MM

Maintenance Manual
Straw Applicator 30
663350-0500

WARNING
Read and follow all safety precaution instructions throughout this
document and on safety signs attached to this equipment.
Failure to follow all safety precaution instructions could result in death or
serious injury.

Doc. No. MM-3541840-0101

Copyright © 2018 Tetra Pak International S.A.
All rights reserved. No part of this document may be reproduced or copied in any form or by
any means without written permission from Tetra Pak Packaging Solutions AB.

, Tetra Pak, and all other trademarks displayed in this document are the property of the
Tetra Pak International SA. Tetra Pak Packaging Solutions AB together with Tetra Pak
International SA form part of ‘the Tetra Pak Group’. The content of this document is in
accordance with the design and construction of the machine or equipment at the time of
publishing. The Tetra Pak Group reserves the right to introduce design modifications without
prior notice.
The English language version of this document contains the original instructions. All other
language versions are translations of the original instructions.
This document was produced and printed by:
Tetra Pak Packaging Solutions AB
Ruben Rausings gata
SE-221 86 Lund
Sweden

Doc. No. MM-3541840-0101

Issue 2018-02
This document is valid for: Introduction
Safety Precautions
1 Electric Equipment
Serial No. / Machine No.
Year of Manufacture Sign. 2 Conveyor Section
3 Applicator Unit
4 Straw Detector Integrated

MM
Maintenance Manual
5
6
7
8
Hotmelt Equipment
Machine Body
Machine Covering
Air Equipment
9 Regular Accessories
10 General
11 Safety System Description
Straw Applicator 30
663350-0500

Machine or equipment configurations that

this document is valid for are described on
the next page.

Doc. No. MM-3541840-0101

Issue 2018-02

Tetra Pak Packaging Solutions AB

Valid for:
Name Drawing Specification and Additional Information
Development Step

Straw Applicator 30 663350-0500 Package shape:

- Tetra Brik, TB
- Tetra Brik Aseptic, TBA
- Tetra Prisma Aseptic, TPA
- Tetra Top, TT
 Update Log for Doc. No. MM-3541840-0101
This table shows all changes made to this document, including installed
rebuilding kits, added or removed pages. Page numbering on added pages
begins with UP.

Date Installed Kit Added Pages Removed Pages Signature

(Doc. No.)
Date Installed Kit Added Pages Removed Pages Signature
(Doc. No.)
 Introduction

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Doc. No. MM-3541840-0101 7 (728)
 Introduction

Description
This chapter contains basic information about this manual and the related
Tetra Pak® equipment.

8 (728) Doc. No. MM-3541840-0101

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Introduction Table of Contents

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Abbreviations and Terminology ..............................11

Manual Information ............................................. 13
Delivered Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
EM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
IM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
MM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TeM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Page Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Page Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Typographical Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Machine Introduction .......................................... 17

Intended Use of the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
EU Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Identification ..................................................... 18
EAC Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
China RoHS2 Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Machine Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Electrical Equipment Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Delivered Design Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Orientation........................................................ 23
Hygiene ............................................................ 25
Environment...................................................... 26
Waste Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fluids and Chemical Products . . . . . . . . . . . . . . . . . . . . . . . . . 26
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Table of Contents Introduction

Hydrogen Peroxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Cooling Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Separation of Materials and Components. . . . . . . . . . . . . . . 26
Electrical Components. . . . . . . . . . . . . . . . . . . . . . . . . . 27
Packaging and Additional Material . . . . . . . . . . . . . . 27

How to Use This MM............................................ 28

Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Procedure Start Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

TPMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
How TPMS Works. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
TPMS Maintenance Recommendation Overview . . . . . . . . 30

Assistance and Inquiries...................................... 32

10 (728) Doc. No. MM-3541840-0101

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Introduction Abbreviations and Terminology

Abbreviations and Terminology*

Abbreviation/Terminology Meaning Translation
ANSI American National American National
Standards Institute Standards Institute
BFT Bent Foil Treater Bent Foil Treater
CE Conformité Conformité
Européenne/European Européenne/European
Conformity Conformity
DC Direct Current Direct Current
DE Distribution Equipment
DHCP Dynamic Host Dynamic Host
Configuration Protocol Configuration Protocol
DIP Dual In-Line Package Dual In-Line Package
DNS Domain Name System Domain Name System
EAC Eurasian Conformity Eurasian Conformity
EDS Electronic Data Sheet Electronic Data Sheet
EEA European Economic European Economic
Area Area
EM Electrical Manual Electrical Manual
ESD Electrostatic Sensitive Electrostatic Sensitive
Device Device
FM Filling Machine Filling Machine
FTP File Transfer Protocol File Transfer Protocol
HMI Human Machine Human Machine
Interface Interface
I/O Input/Output Input/Output
IM Installation Manual Installation Manual
IP Internet Protocol Internet Protocol
ISO International Standards International Standards
Organization Organization
IVC Industrial Vision Industrial Vision
Camera Camera
LED Light Emitting Diode Light Emitting Diode
LGV Laser Guided Vehicle Laser Guided Vehicle
MAC Media Access Control Media Access Control
(address) (address)
MM Maintenance Manual Maintenance Manual
OM Operation Manual Operation Manual
PC Personal Computer Personal Computer
PLC Programmable Logic Programmable Logic
Controller Controller
PoB Print on board Print on board
PoMF Print on metallized film Print on metallized film
RM Rebuilding Manual Rebuilding Manual
SA30 Straw Applicator 30 by Straw Applicator 30 by
Tetra Pak Tetra Pak
SD Straw Detector Straw Detector
SPC Spare Parts Catalogue Spare Parts Catalogue
TB Tetra Brik Tetra Brik

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Abbreviations and Terminology Introduction

Abbreviation/Terminology Meaning Translation

TBA Tetra Brik Aseptic Tetra Brik Aseptic
TCA Tetra Classic Aseptic Tetra Classic Aseptic
TCP Transmission Control Transmission Control
Protocol Protocol
TeM Technical Manual Technical Manual
TPA Tetra Prisma Aseptic Tetra Prisma Aseptic
TPMS Tetra Pak Maintenance Tetra Pak Maintenance
System System
TPOP Tetra Pak Operator Tetra Pak Operator
Panel Panel
TS Transversal Seal Transversal Seal
TT Tetra Top Tetra Top
TWA Tetra Wedge Aseptic Tetra Wedge Aseptic
UP Update Pages Update Pages
USB Universal Serial Bus Universal Serial Bus

12 (728) Doc. No. MM-3541840-0101

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Introduction Manual Information

Manual Information
The Tetra Pak Group recommends reading all delivered manuals carefully. Make
sure that the delivered manuals are available to personnel who operate or maintain
the equipment.

