmed Outlet Algorithm. If no algorithm is
programmed, the following will be displayed.
Outlet Algorithm
Not Prog. This Step
Pressing the [5] key displays the programmed Humidity #1 and Aux. #2 algorithm
set points. Shown below, the algorithm is not programmed.
Humidity #1 12.5
No Set Point Algo.
Auxiliary #2 0.2
No Set Point Algo.
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Pressing the [6] key displays the value of the Main Fan and Makeup Air in inches
of water. It also displays the maximum valve position setting and actual valve
position setting.
2.65” H2O Main Fan
0.07” H2O Make Air
Max. Valve= 4095
Act. Valve= 1485
Pressing the [7] key displays the following.
pT1= 1838
dT1= 0008
pT2= 0400
dT2= 0000
iT= -0521
vT= 12mm
iT2= +1042
vT2= 4095
The notation is as follows:
pT1= Outlet Temperature Proportional component
iT1= Outlet Temperature Integral component
dT1= Outlet Temperature Derivative component
vT1= Outlet Temperature Valve Position desired
pT2= Inlet Temperature Proportional component
iT2= Inlet Temperature Integral component
dT2= Inlet Temperature Derivative component
vT2= Inlet Temperature Valve Position desired
Pressing the [8] key displays programmed reversing times and the timers
counting down.
CW= 16 sec
CCW= 16 sec
Dwell= 4 sec 4.0
11: 2
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Using the Override Displays
Screen 1
To enter into the override displays, the operator will need to press the Up and
Down arrows simultaneously. The following will be a review of screen number 1.
Machine Diagnostic
Machine is OK or Displays a Fault
Line 1 displays that you are in the Machine Diagnostics.
Lines 2, 3, and 4 display the machine status. For example, if the machine was in
the load position with the front door open the display would read line 2 Machine
not at Run. Line 3 would display Front Door not Closed.
Press the Up arrow to advance to the screens.
Screen 2
Rack #1
Rack #2
00000000
00000000
Rack #3 Var. Speed
00000000
00000000
(1= On 0 = Off)
(1= On 0 = Off)
Line 1 displays the rack 1, 1-8 and rack 2, 1-8.
Line 2 displays the rack 1, 1-8 and rack 2, 1-8 status. For example, if outputs
107 and 204 were on the display would read 00000010 00010000.
Line 3 displays the rack 3, 1-8 and Variable Speed.
Line 4 displays the rack 3, 1-8 and rack 4, 1-8 status. For example, if outputs
307 were on the display would read 00000010 00000000.
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Screen 3
ACInp 1-8 ACInp 9-16
00000000
00000000 (1= On 0 = Off)
DCInp 1-8 DCInp 9-16
00000000
00000000 (1= On 0 = Off)
Line 1 displays the AC Inputs 1-8 and 9-16.
Line 2 displays the AC Inputs 1-8 and 9-16 status. For example, if Inputs 7 and
12 were on the display would read 00000010 00010000.
Line 1 displays the DC Inputs 1-8 and 9-16.
Line 2 displays the DC Inputs 1-8 and 9-16 status. For example, if Inputs 7 and
12 were on the display would read 00000010 00010000.
Screen 4
Humidity #1
Hum./Aux #2 68.2
Aux Temp. #1
Aux Temp. #1
80.3
80
80
This is the actual value of the moisture and auxiliary temperature sensors.
Screen 5
Serial Num. = 00000
Hour Meter = 0
00-00-0000 (Software Date) ID#=000 (Arcfiber board setting)
TUMB VER 3.0 R 0.0
Line 1 displays the serial number.
Line 2 displays the hour meter.
Line 3 displays the Software date and Arcfiber ID. For example, if the software
date was July 4, 2000 and the machine ArcNet ID was 4 the display would read
07-04-2000 ID#4.
Line 4 displays the software name, version number, and revision number.
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Screen 6
Item # =
Lot # =
Cust. # =
Weight =
000000
000000
000000
0
In automated systems, this screen displays the item, lot, and customer numbers
along with the actual weight being processed in the machine.
Press the Down arrow to advance to back to screen 1.
Time in MM:SS = 00:00
Level in In. = 00.0
Temp. In Deg. = 000F
Cylinder RPM's = 000
Press the [CLR] key to return to the machine state.
Waiting to Receive Load State
If the machine were in the waiting to receive state, the display would read as
follows:
Waiting For Dryer
To Receive Load!!
Depress [YES] Key To
Select Formula
Switching to
* The MicroPulse *
Softrol Systems
c. 1988-2002
Softrol Systems, Inc
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Formula Execution State
If the machine were executing a formula, the machine would read as follows:
Formula Name
Operation Name
Step # 1
Line # 2
T=0:26
S=9:56
Line 1 displays the formula name. For example, if the formula name were
Sheets, the display would read Sheets.
Line 2 displays the operation name. For example if the name of the operation
were Initial Heat, the display would read INITIAL HEAT.
Line 3 displays the step number and the line number that the formula is
executing.
Line 4 displays the total time the formula has been running and the remaining
time in the step.
Reinitializing the Front Panel Display
If there is a power interruption to the FPD, the FPD will need to be reinitialized.
To reinitialize the FPD press the [UP] and [Down] arrow keys simultaneously.
Then the [UP] and [ENT] keys simultaneously.
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Copying Memory Contents
All power must be turned off before inserting or removing printed circuit boards.
The memory card is very static sensitive device. Always touch the machine
before touching the circuit boards. Hold the circuit boards by the edges to
minimize contact with the components. This procedure is used to duplicate
formulas, operations, setups, calibrations, vocabs, and passwords between
machines. This process reduces programming time for multiple machines and
achieves standardization among machines. The transfer can be done two
different ways. THIS PROCEDURE IS USED ON NON-AUTOMATED
SYSTEMS ONLY but may be used before any automation is performed. These
two procedures copy the Automation Setups causing loading and unloading
problems.
1. All power must be turned off before inserting or removing printed circuit
boards. Remove the E3-FLOWMEM slot 5 card from the unprogrammed
machine and place it into the slot 4 of the programmed machine. Then copy slot
5 to 4.
2. All power must be turned off before inserting or removing printed circuit
boards. Remove the E3-FLOWMEM slot 5 card from the programmed machine
and place it into the slot 4 of the unprogrammed machine. Then copy slot 4 to
5.
This process replaces whatever is stored on the E3-FLOWMEM card. Be careful
not to replace the contents of an unprogrammed E3-FLOWMEM onto the
programmed E3-FLOWMEM. Because the procedure is the same for both
methods only one method will be explained.