It is important to keep this manual for the lifetime of the equipment and to pass the
manual on to any subsequent holder or user.
Any item that is named specifically in this manual is to be considered a designated
item for the equipment. Designated items are verified by the Tetra Pak Group for use
with the equipment.

The Tetra Pak Group will not be held responsible for any damage, loss, injury, or
death caused by not following the instructions in the manuals that accompany this
equipment, or by a failure to use designated items specified in the manuals that
accompany this equipment.

Delivered Manuals
Manuals delivered with this equipment:

EM
The Electrical Manual provides technicians with information about the equipment’s
electrical system.

IM
The Installation Manual provides technicians with information required to safely
install the equipment.

MM
The Maintenance Manual provides technicians with information on maintaining the
equipment.

OM
The Operation Manual provides the operator with information on handling and
operating the equipment before, during, and after production.

SPC
The Spare Parts Catalogue provides the information necessary to order spare parts
from the Tetra Pak Group.

TeM
The Technical Manual provides information that is needed during the crate handling
process when the crate is equipped with a metal folder.
This includes

• the data and information concerning the crate and crated equipment
• the information concerning lifting machinery and lifting accessories
• the procedures for receiving, opening the crate, and unpacking the equipment

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Manual Information Introduction

Page Layout
Every main page in a manual contains a header and a footer. The page header
contains the chapter name (1) and the section name (2). The page footer contains
the page number (3), and the document number (4). See also the Page Numbering
section.

1 2

9 General 9.2 Technical Data

Doc. No. MM-2730517-0103 41 (60)

4 3
1 Chapter name
2 Section name
3 Page number
4 Document number
.

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Introduction Manual Information

Page Numbering
A page number has two parts:
• consecutive page number (1)
• total number of pages (2) in user manual

31 (356)
1 2
1 Consecutive page
number
2 Total number of pages

Note! The letters UP (3) may appear before the consecutive page number (4) if the
user manual includes update pages. The consecutive page number (4) and the total
number of pages (5) of update pages do not follow the existing sequential page
numbering of the user manual.

UP-11 (18)
3 4 5
3 UP
4 Consecutive page
number
5 Total number of pages
.

Typographical Conventions
Physical buttons on the operator panel, emergency stop devices, program steps, and
program tasks are printed in CAPITAL LETTERS.
Names of buttons, entry fields, menu items, or other objects that allow the user to
control the user interface are printed in Courier.

Information that is displayed on the user interface, is to be repeated in the user

manual, but is not used to control the user interface, is printed in COURIER CAPITAL
LETTERS.
Cross-references are underlined.

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Manual Information Introduction

Symbols
Symbols used in illustrations.

A pointer arrow indicates the position of

an object.

A zoom arrow indicates that an object

view is enlarged. The arrow points
towards the enlarged view of the object.

A rotation movement arrow indicates

rotational movement of an object. The
arrow points in the direction of rotation.
A straight movement arrow indicates
movement of an object.
The arrow points in the direction of
movement.
.

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Introduction Machine Introduction

Machine Introduction
Intended Use of the Equipment
The intended use of this Tetra Pak equipment is to attach drinking straws onto
Tetra Brik packages (TB and TBA), Tetra Prisma Aseptic packages (TPA), or
Tetra Top packages (TT).

All other use is prohibited. Tetra Pak will not be held responsible for injury or damage
if the equipment is used for any other purpose than the intended use described
above.

Manufacturer
This Tetra Pak® equipment is manufactured by
Tetra Pak Packaging Solutions AB
Ruben Rausings gata
SE-221 86 Lund
Sweden

EU Declaration of Conformity
A copy of the EU Declaration of Conformity can be found in the Installation Manual.
The signed EU Declaration of Conformity is delivered separately with the equipment.

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Identification Introduction

Identification
EAC Compliance
This equipment complies with the regulations of the Eurasian Customs Union.

China RoHS2 Compliance

This equipment may contain one or more of the following substances: Pb, Hg, Cd,
Cr6+, PBB, and PBDE.

The Environmental Protection Use Period is 25 years.

The Hazardous Substances Disclosure Table can be found in the Disassembly and
Removal chapter in the IM.

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Introduction Identification

Machine Plate
The illustration below shows an example of the machine plate and its location on the
equipment. The machine plate carries data needed when contacting the Tetra Pak
Group concerning this specific equipment.
Make sure that the equipment data in the front pages of this manual corresponds to
the machine plate data and the machine specification.

1 2 3 4 5

10 9 8 7 6
Main machine
1 Machine type 5 Manufacturer
2 Drawing specifications 6 EAC mark
3 Machine serial number 7 China RoHS2 mark (if
4 CE mark applicable)
8 Month of manufacture
9 Assembled in
10 Year of manufacture
.

(Cont’d)

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Identification Introduction

(Cont’d)

1 2 3 4 5

10 9 8 7 6
BFT
1 Machine type 5 Manufacturer
2 Drawing specifications 6 EAC mark
3 Machine serial number 7 China RoHS2 mark (if
4 CE mark applicable)
8 Month of manufacture
9 Assembled in
10 Year of manufacture
.

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Introduction Identification

Electrical Equipment Marking

The illustration below shows an example of the electrical equipment marking and its
location on the equipment. The electrical equipment marking specifies the electrical
characteristics for the equipment at the connection point.

1
2

3
4

9 8 7 6
1 Electrical doc. No. 4 Full-load current 7 Supply voltage
2 Electrical doc. BoM 5 Short-circuit capacity 8 Phase
3 Equipment Master No. 6 Maximum supply 9 Frequency
source impedance
.

Delivered Design Label

The illustration below shows an example of the delivered design label and its location
on the equipment. The delivered design label lists information tracking any rebuilding
done to the electrical design, and any alterations done in the electrical cabinet and to
related electrical components.

The delivered design label is filled in by the person performing the rebuilding or
alteration.
(Cont’d)

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Identification Introduction

(Cont’d)

22 (728) Doc. No. MM-3541840-0101

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Introduction Orientation

Orientation
The illustration below shows the orientation of the equipment. This orientation
information will be used throughout this manual. The arrows indicate the flow of
material.

D A

B
Main machine
A Front
B Left-hand side
C Right-hand side
D Back
.

(Cont’d)

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Orientation Introduction

(Cont’d)

A D

C
BFT
A Front
B Left-hand side
C Right-hand side
D Back

.
Note! The machine can process the straw ladder band in either direction.

24 (728) Doc. No. MM-3541840-0101

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Introduction Hygiene

Hygiene
• Never clean the floors or the machine in the filling room (area) when the machine
is in production.
• Keep your hands and gloves clean.
• Always wear some type of hair protection (cap or hairnet) and clean clothes
(preferably white).
• Do not wear a watch, ring, necklace, earrings, or any other exposed jewellery.

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Environment Introduction

Environment
Waste Management
Separate, recycle, or dispose of all material and components in a safe, and
environmentally responsible way, or according to national legislation or local
regulations. If there is any uncertainty regarding what material a component is made
of, contact the Tetra Pak Group. Use a certified (ISO 14001 or similar) scrapping or
waste handling company.

Fluids and Chemical Products

Drain all liquids into collecting vessels. Do not mix different liquids into the same
vessel. Follow the instructions in the Safety Data Sheets for the disposal of the
different fluids and dispose of according to national legislation or local regulations.

Hydrogen Peroxide
Follow the instructions in the Safety Data Sheets, national legislations, and local
regulations for the disposal. Flush the hydrogen peroxide system with distilled water
to dilute any remaining hydrogen peroxide to a safe level.
For further details see the Hazardous Substances section in the Safety Precautions
chapter.

Cooling Media
Equipment containing any kind of cooling media must be dismantled, but only as far
as can be considered safe without any cooling media leakage. Follow national
legislation or local regulations. Send the cooling media to an authorized company
for proper handling.

For further details see the Hazardous Substances section in the Safety Precautions
chapter.

Separation of Materials and Components

Separate the following materials. Recycle or dispose of the materials as
appropriate. Follow specific recycling instructions, if such are given by the
component supplier.
• stainless steel (panels and doors)
• cast iron (frames)
• brass
• glass (windows, and so on)
• rubber (seals, O-rings, and so on)
• nylon and other plastics
• electrical cables
• hydraulic hoses
• central lubrication hoses
• pneumatic hoses
• electrical components
• batteries
• mercury (UV-lamp)

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Introduction Environment

Electrical Components
Electrical components and batteries may need to be disposed of in special waste
management systems. Follow national legislation or local regulations.
Packaging and Additional Material
Remaining packaging material and additional material such as strips, caps, tops,
corrugated cardboard, and plastic film wrapping shall be sent for recycling or
disposed of according to national legislation or local regulations.

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How to Use This MM Introduction

How to Use This MM

Procedures
The name of the chapters and sections in the MM correspond to the groups in the
structure of the equipment. Procedures correspond to a chapter or a section:
• The hyphens indicate that it is a procedure heading. The example shows a
heading for Procedure number 3 in Section 1.5.
• The text after the second hyphen tells what type of procedure it is. Check,
Change, and Set are common procedure types.

1.5-3 Outfeed Servo - Change Bearings

Maintenance procedures in this manual are connected to the Tetra Pak

Maintenance System, TPMS. See the TPMS section.

Procedure Start Table

Procedures in this manual begin with a table providing information needed to
perform the procedure.
• Machine Status (1) shows actuator status, program step, and any other machine
status necessary to begin the procedure. If an actuator status is omitted, this
implies that the status of the actuator is not relevant for the procedure. If an
actuator status is "LOCKED in OFF position", this implies that the supply must be
turned off according to the prescribed lockout procedure in the Maintenance
Manual.
• Special Equipment (2) shows a list of personal protective equipment and special
tools that are not normally carried by a service technician, but are needed in the
procedure.
• Consumables (3) shows items, such as lubricants, that are required to perform
the procedure. Consumables do not include replacement parts.
• SPC Reference (4) shows the assembly number, found in the index of the SPC.
Machine Status Electrical supply disconnecting device in
position O (LOCKED in OFF position)
Main air valve LOCKED in OFF position
1 Main steam valve ON
Main water valve ON
Special Equipment Torque wrench minimum 55 Nm
Protective gloves TP No. 90303-12
2 Apron TP No. 90303-13
Consumables 2 litre high pressure oil
Grease, code N
3
SPC Reference 123456-0100
4
1 Machine Status
2 Special Equipment
3 Consumables
4 SPC Reference
.

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Introduction How to Use This MM

TPMS
TPMS is the maintenance methodology to handle all maintenance-related work
processes from development and the whole life cycles for Tetra Pak® machines and
equipment. The TPMS methodology is reliability-centred (best industry practice) and
aims at finding the right combination of predetermined, condition-based, and
corrective maintenance. In maintenance, the challenge is to find the right level of
investment in parts and labour effort to achieve the desired performance, quality, and
reliability. Thanks to TPMS, it is possible to create maintenance plans with a good
balance between what is invested and what it received in return.

How TPMS Works

Users around the globe continuously feed the system with maintenance data. The
data is continuously evaluated and then utilised to improve maintenance
recommendations and customer-specific scheduling of maintenance tasks. TPMS
takes a holistic approach to maintenance by including the actions needed to
contribute to plant efficiency. With this advanced maintenance management tool, the
maintenance checklists are designed to include latest updates of our
recommendations to meet the demands for fewer unscheduled stops, reduced
waste, and less interference with production.

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How to Use This MM Introduction

TPMS Maintenance Recommendation Overview

With the Tetra Pak Group's extensive experience of managing maintenance on
Tetra Pak® packaging lines, together with our advanced maintenance management
tools, we can support you in tailoring the right maintenance plans (checklists) to
follow the maintenance system in a consistent way. Using TPMS is a foundation to
having your machine run at its best. Checklists can be managed and delivered
directly from your local Tetra Pak service station. In the checklist you will find
information concerning what tasks shall be done and when they shall be done.
Furthermore, the document reference will give guidance as to how to perform the
work. The document references are MM, SPC, OM, RM, EM, and TeM.