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The vocabs are stored on the E3-REMK4A card that is connected to the E3PRO63K4 card in slot 1. If the user wishes to copy the vocabs along with the
setups, formulations, operations, and passwords they will have to be copied to
the slot 5 E3-FLOWMEM card. After machine 1 (programmed machine) has
been programmed, copy the vocabs.
At the Waiting for Load screen enter a valid level 7 password.
1=Setups
3=Maint.
5=Totals
Selection?
2=Program
4=Diagnos
6=Clock
0=exit
Select 2=Program.
1=Ops2=Formulas
3=Clr Ops 4=Clr Forms
5=Copy
6=Vocabs
Selection? 0=exit
Select 5=Copy.
1=Copy Slot Cards
2=Copy Vocabs
Selection? 0=exit
Select 2=Copy Vocabs.
1=Vocabs to Slot 5
2=Slot 5 to Vocabs
0=exit
Select 1=Vocabs to Slot 5. Be careful not to select 2=Slot 5 to Vocabs. That
could potentially change all of your formula, operation, and maintenance names
along with all other programmable vocabs.
Copy Vocabs to Slot 5
Key in Password!!!
NO = exit
Enter a valid level 7 password.
Verify
YES to Continue
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1=Ops
3=Clr Ops
5=Copy
Selection?
2=Formulas
4=Clr Forms
6=Vocabs
0=exit
Select 5=Copy.
1=Copy Slot Cards
2=Copy Vocabs
Selection? 0=exit
1=Ops
3=Clr Ops
5=Copy
Selection?
2=Formulas
4=Clr Forms
6=Vocabs
0=exit
Now that all vocabs are backed up on the E3-FLOWMEM card, the user will be
ready to continue.
Turn off the main circuit breaker of the machine that has not been programmed
(machine 2). Remove the E3-FLOWMEM slot 5 card from the machine.
Turn off the main circuit breaker of the machine that has been programmed
(machine 1). Place the E3-FLOWMEM card from machine 2 into slot 4.
Turn on the circuit breaker on machine 1.
At the Waiting for Load screen enter a valid level 7 password.
1=Setups
3=Maint.
5=Totals
Selection?
2=Program
4=Diagnos
6=Clock
0=exit
Select 2=Program.
1=Ops
3=Clr Ops
5=Copy
Selection?
13: 3
2=Formulas
4=Clr Forms
6=Vocabs
0=exit
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Select 5=Copy.
1=Copy Slot Cards
2=Copy Vocabs
Selection? 0=exit
Select 1=Copy Slot Cards
1=Copy Slot 5 to 4
2=Copy Slot 4 to 5
Selection? 0=exit
Select 1=Copy Slot 5 to 4
Copy Slot 5 to 4
Key in Password!!!
NO = exit
Enter a valid level 7 password and all formulas, operations, setups, password,
and vocabs are now stored on the E3-FLOWMEM card from machine 2.
Turn off the main circuit breaker of the machine 1. Remove the E3-FLOWMEM
card from machine 2 and place the E3-FLOWMEM card from machine 3 and
follow the procedure beginning with replacing machine 2 with machine 3. If no
other machines are to be copied, turn on the main circuit breaker.
Return to machine 2. Place the E3_FLOWMEM card back into slot 5. Turn on
the main circuit breaker to the machine.
At the Waiting for Load screen enter a valid level 7 password.
1=Setups
3=Maint.
5=Totals
Selection?
2=Program
4=Diagnos
6=Clock
0=exit
Select 2=Program.
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1=Ops
3=Clr Ops
5=Copy
Selection?
2=Formulas
4=Clr Forms
6=Vocabs
0=exit
Select 5=Copy.
1=Copy Slot Cards
2=Copy Vocabs
Selection? 0=exit
Select 2=Copy Vocabs.
1=Vocabs to Slot 5
2=Slot 5 to Vocabs
0=exit
Select 2=Slot 5 to Vocabs. Be careful not to select 1=Vocabs to Slot 5. That
could potentially change all of your formula, operation, and maintenance names
along with all other programmable vocabs. This will copy all of the vocabs to the
E3-REMK4A card allowing the user to view them.
Copy Slot 5 to Vocabs
Key in Password!!!
NO = exit
Enter a valid level 7 password.
Verify
YES to Continue
1=Ops
2=Formulas
3=Clr Ops 4=Clr Forms
5=Copy
6=Vocabs
Selection? 0=exit
Exit out of the control and the user is ready to execute formulas.
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Notes:
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Hardware Overview
The MicroPulse Controller consists of Slot Cards that reside in an Mb8-K4A
(Mother Board). Residing in the processor slot, you will find two cards that attach
to each other then plug into the Mb8-K4A. The REM-K4A attaches to the E3PRO63K4A card. The E3-PRO63K4A then attaches to the Mb8-K4A. In Slot 1
you will find an ACI16 card. In Slot 2 resides an AIO420 card. In slot 3 resides
an E3-DCIP16 card. In Slot 5 you will find an E3-FLOWMEM card. In Slot 6 you
will find the optional ARCFIBER card. The remaining Slots are empty and used
for different machine configurations.
Mb8-K4A (Mother Board)
This board connects all of the cards in the rack. It houses the EEPROM where
the manufacturers setups reside and is also the Processor Board for the
MicroPulse Controllers. With the Mb8-K4A card mounted into the machine,
starting from left to right, there is a 6 pin 250V 10 AMP connector. In Pin 1 you
will find a 299 black wire 0 VDC. In Pin 2 you will find a blue wire +15 VDC. In
Pin 3 you will find a purple wire +5VDC. In Pin 5 will be a purple wire 0VDC.
Next to the 6 Pin connector, you will see two Red LED's. The first LED will flash
on and off when the control is resetting itself. The second LED is on steady when
there is power to the control. Next you will see the Communication Ribbon
Connection to the I DR-8G4 Boards with the Ribbon Red attached on the arrow
side of the connector. You will then find 9 Slots for the remaining cards. If the
Mb8-K4A is to be replaced, please notify Softrol service department for
instructions regarding the EEPROM replacement.
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Processor Slot
The REM-K4A and the E3-PRO63K4A cards are housed here. The REM-K4A
card is the memory card. This card houses the Timekeeper RAM and the
Lithium Battery in the IC4 socket. The IC3 socket contains the Boot memory.
The IC2 socket contains an AT49F040 eprom. This socket is currently used for
the program. The IC1 socket is open for later use of an AT49F040 eprom. The
REM-K4A card also has an Auxiliary COM 1 port and an Auxiliary COM 2 port.