.
Note! The layout of the checklist is subject to change.
For those customers that intend to set up their own maintenance system and plans,
the Tetra Pak Group can on a upon-request basis provide a maintenance
recommendation overview for the specific equipment, including tasks required to
keep the equipment in good condition. The recommendation will be provided free of
charge for up to a year after delivery.
(Cont’d)

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Introduction How to Use This MM

(Cont’d)

The following items can be found in the maintenance recommendation overview:

Task Document
Task Code Trade Task Action Description Reference Interval
Number of the Skill required to Check, Change, Work description Where info can When the task
task perform the task Turn, and so on be found on how shall be
to perform this performed
task

The Tetra Pak Group's Maintenance recommendations are continuously updated

and improved based on user feedback.

Note! Contact the local Tetra Pak® office for additional information and support
regarding TPMS.

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Assistance and Inquiries Introduction

Assistance and Inquiries

For assistance when operating this equipment, submit your questions using the
QuTI-P tool. The QuTI-P tool shall also be used for all other inquiries, comments, or
suggestions that you may have, as well as giving feedback concerning the user
manuals delivered with this equipment.
If access to the Tetra Pak® intranet is available, access the QuTI-P tool by typing
“QuTI-P” in the address field of your browser. If access to QuTI-P is not available,
request access by contacting the Global Service Desk.

If access to the Tetra Pak intranet is not available, contact the nearest Tetra Pak
representative.

32 (728) Doc. No. MM-3541840-0101

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 Safety Precautions

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 Safety Precautions

Description
Safety Precaution Instructions

WARNING
Read and understand this manual before using the machine.
Failure to follow safety precautions and instructions can result in death or serious
injury.

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Safety Precautions Table of Contents

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Safety Messages Description ................................ 37

Personnel Requirements...................................... 38
Skilled Person . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Instructed Person . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Safety Signs ...................................................... 39

Locations of Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Protective Devices .............................................. 44

Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Emergency Stop Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Safeguards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Indicating Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Protective Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Safe Manual Handling.......................................... 49

Personal Protection ............................................ 50
Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Entanglement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Hazardous Substances ........................................ 51

Disposal of Chemical Substances . . . . . . . . . . . . . . . . . . . . . . . . . 51

Supply Systems ................................................. 52

Definition of Lockout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Electrical Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Residual Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Electrical Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Socket Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Valid for all countries except USA and
Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Valid for USA and Canada . . . . . . . . . . . . . . . . . . . . . . . 57

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Table of Contents Safety Precautions

Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Hotmelt Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

36 (728) Doc. No. MM-3541840-0101

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Safety Precautions Safety Messages Description

Safety Messages Description

A safety message is always accompanied by a safety alert symbol and a signal
word.

The safety alert symbol is used to alert about potential personal injury hazards. To
avoid hazards, obey all safety messages that follow this symbol.
The following safety alert symbols and signal words are used in this manual to inform
the user of hazards.

Danger indicates an imminently

DANGERI
DANGER hazardous situation which, if not
avoided, will result in death or serious
injury.

Warning indicates a potentially

WARNING hazardous situation which, if not
avoided, could result in death or
serious injury.

Caution indicates a potentially

CAUTION hazardous situation which, if not
avoided, may result in minor or
moderate injury. It may also be used to
alert against unsafe practices.
CAUTION Caution without the safety alert symbol
indicates a potentially hazardous
situation which, if not avoided, may
result in property damage.

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Personnel Requirements Safety Precautions

Personnel Requirements
Note! Personnel includes all persons working on or near this equipment.
Only skilled or instructed persons are allowed to work with this equipment.

Skilled Person
A skilled person must have relevant education and experience to enable him or her
to identify hazards, analyse risks, and avoid hazards which electricity, machinery,
chemicals, other energies, and supply systems on this equipment can create.
Skilled persons must meet local regulations, such as certifications and qualifications
for working with these energies and systems.

Instructed Person
An instructed person must be adequately advised or supervised by a skilled person.
The skilled person enables the instructed person to identify hazards, analyse risks,
and avoid hazards which electricity, machinery, chemicals, other energies, and
supply systems on this equipment can create.

38 (728) Doc. No. MM-3541840-0101

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Safety Precautions Safety Signs

Safety Signs
WARNING
Damaged or missing safety signs.
Safety signs are used to indicate safety hazards. If the signs are missing or
damaged, they can not fulfil this function. Replace all missing or damaged safety
signs immediately.
Safety signs are attached to the equipment. The table below lists all the signs that
are used, and illustrations show their locations on the equipment. Each position
number refers to two standards of a safety sign in the table, but only one is used on
the equipment.

• Make sure that each safety sign is legible and in its correct position after
installation and maintenance.
• Replace all missing or damaged safety signs immediately.

Pos ISO Standard ANSI Standard

4
WARNING
Moving part
can crush and cut.
Do not operate with
guard removed.
Follow lockout procedure
before maintenance.

Moving part can crush and cut.

Do not operate with guard removed.
Follow lockout procedure before maintenance.
5
WARNING
Moving parts can
crush and cut.

Do not put hands into

the machine.
Follow lockout procedure
before maintenance.

Moving part can crush and cut.

Do not put hands into the machine.
Follow lockout procedure before maintenance.
10
DANGER
Hazardous voltage.
Will shock, burn, or cause death.
Follow lockout procedure
before maintenance.

Hazardous voltage.
Will shock, burn, or cause death.
Follow lockout procedure before maintenance.
11

5 MIN.

(Cont’d)

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Doc. No. MM-3541840-0101 39 (728)
Safety Signs Safety Precautions

(Cont’d)

Pos ISO Standard ANSI Standard

Hazardous residual voltage on capacitors.
Will shock, burn or cause death.
Disconnect power and wait 5 minutes before opening.
Follow instructions for safe work practices.
14
WARNING
Hazardous voltage could be
present with power supply
disconnector switched off.
Can shock, burn, or cause death.
Conductors supplied from
an external source. Follow lockout
procedure before maintenance.

Hazardous voltage could be present with power supply

disconnector switched off.
Can shock, burn or cause death.
Conductors supplied from an external source.
Follow lockout procedure before maintenance.
15
CAUTION
Laser Radiation.
Do not stare into
beam.
Class 2 laser product

Laser Radiation.
Do not stare into beam.
Class 2 laser product.
16

Hazardous voltage.
Can shock, burn, or cause death.
Read Maintenance Manual (MM) before using this socket outlet.
24
CAUTION
Risk of equipment
damage.
Do not let water
into this area.