The COM 1 is for ModBus communications while COM 2 is for a 232 type
communications. The REM-K4A attaches to the E3-PRO63K4A card. The E3PRO63K4A resides in the Processor Slot of the Mother Board. The E3PRO63K4A card will have J2 pins jumpered. It will have a four pin IIC or FPD
Connection. Pin 1 is for +5VDC. Pin 2 is for the Ground. Pin 3 is for the Clock.
Pin 4 is for Data. The Data and Clock is one twisted pair. The Ground and the
+5VDC is one twisted pair.
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Slot 1 the ACI16
This card is usually used for 24 volts AC and has 16 inputs. LED's correspond to
inputs and light up when power is applied. When the input is AC, the LED is
orange. This card can be used on two circuits with different commons. With the
card residing in its proper slot the first common is Red wire 200. The second
common is also a Red wire 200 +24 VDC. The remaining wires are inputs s1-01
through s1-16 and are Blue wires.
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Slot 2 the E3-AIO420
The E3-AIO420 is for 4 to 20 mA inputs and outputs. Pin 1 (S3-01) is a 4 to 20
mA input from the Main Fan Suction. Pin 2 (S3-02) is a 4 to 20 mA input from
the Make Up Air. Pin 3 (S3-03) is a 4 to 20 mA input for the Inlet Temperature
Probe. Pin 4 (S3-04) is a 4 to 20 mA input for the Outlet Temperature Probe.
Pin 5 (S3-05) is a 4 to 20 mA input for the Humidity 1 Probe. Pin6 (S3-06) is a 4
to 20 mA input for the Humidity 2 Probe. Pins 7 and 8 (S3-07 and S3-08) are for
optional temperature probes. Pin 9 (S3-09) is +15VDC from BUS. Pin 10 (S310) is 15V ground from BUS. Pin 11 (S3-11) is Counter 1 Sinking. Pin 12 (S312) is Counter 2 Sinking. Pin 13 is positive of 4-20 mA output 1. Pin 14 (S3-14)
is negative of 4-20 mA output 1. Pin 15 (S3-15) is positive of 4-20 mA the
optional output 2. Pin 16 (S3-16) is negative of 4-20 mA the optional output 2.
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Slot 3 the DCIP16
This card has 16 DC inputs. The voltage of the inputs must be the same as the
volts on AGND (0VDC) and +15/24VDC of the mother board. +DC volts is
supplied to the card from the motherboard and connecting an input pin to AGND
turns on the input. Visual indication of input on condition is a red LED on the
back side of the card. The wires are inputs s3-01 through s3-16 and are Black
wires.
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Slot 5 the E3-FLOWMEM128NV
The E3-FLOWMEM128 NV card is a four channel AC or DC memory card.
Channel 1 is used for the RPM sensor with the ground in Pin A, the signal in Pin
B, and the +15 VDC in Pin C. Channel 2 is a spare. Channel 3 is for the Water
Meter with the ground in Pin A, the signal in Pin B, and the +15 VDC in Pin C.
Channel 4 is a spare. A Timekeeper RAM and Lithium Battery is also socketed
to this card.
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Slot 6 the ARCFIBER
The ARCFIBER card contains an ArcNet Media. The ArcNet Media controller
can drive three different types media depending on the jumper configuration.
One ArcNet Media is Twisted-pair Communication (TP). To use the TP
communications, the card must be jumpered as follows; viewing the ARCFIBER
name to your right, JP1 need pins 1 and 2 jumped. JP2 needs both sets of pins
1 and 2 jumped. JP3 needs both sets of pins 1 and 2 jumped. Please note, that
if the machine is at the end of the communication loop, JP5 needs to be jumped
also.
The second ArcNet Media is COAX Communication. To use the COAX
communications, the card must be jumpered as follows: viewing the ARCFIBER
name to your right, JP1 need pins 1 and 2 jumped, JP2 needs both sets of pins 1
and 2 jumped, and JP3 needs both sets of pins 2 and 3 jumped. Please note
that if the machine is at the end of the communication loop, JP4 needs to be
jumped. If a 93-ohm terminator is placed onto the ArcNet connector DO NOT
JUMPER JP4.
The final ArcNet Media is Fiber Optic Communication (FO). To use the FO
communications, the card must be jumpered as follows: viewing the ARCFIBER
name to your right, JP1 need pins 2 and 3 jumped, JP2 needs the top set of pins
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2 and 3 jumped, and JP3 needs the top set of pins 1 and 2 jumped. Software
must configure the ArcNet controller for back plane mode to properly transmit
and receive.
On systems where the machine is connected to a PulseNet network, this board
needs to be set so that each individual machine establishes its own identity that
is known as the Node ID. To do this the ARCFIBER card needs to be set up.
The Node ID for the board is setup by setting the 8-position DIPswitch to the
proper binary code representing the particular node number from 0 to 255. The
switches are numbered 1 through 8 with 1 being the least significant bit of the
node. The ON position represents logic 0; the OFF position represents logic 1.
For example, to set the node ID as 31 first convert the decimal to binary, then
determine the switch positions.
Switch #
Decimal
Binary
1
1
Off
2
2
On
3
4
Off
4
8
On
5
16
On
6
32
Off
7
64
Off
8
128
On
EXAMPLE: Node ID 101
x xx
x
x x
xx
12345678
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There are two output racks known as IDR-8G4. The IDR-8G4 is an 8
output/input (AC/DC, opto-isolated) interface card called a RACK under 12C
control. The card is addressable with eight unique addresses. A fuse tester for
the opto modules is built in and located to the right of the red LED. Placing
jumpers on the 1, 2, and 4 pins sets the RACK address. Please note that jumper
numbers total to one less than the RACK number meaning a RACK address can
be setup by subtracting one from the desired RACK number and then installing
jumpers to get the desired results. For example if the address for RACK 6 is
desired, subtract one from six to get five, then jumper pins 1 and 4. Please
review the following example of RACK addresses:
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Notes:
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Machine Error Faults
One of the advantages of the technology in the MicroPulse Dryer controller is the
ability of the controller to monitor the machine and itself. If something out of the
ordinary occurs, the controller will sound an alarm and warn the operator of the
problem that exists.
Errors require a level four (4) or higher password, to be cleared. Following are
examples and how to troubleshoot error faults:
RESET OVERLOADS!
One or more of the overloads have tripped on the Basket Motor, Exhaust Blower
Motor or Combustion Blower Motor (not on Steam Dryers).
EMERGENCY STOP!
The emergency stop has interrupted the control circuit.
RESET 15a CIRCUIT!
The 15 amp circuit breaker has been tripped.
FAN DOOR OPEN!