Risk of equipment damage.

Do not let water into this area.
27

(Cont’d)

40 (728) Doc. No. MM-3541840-0101

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Safety Precautions Safety Signs

(Cont’d)

Pos ISO Standard ANSI Standard

Hot surface.
Do not touch.
Follow lockout procedure before maintenance.
35
CAUTION
Do not reach in.
Moving parts may
cause injury.
Follow instructions for
safe work practice.

Do not reach in.

Moving parts may cause injury.
Follow instructions for safe work practice.
37
WARNING
To prevent serious injury:
- Do not operate this machine unless all doors are
closed and guards are in place and operating.
- Machine starts automatically. Stay clear of machine
when it is operating.
- Read manual before first operating machine.
If manual is missing, contact Tetra Pak.

To prevent serious injury:

• Do not operate this machine unless all doors are closed and guards are
in place and operating.
• Machine starts automatically. Stay clear of machine when it is operating.
• Read manual before first operating machine. If manual is missing,
contact Tetra Pak.
38
WARNING
To prevent serious injury:
Do not operate this machine unless all doors are
closed and guards are in place and operating.
Read manual before first operating machine. If
manual is missing, contact Tetra Pak.

To prevent serious injury:

Do not operate this machine unless all doors are closed and guards are in
place and operating. Read manual before first operating machine. If
manual is missing, contact Tetra Pak.
40

Not applicable

Hazardous voltage.
Will shock, burn, or cause death.
Disconnect power before opening.

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Safety Signs Safety Precautions

Locations of Safety Signs

37

35
35

24 27
4 5
27

10

10

37 40
15 24
10

11 38 14 16

16 14
(Cont’d)

42 (728) Doc. No. MM-3541840-0101

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Safety Precautions Safety Signs

(Cont’d)

38

10

11 40

BFT

15
Barcode scanner

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Protective Devices Safety Precautions

Protective Devices
There are different kinds of protective device designed to ensure safe use of the
equipment. See the sections below.

WARNING
Hazardous zones.
Hazardous zones are safeguarded and provided with protective devices. Do not
inch or run this equipment if any protective device is inoperative.
Change inoperative components of the safety system immediately.

For the locations of safeguards and/or other protective devices not mentioned in this
section, see the Maintenance Manual.

Emergency Stop
DANGERI
DANGER
Hazardous voltage.
Will shock, burn, or cause death.
Hazardous voltage remains ON after activating an EMERGENCY STOP.
Emergency stop devices are used to stop this equipment immediately in a
hazardous situation. Learn the positions of all emergency stop devices and how to
use them.
Instructions for a normal production stop are included in the Stop chapter of the
Operation Manual.

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Safety Precautions Protective Devices

Emergency Stop Buttons

CAUTION
Equipment damage.
The equipment can be damaged if it is not stopped in the correct way. Use the
EMERGENCY STOP buttons in case of emergency only.
Push one of the EMERGENCY STOP buttons to stop this equipment immediately.
The location of each EMERGENCY STOP button is shown by an arrow.

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Protective Devices Safety Precautions

Safeguards

WARNING
Moving machinery parts.
Never defeat or bypass the interlocking devices.
Movable guards, for example, doors and covers leading to hazardous zones, are
fitted with interlocking devices where required. These devices are usually electric
safety switches that are parts of the safety system and must never be defeated,
bypassed, or otherwise made inoperative.
Where movable guards (doors) are equipped with means to be locked in a
nonclosed position, any person with the intention to preside, for any reason, behind
such a guard must lock the guard in the nonclosed position by use of a padlock.
Note! For work on the electrical equipment, the electrical power must also be
disconnected.

CAUTION
Corners and edges.
Close the doors, guards, or parts of the equipment unless they must be open during
work.

CAUTION
Burn hazard.
Parts of the equipment protected by guards may be hot after operation. Allow
components to cool down or use personal protective equipment.
After installation and maintenance, and before this equipment is inched or run,
check that all safeguards are in place and that they operate correctly.
.

CAUTION
Equipment damage.
The equipment can be damaged if it is not stopped in the correct way. Never stop
this equipment by opening a movable guard, for example, a door or cover, equipped
with an interlocking device.
The location of each interlocking device is shown by an arrow.

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Safety Precautions Protective Devices

Indicating Tower
An indicating tower is a column of light elements:
• A red light (1) indicates a hazardous condition. This is a situation that requires
immediate action.
• A yellow light (2) indicates an abnormal or impending critical condition. This is a
condition calling for action by the operator.
• A blue light (3) indicates that operator action is required.
• A green light (4) indicates a normal condition.

1
2
3
4

Main machine
1 Red light
2 Yellow light
3 Blue light
4 Green light

2
4

BFT
2 Yellow light
4 Green light

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Protective Devices Safety Precautions

Protective Covers
After maintenance, check that all covers are fitted to the machine before it is run.

48 (728) Doc. No. MM-3541840-0101

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Safety Precautions Safe Manual Handling

Safe Manual Handling

Use mechanical lifting aids whenever possible. If mechanical lifting aids are not
available, do not attempt to lift loads over 23 kg without the assistance of a
colleague. Avoid lifting below knee height and above shoulder height. If it is
necessary to lift from the floor, follow the instructions below to reduce the risk of back
and disc injuries.

• Use safety shoes and be sure that the surface of the floor is not slippery.
• Get close to the load.
• Take a wide stance and find the best positions for your feet.
• Bend your hips and knees, and use your leg muscles.
• Keep the load close to your body.
• Do not twist your body while moving the load.
• Take small steps when turning.

In order to reduce the risk of injury to discs and back muscles, be careful to not bend
or twist your back when lifting. Keep the load close to your body to reduce the strain
on your back.

To reduce the ergonomic risks to each individual operator, job rotation is

recommended, so that recovery and variety are provided.

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Personal Protection Safety Precautions

Personal Protection
This section applies to all personnel at all times when this equipment is in operation.
For special personal protective equipment required when handling hazardous
substances, see the Hazardous Substances section.

Noise
CAUTION
Hazardous noise.
May cause impaired hearing.
Hearing protection is recommended whenever this equipment is in operation.

Entanglement

WARNING
Risk of entanglement.
Do not wear jewellery or loose clothing when working on or near this equipment.
Restrain long hair with, for example, clips or rubber bands.

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Safety Precautions Hazardous Substances

Hazardous Substances
WARNING
Contact with chemicals can cause death, serious injury, or illness.
Always read and follow the instructions in the safety data sheet supplied by the
manufacturer or local supplier, when handling chemicals.
Make sure that
• the safety data sheet is available
• preparations have been done to ensure that the stated safety measures in the
safety data sheet can be followed
• the locations of the first aid equipment are learned in order to act immediately in
case of an accident

Disposal of Chemical Substances

Always read and follow the disposal instructions in the safety data sheet supplied by
the manufacturer or local supplier.

It is strongly recommended that used chemical containers are

• disposed of according to the instructions immediately after use
• not used as disposal containers for other chemicals in order to avoid uncontrolled
chemical reactions within the container
.

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Supply Systems Safety Precautions

Supply Systems
Definition of Lockout Procedure
A lockout procedure is a procedure to put each necessary energy isolating device in
its safe position to prevent the energisation of the equipment, such as when a
maintenance procedure should be carried out.
A lockout is the use of a device, for example, a padlock, to make sure that an energy
isolating device cannot be operated.

An energy isolating device is a mechanical device that physically prevents

transmission or release of energy, such as an electrical supply disconnecting
device.
A detailed instruction for the specific lockout procedure(s) for this equipment is
found in the Maintenance Manual.

Electrical Supply
DANGERI
DANGER
Hazardous voltage and moving machinery.
The electrical supply disconnecting device must be in position O (OFF) and secured
with a lock before any work with the equipment that requires the electrical supply to
be disconnected. See the Machine Status section of the Procedure Start Table.
Note! The key to the lock must be removed by the technician and retained in
his/her possession until all work is completed.

DANGERI
DANGER
Hazardous voltage can be present with the electrical supply disconnecting
device in position O (OFF).
Circuits identified by orange-coloured conductors are not disconnected by the main
electrical supply disconnecting device. The location of the electrical supply
disconnecting device of these circuits is described in the procedures that include
work on these types of circuit.
Certain procedures may require that the electrical supply disconnecting device is in
position | (ON). These exceptions are clearly stated in the manuals.
(Cont’d)

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Safety Precautions Supply Systems

(Cont’d)

The illustrations show the electrical supply disconnecting device and its location.
Any equipment connected to the main machine will be dead when the electrical
supply disconnecting device on the main machine is switched OFF.

Main machine
.

The electrical supply disconnecting device on the BFT is coloured red and yellow,
which means that it can be used as an emergency switching off device.

BFT
.

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Supply Systems Safety Precautions

Residual Voltage

DANGERI
DANGER
Hazardous voltage.
Will shock, burn, or cause death.
After the electrical supply disconnecting device is turned to position O (OFF),
residual voltage remains in the capacitor circuits. Wait five minutes before opening
the enclosure containing these circuits. Ensure that no residual voltage remains on
the capacitors before touching them.

Electrical Cabinet
DANGERI
DANGER
Hazardous voltage.
Will shock, burn, or cause death.
Parts behind doors to the electrical cabinet may be live. The electrical supply
disconnecting device must be turned to position O (OFF) and secured with a lock
before performing maintenance inside the electrical cabinet.
Note! The key to the lock must be removed by the technician and retained in
his/her possession until all work is completed.
The use of a key or a tool is necessary to access to the electrical cabinet.

Make sure that the electrical cabinet doors are closed after working inside the
electrical cabinet. Doors with locks must be locked.
(Cont’d)

54 (728) Doc. No. MM-3541840-0101

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Safety Precautions Supply Systems

(Cont’d)

The location of each electrical cabinet is shown by an arrow.

Main machine

BFT
.

Socket Outlet

WARNING
Hazardous voltage.
Can shock, burn, or cause death.
Read the Maintenance Manual before using this socket outlet.

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Doc. No. MM-3541840-0101 55 (728)
Supply Systems Safety Precautions

Valid for all countries except USA and Canada

The socket outlet (2) is connected to a residual current device (1) to protect users
against electrical shock if there is an earth fault in the connected equipment. The
residual current device must be tested each time before the socket outlet is being
used. See the Maintenance Manual for test procedure.
The illustrations show the socket outlet, the residual current device, and their
locations.

1 2
1 Residual current
device, A01F1022
2 Socket outlet,
A01X1020
.

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Safety Precautions Supply Systems

Valid for USA and Canada

The socket outlet (1) has a built-in residual current device to protect users against
electrical shock if there is an earth fault in the connected equipment. The residual
current device must be tested each time before the socket outlet is being used. See
the Maintenance Manual for test procedure.
The illustration shows the socket outlet and its location.

1 Socket outlet,
A01X1020
.

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Doc. No. MM-3541840-0101 57 (728)
Supply Systems Safety Precautions

Air Supply

WARNING
Compressed air and moving machinery.
Close the air supply valve and lock it, and safely release compressed air from the air
system before any work with the equipment that requires the air supply to be closed.
See the Machine Status section of the Procedure Start Table.
Note! The key to the lock must be removed by the technician and retained in
his/her possession until all work is completed.
Certain maintenance procedures may require air supply systems to be on. These
exceptions are clearly stated in the manuals.

The illustrations show the main air valve (1), the lock (2), and their location.

1 Main air valve

2 Lock
.

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Safety Precautions Supply Systems

Hotmelt Equipment
DANGERI
DANGER
Hazardous voltage.
The voltage is 400V inside the hotmelt unit. Risk of immediate danger to life through
electrical shock.
Never flush water or any other liquid towards the hotmelt unit when cleaning the
machine. Failure to obey will result in danger to your life.

WARNING
Risk of injuries.
All service work on the hotmelt unit must be carried out by authorized personnel.
Always wear safety glasses, protective gloves, and other protective clothing to avoid
injuries caused by splashing adhesive.

WARNING
Risk of injuries.
Never remove any part or component until air and the electrical supply to the
machine have been disconnected and the pressure of the adhesive in the system
has been relieved.

WARNING
Risk of burns.
Failure to relieve any remaining air or liquid (adhesive) pressure may cause serious
injuries from burning when the hotmelt filter is detached or flushed.

WARNING
Risk of burns.
During heating and production the unit gets hot. The hotmelt tank contains heated
adhesive which can cause serious injuries. Do not touch the adhesive.