The Exhaust Blower fan door is not fully closed or the controller is not sensing
the Door Switch input.
LOW GAS PRESSURE
The gas pressure has dropped below a safe operating range. (Optional- IRI /
CSA style Dryers)
I/O Rack #1 Fault
The I2C Chip on I/O Rack #1 did not respond to a request by the MicroPulse
Controller CPU via the I2C Cable. Check the condition of the cable for possible
damage. Verify the machine setups.
I/O Rack #2 Fault
The I2C Chip on I/O Rack #2 did not respond to a request by the MicroPulse
Controller CPU via the I2C Cable. Check the condition of the cable for possible
damage. Verify the machine setups.
I/O Rack #3 Fault
The I2C Chip on I/O Rack #3 did not respond to a request by the MicroPulse
Controller CPU via the I2C Cable. Check the condition of the cable for possible
damage. Verify the machine setups.
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I/O Rack #4 Fault
The I2C Chip on I/O Rack #4 did not respond to a request by the MicroPulse
Controller CPU via the I2C Cable. Check the condition of the cable for possible
damage. Verify the machine setups.
I/O Rack #5 Fault
The I2C Chip on I/O Rack #5 did not respond to a request by the MicroPulse
Controller CPU via the I2C Cable. Check the condition of the cable for possible
damage. Verify the machine setups.
I/O Rack #6 Fault
The I2C Chip on I/O Rack #6 did not respond to a request by the MicroPulse
Controller CPU via the I2C Cable. Check the condition of the cable for possible
damage. Verify the machine setups.
Outlet Temp Low
The outlet temperature sensed was equal to or lower than the programmed setup
Outlet Temp Lo. Verify the machine setups. Verify the programmed formula.
Check the outlet temperature probe (RTD).
Outlet Temp High
The outlet temperature sensed was equal to or higher than the programmed
setup Outlet Temp Hi. Verify the machine setups. Verify the programmed
formula. Check the outlet temperature probe (RTD).
Max Heat Time Error
The drying time has equaled the programmed time for the Heat Overtime Error
setup. Verify the machine setups. Verify the programmed formula. Check for
proper air flow.
No Heat Error
The MicroPulse controller did not sense any heat during the formula. Check the
temperature probes. Check the slot three E3-AIO420 board for proper operation.
Inlet Temp Low
The inlet temperature sensed was equal to or lower than the programmed setup
Inlet Temp Lo. Verify the machine setups. Verify the programmed formula.
Check the inlet temperature probe (RTD).
Inlet Temp High
The inlet temperature sensed was equal to or higher than the programmed setup
Inlet Temp Hi. Verify the machine setups. Verify the programmed formula.
Check the inlet temperature probe (RTD).
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Fire Safety Trip
The MicroPulse controller has sensed a problem with the Flame Safeguard
Control (Fire-eye or Honeywell). Check the Flame Safeguard Control (Fire-eye
or Honeywell) for proper operation or damage. Check Flame Rod or UV Scanner
for proper operation or lint build-up.
Main Fan Error
The Exhaust Blower Pressure is too low or not being sensed by the Exhaust
Blower Pressure Switch. Verify the Exhaust Blower is functioning and creating 2
to 6 inches of W.C. suction. Check Exhaust Blower Pressure Switch wiring and
the Pressure switch. (Optional) The MicroPulse controller did not sense the
main fan working properly. Check the main fan for obstructions. Check for lint
buildup.
Combustion Fan Error
The Combustion Blower Pressure is too low or not being sensed by the
Combustion Blower Pressure Switch. Verify the Combustion Blower is
functioning and creating 4 to 12 inches of W.C. pressure (depending upon Dryer
model). Check Combustion Blower Pressure Switch wiring and the Pressure
switch. (Optional) The MicroPulse controller did not sense the combustion fan
working properly. Check the combustion fan for obstructions. Check for lint build
up.
Basket Not Rotating
The MicroPulse controller did not sense the basket was rotating. Check the
basket rotation proximity switch.
Lint (Lint House) System Pressure Switch
The MicroPulse controller sensed that there is a pressure build up in the lint
system. Check the Lint Collector Pressure Switch and check for lint build-up.
Horizontal Switch Error
The MicroPulse controller did not sense the machine is in the horizontal position.
Check the horizontal switch.
Door Not Closed
The MicroPulse controller did not sense the machines door(s) were fully closed.
Check the door closed switch(s).
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Notes:
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The MicroPulse Dryer controller has default operations ranging from operation
numbers 33 to 64. These operations may be edited but the operation names
may not. These are for the user to use to learn to program by or even to use in
their formulations. The MicroPulse Dryer controller also has default formulas
ranging from formulas 100 to 128. These formulas
and formula names may
be edited.
Operation #33 INITIAL HEAT
0001: INITIAL HEAT
0002: Inlet Temperature 600.F
0003: Outlet Temperature 200.F
0004: Run Time 3:00
0005: END OF OPERATION
Operation #34 VALVE POSITION LIMIT
0001: VALVE POSITION LIMIT
0002: Max Gas Valve Setting = 3500
0003: END OF OPERATION
Operation #35 HEAT WITH RECIRC.
0001: HEAT WITH RECIRC.