CAUTION
Risk of burns.
During tank drainage never touch the drain shut.
.

(Cont’d)

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Supply Systems Safety Precautions

(Cont’d)

WARNING
Burn hazard.
The hotmelt nozzles and their covers are very hot and there is risk of severe burns.
Never touch the hotmelt nozzles or their covers.
Note! The section Hotmelt Equipment in this manual only deals with what is
specific for this machine.
Always refer to the documentation provided from Nordson Corporation (included in
English in the delivery from Tetra Pak) before doing any kind of work on the hotmelt
equipment.

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 1 Electric Equipment

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Doc. No. MM-3541840-0101 61 (728)
 1 Electric Equipment

Description
SPC Reference 663309-0500
.

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1 Electric Equipment Table of Contents

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

1.1 Electrical Cabinet ............................................... 67

1.1-1 Electrical Equipment - Load Firmware in PLC
and Servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

1.1.1 PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.1.1-1 PLC - CPU Status Indication . . . . . . . . . . . . . . . . . . . . . . 70
1.1.1-2 Preparation for PLC Communication - Configure
PC Network Communications . . . . . . . . . . . . . . . . . . . . . 72
1.1.1-3 Preparation for PLC Communication - Set IP
Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.1.1-4 Preparation for PLC Communication - Configure
RSLinx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.1.1-5 Preparation for PLC Communication - Register
the EDS File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.1.1-6 PLC - Download Program. . . . . . . . . . . . . . . . . . . . . . . . . 88
1.1.1-7 PLC - Load Firmware in PLC and Ethernet
Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.1.1-8 PLC - Install Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.1.1-9 PLC - Remove Module . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.1.1-10 PLC Power Supply - Change Fuse . . . . . . . . . . . . . . . 106
1.1.1-11 PLC Power Supply - Change Module . . . . . . . . . . . . . 107
1.1.1-12 PLC - Attach Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.1.1-13 PLC Input/Output Module - Disconnect/Connect
Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.1.1.1 PLC and Ethernet Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.1.1.1-1 PLC and Ethernet Modules - Set IP Address . . . . . . . 111

1.1.2 Frequency Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115

1.1.3 Servo Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
1.1.4 NAT Router . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
1.1.4-1 NAT Router - Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.1.4-2 NAT Router Several Machines - Set . . . . . . . . . . . . . . 119
1.1.4-3 NAT Router - Troubleshoot . . . . . . . . . . . . . . . . . . . . . . 122

1.1.5 Safety System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

1.1.5-1 Safety System - Change Modules . . . . . . . . . . . . . . . . 124
1.1.5.1 Pluto Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

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Table of Contents 1 Electric Equipment

1.1.5.2 Safeguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

1.1.5.3 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

1.1.6 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

1.1.6-1 Overvoltage Protector - Change Fuse. . . . . . . . . . . . . 125
1.1.6-2 Miniature Circuit Breaker - Reset Fuse . . . . . . . . . . . . 126
1.1.6.1 Residual Current Device (All Countries except USA
and Canada) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
1.1.6.1-1 Residual Current Device - Check Function . . . . . . . . 126
1.1.6.2 Residual Current Device (USA and Canada) . . . . . . . . . . . 127
1.1.6.2-1 Residual Current Device - Check Function . . . . . . . . 127
1.1.6.3 Multi Circuit Protector (All Countries except USA
and Canada) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
1.1.6.3-1 Multi Circuit Protectors - Change . . . . . . . . . . . . . . . . . 128
1.1.6.3-2 Multi Circuit Protectors - Set . . . . . . . . . . . . . . . . . . . . . 130
1.1.6.4 Digital Multi Circuit Protector (USA and Canada). . . . . . . 132
1.1.6.4-1 Digital Multi Circuit Protector - Configure . . . . . . . . . . 133
1.1.6.4-2 Digital Multi Circuit Protector - Reset Alarms. . . . . . . 138
1.1.6.4-3 Digital Multi Circuit Protector - Troubleshoot . . . . . . . 141
1.1.7 Control Devices and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1.1.7-1 Control Devices and Sensors - Set Proximity
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

1.1.8 PLMS SNP (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

1.1.8-1 PLMS SNP - Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.1.8-2 SNP Module - Change . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1.1.8-3 SNP Module - Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.1.8-4 PLMS SNP Data Collection - Check . . . . . . . . . . . . . . 150

1.1.9 Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

1.1.9.1 Filter Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.1.9.1-1 Filter and Fan - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.1.9.1-2 Filter - Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.1.9.1-3 Fan - Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1.1.10 Cooling Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.1.10-1 Cooling Unit - Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.1.10-2 Cooling Unit - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.1.10-3 Cooling Unit - Change . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.1.10-4 Cooling Unit - Set Temperature. . . . . . . . . . . . . . . . . . . 162

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1.1.10-5 Cooling Unit - Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

1.1.10-6 Cooling Unit - Error Handling. . . . . . . . . . . . . . . . . . . . . 166

1.2 TPOP HMI ........................................................ 170

1.2.1 Cooling Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.2.1-1 Cooling Air Intake - Check Filter and Fan . . . . . . . . . . 170
1.2.1-2 Cooling Air Intake - Change Filter. . . . . . . . . . . . . . . . . 171
1.2.1-3 Cooling Air Intake - Change Fan. . . . . . . . . . . . . . . . . . 171
1.2.2 TPOP Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
1.2.2.1 User Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
1.2.2.1-1 User Management - Description . . . . . . . . . . . . . . . . . . 172
1.2.2.1-2 User Management - Log On as a User . . . . . . . . . . . . 174
1.2.2.1-3 User Management - Change User Password . . . . . . 177
1.2.2.1-4 User Management - Change User Settings . . . . . . . . 181
1.2.2.1-5 User Management - Add Language. . . . . . . . . . . . . . . 182
1.2.2.2 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1.2.2.2-1 Install - Load Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1.2.2.2-2 Install - Download Program Using a PC . . . . . . . . . . . 185
1.2.2.2-3 Install - Download Program Using a Secure
Digital Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
1.2.2.3 Machine Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
1.2.2.3-1 Machine Setup - Shut Down TPOP . . . . . . . . . . . . . . . 192
1.2.2.3-2 Machine Setup - Disable Screen Saver . . . . . . . . . . . 193
1.2.2.3-3 Machine Setup - Set IP Address and Subnet
Mask Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
1.2.2.3-4 Machine Setup - Delete Application Program . . . . . . 203
1.2.2.3-5 Machine Setup - Load Application Program. . . . . . . . 207
1.2.2.3-6 Machine Setup - Set Start-Up Language . . . . . . . . . . 211
1.2.2.3-7 Machine Setup - Reset TPOP . . . . . . . . . . . . . . . . . . . . 213
1.2.2.3-8 Machine Setup - Run Application . . . . . . . . . . . . . . . . . 214
1.2.2.3-9 Machine Setup - Calibrate Touch Screen . . . . . . . . . . 215
1.2.2.3-10 Machine Setup - Set Date, Time and Regional
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
1.2.2.3-11 Machine Setup - Font Linking . . . . . . . . . . . . . . . . . . . . 224
1.2.2.4 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
1.2.2.4-1 Configuration - Change PLMS
Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227