0002: Recirculation On
0003: Inlet Temperature 600.F
0004: Outlet Temperature 190.F
0005: Run Time 13:00
0006: END OF OPERATION
Operation #36 PURGE - NO HEAT
0001: PURGE - NO HEAT
0002: Run Time 5:00
0003: END OF OPERATION
Operation #37 BYPASS LINT FILTER
0001: BYPASS LINT FILTER
0002: Lint Bypass
0003: Aux Output #1 2:00
0004: Run Time 3:00
0005: END OF OPERATION
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Operation #38 COOLDOWN
0001: COOLDOWN
0002: Cooldown When Temp > 135.F
0003: Run Time 5:00
0004: END OF OPERATION
Operation #39 ROTATE CW ONLY
0001: ROTATE CW ONLY
0002: Rotate CW for 999 Seconds
0003: END OF OPERATION
Operation #40 REVERSE 30/30/2
0001: REVERSE 30/30/2
0002: Rotate CW for 30 Seconds
0003: Rotate CCW for 30 Seconds
0004: Dwell Timer 2 Seconds
0005: END OF OPERATION
Operation #41 REVERSE 30/30/4
0001: REVERSE 30/30/4
0002: Rotate CW for 30 Seconds
0003: Rotate CCW for 30 Seconds
0004: Dwell Timer 4 Seconds
0005: END OF OPERATION
Operation #42 REVERSE 50/50/2
0001: REVERSE 50/50/2
0002: Rotate CW for 50 Seconds
0003: Rotate CCW for 50 Seconds
0004: Dwell Timer 2 Seconds
0005: END OF OPERATION
Operation #43 REVERSE 50/50/4
0001: REVERSE 50/50/4
0002: Rotate CW for 50 Seconds
0003: Rotate CCW for 50 Seconds
0004: Dwell Timer 4 Seconds
0005: END OF OPERATION
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Operation #44 REVERSE 90/90/2
0001: REVERSE 90/90/2
0002: Rotate CW for 90 Seconds
0003: Rotate CCW for 90 Seconds
0004: Dwell Timer 2 Seconds
0005: END OF OPERATION
Operation #45 REVERSE 90/90/4
0001: REVERSE 90/90/4
0002: Rotate CW for 90 Seconds
0003: Rotate CCW for 90 Seconds
0004: Dwell Timer 4 Seconds
0005: END OF OPERATION
Operation #46 TUMBLE ONLY
0001: TUMBLE ONLY
0002: Tumble Only
0003: Run Time 0:00
0004: END OF OPERATION
Operation #47 LOW TEMP HEAT CYCLE
0001: LOW TEMP HEAT CYCLE
0002: Recirculation On
0003: Inlet Temperature 525.F
0004: Outlet Temperature 170.F
0005: Run Time 18:00
0006: END OF OPERATION
Operation #48 MED TEMP HEAT CYCLE
0001: MED TEMP HEAT CYCLE
0002: Recirculation On
0003: Inlet Temperature 550.F
0004: Outlet Temperature 190.F
0005: Run Time 16:00
0006: END OF OPERATION
15: 3
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Operation #49 HI TEMP HEAT CYCLE
0001: HI TEMP HEAT CYCLE
0002: Recirculation On
0003: Inlet Temperature 600.F
0004: Outlet Temperature 200.F
0005: Run Time 14:00
0006: END OF OPERATION
Operation #50 LIGHT CONDITION
0001: LIGHT CONDITION
0002: Recirculation On
0003: Inlet Temperature 525.F
0004: Outlet Temperature 170.F
0005: Run Time 4:00
0006: END OF OPERATION
Operation #51 MEDIUM CONDITION
0001: MEDIUM CONDITION
0002: Recirculation On
0003: Inlet Temperature 550.F
0004: Outlet Temperature 180.F
0005: Run Time 6:00
0006: END OF OPERATION
Operation #52 HEAVY CONDITION
0001: HEAVY CONDITION
0002: Recirculation On
0003: Inlet Temperature 600.F
0004: Outlet Temperature 190.F
0005: Run Time 8:00
0006: END OF OPERATION
Operation #53 INLET ALGORITHM
0001: INLET ALGORITHM
0002: Recirculation On
0003: Inlet Temperature 600.F
0004: Outlet Temperature 200.F
0005: End Step If Inlet < 375.F for 0:30
0006: Run Time 15:00
0007: END OF OPERATION
15: 4
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Operation #54 OUTLET ALGORITHM #1
0001: OUTLET ALGORITHM #1
0002: Recirculation On
0003: Inlet Temperature 600.F
0004: Outlet Temperature 200.F
0005: End Step If Outlet Rises From 150 to 160.F in 0:25
0006: Run Time 6:00
0007: END OF OPERATION
Operation #55 OUTLET ALGORITHM #2
0001: OUTLET ALGORITHM #2
0002: Inlet Temperature 600.F
0003: Outlet Temperature 200.F
0004: End Step If Outlet Rises From 200 to 200.F in 99:00
0005: Run Time 14:00
0006: END OF OPERATION
Operation #56 HUMIDITY ALGORITHM 1
0001: HUMIDITY ALGORITHM 1
0002: Recirculation On
0003: Inlet Temperature 600.F
0004: Outlet Temperature 200.F
0005: End Step If Humidity #1 < 10.0 for 0:30
0006: Run Time 14:00
0007: END OF OPERATION
Operation #57 HUMIDITY ALGORITHM 2
0001: HUMIDITY ALGORITHM 2
0002: Recirculation On
0003: Inlet Temperature 600.F
0004: Outlet Temperature 200.F
0005: End Step If Humidity #2 < 10.0 for 0:30
0006: Run Time 14:00
0007: END OF OPERATION
15: 5
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Operation #58 ONE CAKE ALGORITHM
0001: ONE CAKE ALGORITHM
0002: Recirculation On
0003: Inlet Temperature 600.F
0004: Outlet Temperature 200.F
0005: Run Time 10:00
0006: END OF OPERATION
Operation #59 UNLOAD MANUALLY
0001: UNLOAD MANUALLY
0002: Auto Discharge Front
0003: Run Time 0:05
0004: END OF OPERATION
Operation #60 UNLOAD SMALL PIECES
0001: UNLOAD SMALL PIECES
0002: Auto Discharge Front
0003: Run Time 0:05
0004: Rotate CW for 15 Seconds
0005: Rotate CCW for 15 Seconds
0006: Dwell Timer 5 Seconds
0007: Run Time 1:30
0008: END OF OPERATION
Operation #61 UNLOAD MEDIUM PIECES
0001: UNLOAD MEDIUM PIECES
0002: Auto Discharge Front
0003: Run Time 0:05
0004: Rotate CW for 10 Seconds
0005: Rotate CCW for 10 Seconds
0006: Dwell Timer 5 Seconds
0007: Run Time 1:10
0008: END OF OPERATION
15: 6
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Operation #62 UNLOAD LARGE PIECES
0001: UNLOAD LARGE PIECES
0002: Auto Discharge Front
0003: Run Time 0:05
0004: Rotate CW for 2 Seconds
0005: Rotate CCW for 2 Seconds
0006: Dwell Timer 4 Seconds
0007: Run Time 1:00
0008: END OF OPERATION
Operation #63 RUNNING PROMPT
0001: RUNNING PROMPT
0002: Prompt: Check Load!!
0003: Signal Until Operator Cancels
0004: Run Time 0:00
0005: END OF OPERATION
Operation #64 STOPPED PROMPT
0001: STOPPED PROMPT
0002: Tumble Only
0003: Dwell Timer 999 Seconds
0004: Prompt: Is Load Dry?
0005: Signal Until Operator Cancels
0006: Run Time 0:00
0007: END OF OPERATION
15: 7
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Formula #100 Sheets
0001: Sheets
0002: ROTATE CW ONLY
0003: Rotate CW for 999 Seconds
0004: INITIAL HEAT
0005: Inlet Temperature 650.F
0006: Outlet Temperature 190.F
0007: Run Time 8:00
0008: LOW TEMP HEAT CYCLE
0009: Recirculation On
0010: Inlet Temperature 500.F
0011: Outlet Temperature 185.F
0012: Run Time 3:00
0013: REVERSE 30/30/4
0014: Rotate CW for 30 Seconds
0015: Rotate CCW for 30 Seconds
0016: Dwell Timer 4 Seconds
0017: COOLDOWN
0018: Cooldown When Temp > 135.F
0019: Run Time 5:00
0020: END OF FORMULA
Formula #101 Uniforms & Sheet
0001: Uniforms & Sheet
0002: VALVE POSITION LIMIT
0003: Max Gas Valve Setting = 3500
0004: INITIAL HEAT
0005: Inlet Temperature 525.F
0006: Outlet Temperature 170.F
0007: Run Time 3:00
0008: LOW TEMP HEAT CYCLE
0009: Recirculation On
0010: Inlet Temperature 525.F
0011: Outlet Temperature 170.F
0012: Run Time 15:00
0013: COOLDOWN
0014: Cooldown When Temp > 130.F
0015: Run Time 5:00
0016: END OF FORMULA
15: 8
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Formula #102 White Towels
0001: White Towels
0002: INITIAL HEAT
0003: Inlet Temperature 550.F
0004: Outlet Temperature 190.F
0005: Run Time 3:00
0006: MED TEMP HEAT CYCLE
0007: Recirculation On
0008: Inlet Temperature 550.F
0009: Outlet Temperature 190.F
0010: Run Time 13:00
0011: COOLDOWN
0012: Cooldown When Temp > 135.F
0013: Run Time 5:00
0014: END OF FORMULA
Formula #103 Color Towels
0001: Color Towels
0002: INITIAL HEAT
0003: Inlet Temperature 600.F
0004: Outlet Temperature 200.F
0005: Run Time 3:00
0006: HI TEMP HEAT CYCLE
0007: Recirculation On
0008: Inlet Temperature 600.F
0009: Outlet Temperature 200.F
0010: Run Time 11:00
0011: COOLDOWN
0012: Cooldown When Temp > 135.F
0013: Run Time 5:00
0014: END OF FORMULA
15: 9
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Formula #104 Delicates
0001: Delicates
0002: INITIAL HEAT
0003: Inlet Temperature 550.F
0004: Outlet Temperature 190.F
0005: Run Time 3:00
0006: MED TEMP HEAT CYCLE
0007: Recirculation On
0008: Inlet Temperature 550.F
0009: Outlet Temperature 190.F
0010: Run Time 5:00
0011: INLET ALGORITHM
0012: Recirculation On
0013: Inlet Temperature 550.F
0014: Outlet Temperature 190.F
0015: End Step If Inlet < 375.F for 2:00
0016: Run Time 8:00
0017: COOLDOWN
0018: Cooldown When Temp > 135.F
0019: Run Time 5:00
0020: END OF FORMULA
Formula #105 Chef Coats
0001: Chef Coats
0002: OUTLET ALGORITHM #1
0003: Recirculation On
0004: Inlet Temperature 600.F
0005: Outlet Temperature 200.F
0006: End Step If Outlet Rises From 150 to 160.F in 0:25
0007: Run Time 6:00
0008: MED TEMP HEAT CYCLE
0009: Recirculation On
0010: Inlet Temperature 550.F
0011: Outlet Temperature 190.F
0012: Run Time 8:00
0013: COOLDOWN
0014: Cooldown When Temp > 135.F
0015: Run Time 5:00
0016: END OF FORMULA
15: 10
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Formula #106 Kitchen Rags
0001: Kitchen Rags
0002: INITIAL HEAT
0003: Inlet Temperature 600.F
0004: Outlet Temperature 200.F
0005: Run Time 3:00
0006: HI TEMP HEAT CYCLE
0007: Recirculation On
0008: Inlet Temperature 600.F
0009: Outlet Temperature 200.F
0010: Run Time 5:00
0011: HUMIDITY ALGORITHM 1
0012: Recirculation On
0013: Inlet Temperature 600.F
0014: Outlet Temperature 200.F
0015: End Step If Humidity #1 < 10.0 for 0:30
0016: Run Time 14:00
0017: COOLDOWN
0018: Cooldown When Temp > 135.F
0019: Run Time 5:00
0020: END OF FORMULA
Formula #107 Mops
0001: Mops
0002: MED TEMP HEAT CYCLE
0003: Recirculation On
0004: Inlet Temperature 550.F
0005: Outlet Temperature 190.F
0006: Run Time 6:00
0007: COOLDOWN
0008: Cooldown When Temp > 135.F
0009: Run Time 5:00
0010: END OF FORMULA
Formula #108 White Table Linen
0001: White Table Linen
0002: MED TEMP HEAT CYCLE
0003: Recirculation On
0004: Inlet Temperature 550.F
0005: Outlet Temperature 190.F
0006: Run Time 10:00
0007: COOLDOWN
0008: Cooldown When Temp > 135.F
0009: Run Time 5:00
0010: END OF FORMULA
15: 11
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Formula #109 Color Table Linen
0001: Color Table Linen
0002: INITIAL HEAT
0003: Inlet Temperature 550.F
0004: Outlet Temperature 190.F
0005: Run Time 3:00
0006: MED TEMP HEAT CYCLE
0007: Recirculation On
0008: Inlet Temperature 550.F
0009: Outlet Temperature 190.F
0010: Run Time 11:00
0011: COOLDOWN
0012: Cooldown When Temp > 135.F
0013: Run Time 5:00
0014: END OF FORMULA
Formula #110 WhitePoly. Linen
0001: WhitePoly. Linen
0002: LIGHT CONDITION
0003: Recirculation On
0004: Inlet Temperature 550.F
0005: Outlet Temperature 180.F
0006: Run Time 5:00
0007: COOLDOWN
0008: Cooldown When Temp > 135.F
0009: Run Time 5:00
0010: END OF FORMULA
Formula #111 Pool/Spa Towels
0001: Pool/Spa Towels
0002: INITIAL HEAT
0003: Inlet Temperature 600.F
0004: Outlet Temperature 200.F
0005: Run Time 3:00
0006: HI TEMP HEAT CYCLE
0007: Recirculation On
0008: Inlet Temperature 600.F
0009: Outlet Temperature 200.F
0010: Run Time 14:00
0011: COOLDOWN
0012: Cooldown When Temp > 135.F
0013: Run Time 5:00
0014: END OF FORMULA
15: 12
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Formula #112 ColorPoly. Linen
0001: ColorPoly. Linen
0002: ROTATE CW ONLY
0003: Rotate CW for 999 Seconds
0004: INITIAL HEAT
0005: Inlet Temperature 600.F
0006: Outlet Temperature 200.F
0007: Run Time 3:00
0008: HI TEMP HEAT CYCLE
0009: Recirculation On
0010: Inlet Temperature 600.F
0011: Outlet Temperature 200.F
0012: Run Time 5:00
0013: INLET ALGORITHM
0014: Recirculation On
0015: Inlet Temperature 600.F
0016: Outlet Temperature 200.F
0017: End Step If Inlet < 375.F for 0:30
0018: Run Time 7:00
0019: COOLDOWN
0020: Cooldown When Temp > 135.F
0021: Run Time 5:00
0022: END OF FORMULA
15: 13
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Formula #113 Personals
0001: Personals
0002: ROTATE CW ONLY
0003: Rotate CW for 999 Seconds
0004: INITIAL HEAT
0005: Inlet Temperature 600.F
0006: Outlet Temperature 200.F
0007: Run Time 3:00
0008: HI TEMP HEAT CYCLE
0009: Recirculation On
0010: Inlet Temperature 600.F
0011: Outlet Temperature 200.F
0012: Run Time 5:00
0013: INLET ALGORITHM
0014: Recirculation On
0015: Inlet Temperature 600.F
0016: Outlet Temperature 200.F
0017: End Step If Inlet < 375.F for 0:30
0018: Run Time 8:00
0019: COOLDOWN
0020: Cooldown When Temp > 135.F
0021: Run Time 5:00
0022: END OF FORMULA
15: 14
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Formula #114 Diapers
0001: Diapers
0002: VALVE POSITION LIMIT
0003: Max Gas Valve Setting = 3500
0004: ROTATE CW ONLY
0005: Rotate CW for 999 Seconds
0006: PURGE - NO HEAT
0007: Run Time 5:00
0008: INITIAL HEAT
0009: Inlet Temperature 525.F
0010: Outlet Temperature 180.F
0011: Run Time 3:00
0012: MED TEMP HEAT CYCLE
0013: Recirculation On
0014: Inlet Temperature 525.F
0015: Outlet Temperature 180.F
0016: Run Time 5:00
0017: INLET ALGORITHM
0018: Recirculation On
0019: Inlet Temperature 525.F
0020: Outlet Temperature 180.F
0021: End Step If Inlet < 375.F for 0:30
0022: Run Time 7:00
0023: COOLDOWN
0024: Cooldown When Temp > 115.F
0025: Run Time 7:00
0026: END OF FORMULA
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Formula #115 Polyester Pads
0001: Polyester Pads
0002: VALVE POSITION LIMIT
0003: Max Gas Valve Setting = 3500
0004: ROTATE CW ONLY
0005: Rotate CW for 999 Seconds
0006: INITIAL HEAT
0007: Inlet Temperature 525.F
0008: Outlet Temperature 170.F
0009: Run Time 3:00
0010: LOW TEMP HEAT CYCLE
0011: Recirculation On
0012: Inlet Temperature 525.F
0013: Outlet Temperature 170.F
0014: Run Time 5:00
0015: INLET ALGORITHM
0016: Recirculation On
0017: Inlet Temperature 525.F
0018: Outlet Temperature 170.F
0019: End Step If Inlet < 375.F for 0:30
0020: Run Time 7:00
0021: COOLDOWN
0022: Cooldown When Temp > 115.F
0023: Run Time 7:00
0024: END OF FORMULA
15: 16
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Formula #116 Housekeeping Rag
0001: Housekeeping Rag
0002: VALVE POSITION LIMIT
0003: Max Gas Valve Setting = 3500
0004: ROTATE CW ONLY
0005: Rotate CW for 999 Seconds
0006: INITIAL HEAT
0007: Inlet Temperature 550.F
0008: Outlet Temperature 180.F
0009: Run Time 3:00
0010: LOW TEMP HEAT CYCLE
0011: Recirculation On
0012: Inlet Temperature 550.F
0013: Outlet Temperature 180.F
0014: Run Time 5:00
0015: INLET ALGORITHM
0016: Recirculation On
0017: Inlet Temperature 550.F
0018: Outlet Temperature 180.F
0019: End Step If Inlet < 290.F for 1:30
0020: Run Time 9:00
0021: COOLDOWN
0022: Cooldown When Temp > 125.F
0023: Run Time 6:00
0024: END OF FORMULA
15: 17
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Formula #117 AIDS/Disease
0001: AIDS/Disease
0002: HEAVY CONDITION
0003: Recirculation On
0004: Inlet Temperature 600.F
0005: Outlet Temperature 200.F
0006: Run Time 10:00
0007: COOLDOWN
0008: Cooldown When Temp > 135.F
0009: Run Time 5:00
0010: END OF FORMULA
Formula #118 Shirts
0001: Shirts
0002: ROTATE CW ONLY
0003: Rotate CW for 999 Seconds
0004: HEAVY CONDITION
0005: Recirculation On
0006: Inlet Temperature 600.F
0007: Outlet Temperature 200.F
0008: Run Time 8:00
0009: COOLDOWN
0010: Cooldown When Temp > 135.F
0011: Run Time 5:00
0012: END OF FORMULA
Formula #119 Lt. Starch/Extr.
0001: Lt. Starch/Extr.
0002: VALVE POSITION LIMIT
0003: Max Gas Valve Setting = 3500
0004: MEDIUM CONDITION
0005: Recirculation On
0006: Inlet Temperature 550.F
0007: Outlet Temperature 180.F
0008: Run Time 8:00
0009: COOLDOWN
0010: Cooldown When Temp > 115.F
0011: Run Time 6:00
0012: END OF FORMULA
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Formula #120 Extra Rinse Extr
0001: Extra Rinse Extr
0002: VALVE POSITION LIMIT
0003: Max Gas Valve Setting = 3500
0004: HEAVY CONDITION
0005: Recirculation On
0006: Inlet Temperature 550.F
0007: Outlet Temperature 180.F
0008: Run Time 11:00
0009: COOLDOWN
0010: Cooldown When Temp > 115.F
0011: Run Time 7:00
0012: END OF FORMULA
Formula #121 General Wash
0001: General Wash
0002: VALVE POSITION LIMIT
0003: Max Gas Valve Setting = 3500
0004: REVERSE 30/30/4
0005: Rotate CW for 30 Seconds
0006: Rotate CCW for 30 Seconds
0007: Dwell Timer 4 Seconds
0008: INITIAL HEAT
0009: Inlet Temperature 550.F
0010: Outlet Temperature 180.F
0011: Run Time 3:00
0012: LOW TEMP HEAT CYCLE
0013: Recirculation On
0014: Inlet Temperature 550.F
0015: Outlet Temperature 180.F
0016: Run Time 5:00
0017: INLET ALGORITHM
0018: Recirculation On
0019: Inlet Temperature 550.F
0020: Outlet Temperature 180.F
0021: End Step If Inlet < 290.F for 0:30
0022: Run Time 8:00
0023: COOLDOWN
0024: Cooldown When Temp > 135.F
0025: Run Time 5:00
0026: END OF FORMULA
15: 19
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Formula #122 Pillow Cases
0001: Pillow Cases
0002: INITIAL HEAT
0003: Inlet Temperature 600.F
0004: Outlet Temperature 200.F
0005: Run Time 3:00
0006: HI TEMP HEAT CYCLE
0007: Recirculation On
0008: Inlet Temperature 600.F
0009: Outlet Temperature 200.F
0010: Run Time 5:00
0011: INLET ALGORITHM
0012: Recirculation On
0013: Inlet Temperature 600.F
0014: Outlet Temperature 200.F
0015: End Step If Inlet < 310.F for 1:00
0016: Run Time 12:00
0017: COOLDOWN
0018: Cooldown When Temp > 135.F
0019: Run Time 5:00
0020: END OF FORMULA
Formula #123 Extra Heavy Soil
0001: Extra Heavy Soil
0002: INITIAL HEAT
0003: Inlet Temperature 600.F
0004: Outlet Temperature 200.F
0005: Run Time 3:00
0006: HI TEMP HEAT CYCLE
0007: Recirculation On
0008: Inlet Temperature 600.F
0009: Outlet Temperature 200.F
0010: Run Time 6:00
0011: INLET ALGORITHM
0012: Recirculation On
0013: Inlet Temperature 600.F
0014: Outlet Temperature 200.F
0015: End Step If Inlet < 300.F for 1:00
0016: Run Time 12:00
0017: COOLDOWN
0018: Cooldown When Temp > 135.F
0019: Run Time 5:00
0020: END OF FORMULA
15: 20
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Formula #124 Wool Blankets
0001: Wool Blankets
0002: INITIAL HEAT
0003: Inlet Temperature 600.F
0004: Outlet Temperature 200.F
0005: Run Time 3:00
0006: HI TEMP HEAT CYCLE
0007: Recirculation On
0008: Inlet Temperature 600.F
0009: Outlet Temperature 200.F
0010: Run Time 7:00
0011: INLET ALGORITHM
0012: Recirculation On
0013: Inlet Temperature 600.F
0014: Outlet Temperature 200.F
0015: End Step If Inlet < 290.F for 1:00
0016: Run Time 12:00
0017: COOLDOWN
0018: Cooldown When Temp > 135.F
0019: Run Time 5:00
0020: END OF FORMULA
Formula #125 Stain Treatment
0001: Stain Treatment
0002: ROTATE CW ONLY
0003: Rotate CW for 999 Seconds
0004: RUNNING PROMPT
0005: Prompt: Check Load!!
0006: Signal Until Operator Cancels
0007: Run Time 0:30
0008: Run Time 0:05
0009: STOPPED PROMPT
0010: Tumble Only
0011: Dwell Timer 999 Seconds
0012: Prompt: Is Load Dry?
0013: Signal Until Operator Cancels
0014: Run Time 0:00
0015: ROTATE CW ONLY
0016: Rotate CW for 999 Seconds
0017: TUMBLE ONLY
0018: Tumble Only
0019: Run Time 0:30
0020: END OF FORMULA
15: 21
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Formula #126 Cotton Blankets
0001: Cotton Blankets
0002: VALVE POSITION LIMIT
0003: Max Gas Valve Setting = 2000
0004: ROTATE CW ONLY
0005: Rotate CW for 999 Seconds
0006: LOW TEMP HEAT CYCLE
0007: Recirculation On
0008: Inlet Temperature 425.F
0009: Outlet Temperature 160.F
0010: Run Time 12:00
0011: COOLDOWN
0012: Cooldown When Temp > 110.F
0013: Run Time 5:00
0014: END OF FORMULA
Formula #127 Uniforms
0001: Uniforms
0002: TUMBLE ONLY
0003: Tumble Only
0004: UNLOAD MEDIUM PIECES
0005: Auto Discharge Front
0006: Run Time 0:05
0007: Rotate CW for 10 Seconds
0008: Rotate CCW for 10 Seconds
0009: Dwell Timer 5 Seconds
0010: Run Time 1:10
0011: END OF FORMULA
15: 22
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Formula #128 Test Formula
0001: Test Formula
0002: ********* Label 1 *********
0003: ROTATE CW ONLY
0004: Rotate CW for 999 Seconds
0005: LOW TEMP HEAT CYCLE
0006: Recirculation On
0007: Inlet Temperature 500.F
0008: Outlet Temperature 150.F
0009: Run Time 2:00
0010: COOLDOWN
0011: Cooldown When Temp > 150.F
0012: Run Time 2:00
0013: STOPPED PROMPT
0014: Tumble Only
0015: Dwell Timer 999 Seconds
0016: Prompt: Is Load Dry?
0017: Prompt: Call Supervisor!
0018: Signal [Yes] = Label 2 [No] = Label 1
0019: Run Time 0:00
0020: ********* Label 2 *********
0021: ROTATE CW ONLY
0022: Rotate CW for 999 Seconds
0023: COOLDOWN
0024: Cooldown When Temp > 125.F
0025: Run Time 2:00
0026: UNLOAD MANUALLY
0027: Auto Discharge Front
0028: Run Time 0:05
0029: END OF FORMULA
15: 23
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Notes:
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MicroPulse Dryer
Please visit us on the World Wide Web at www.Softrol.com.
Softrol MicroPulse Dryer Manual
Entire Contents © 2000 - 2001 Softrol System, Inc.
1st Edition 12/21/00
Revised 02/23/01- Updated for new K4 processor.
Revised 11/20/01- New Layout
Revised 12/17/01- Updated Hardware Overview AIO-420 error.
Revised 06/12/02- Added error fault lists.
Revised 06/18/02- Correcting the Hardware Overview Slot error.
Revised 09/24/02- Correcting errors in chapters 4,6, and 12.
Revised 10/09/06- Added Gas Meter Type 1 and Type 2 to Setups Defined
No portion of this manual may be duplicated in any manner without
expressed written consent of Softrol Systems, Inc.
1100 Northpoint Parkway
Acworth, GA 30102
770.974.2700
www.softrol.com
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