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1.2.2.4-2 Configuration - Change Package Type . . . . . . . . . . . . 228

1.2.2.4-3 Configuration - Set Line Communication . . . . . . . . . . 229
1.2.2.4-4 Configuration - Identify Main Conveyor
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230
1.2.2.4-5 Configuration - Change Infeed Conveyor
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231
1.2.2.4-6 Configuration - Change Discharge Conveyor
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232
1.2.2.4-7 Configuration - Change IP Address . . . . . . . . . . . . . . . 233
1.2.2.4-8 Configuration - Set Second Discharge Unit
Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234
1.2.2.4-9 Configuration - Select Cooling Unit Option. . . . . . . . . 235
1.2.2.4-10 Configuration - Set iLine XT Option . . . . . . . . . . . . . . . 236
1.2.2.4-11 Configuration - Set Laser Guided Vehicle
Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237
1.2.2.4-12 Configuration - Set Energy Saving Option . . . . . . . . . 238
1.2.2.4-13 Configuration - Set Conveyor Encoder . . . . . . . . . . . . 239
1.2.2.4-14 Configuration - Set Straw Detector
Integrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
1.2.2.5 Recipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
1.2.2.5-1 Recipes - Set Recipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
1.2.2.6 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
1.2.2.6-1 Maintenance - Set Apply Unit . . . . . . . . . . . . . . . . . . . . 247
1.2.2.6-2 Maintenance - Set Pick Position . . . . . . . . . . . . . . . . . 249
1.2.2.6-3 Maintenance - Set Discharge Unit . . . . . . . . . . . . . . . . 254
1.2.2.6-4 Maintenance - Set Infeed Unit Parameters . . . . . . . . 255
1.2.2.6-5 Maintenance - Set Conveyor Unit
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256
1.2.2.6-6 Maintenance - Set Material Maintenance . . . . . . . . . 261
1.2.2.6-7 Maintenance - Set Straw Detector Integrated . . . . . . 263

1.2.3 Barcode Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

1.2.3-1 Barcode Scanner Cable - Change . . . . . . . . . . . . . . . . 276
1.2.3-2 Barcode Scanner - Configure and Test Barcode
Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277

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1.1 Electrical Cabinet

1.1-1 Electrical Equipment - Load Firmware in PLC and Servo
Machine Status Electrical supply disconnecting device in position I (ON)

CAUTION
Risk of damage to the equipment.
If a firmware update is interrupted by a power failure, or a failure in the
communication between the device and the PC, the PLC CPU will be damaged and
must be sent for repair.
Note! Copy the firmware files (.dmk) to folder C:\Program Files (x86)
\ControlFLASH. If another folder is to be used, add the folder in the Control Flash
software by selecting the Browse button in the CATALOG NUMBER window.
Note! The following procedure is valid for all PLC rack-mounted or distributed
modules requiring firmware.
Firmware revision per device:

Ref. Name Firmware

A03K2010 Processor L36 ERM 1769-L36ERM See
Software
Package
A03K2018 Digital Input Module 16, Fast, Series A, 1769-IQ16F/A Do not
to change
A03K2022
A03K2026 Digital Output Module 16, Series B, 1769-OB16P Do not
to change
A03K2028
W30- Servo Axis Control Module, 2198-H015-ERS See
T1010 Software
Package
W30- Servo Axis Control Module, 2198-H015-ERS See
T1020 Software
Package
W40- MainConveyor and ToppSupport PowerFlex 527-STO See
T1010 Software
W40- Package
.
T1020 or Higher
.
.

(Cont’d)

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(Cont’d)

a) Select Flash programming tools → Control Flash.

b) Click Next (1).

1
1 Next
.

c) Select the catalog number of the target device, and click Next (1).

1
1 Next
.

(Cont’d)

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(Cont’d)

d) Select the network path to the target device:

• Network path for A03K2010 (2)
• Network path for W30T1020 (3)
• Network path for W30T1010 (4)
e) Click OK.

4
3

2 Network path for

A03K2010
3 Network path for
W30T1020
4 Network path for
W30T1010
.

f) Select the firmware revision, and click Next (1).

1
1 Next
.

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1.1.1 PLC
Before data can be sent to the PLC from the PC via an Ethernet cable, the PC
needs to be configured.

The following procedures describe how to configure the PC network

communications:
• 1.1.1-2 Preparation for PLC Communication - Configure PC Network
Communications
• 1.1.1-3 Preparation for PLC Communication - Set IP Address
• 1.1.1-4 Preparation for PLC Communication - Configure RSLinx
• 1.1.1-5 Preparation for PLC Communication - Register the EDS File
.

1.1.1-1 PLC - CPU Status Indication

Machine Status Electrical supply disconnecting device in position I
(ON)
SPC Reference 3241500-0100

1 5
2 6
3 7
4 8

1 Controller Mode 6 Ethernet Link Status

(RUN) status indicator (LINK 1) status
2 Force State (FORCE) indicator
status indicator 7 Ethernet Link Status
3 I/O State (I/O) status (LINK 2) status
indicator indicator
4 Controller Status (OK) 8 SD Card Activity (SD)
status indicator status indicator
5 Ethernet Network
Status (NS) status
indicator

Status Condi-
Indicator: tion: Interpretation Recommended Actions
Controller Off The controller is in Program or Test Normal operation - no action is required.
Mode mode.
(RUN) (1) Green The controller is in Run mode.
Force Off No tags contain I/O force values. I/O Normal operation - No action is required.
State forces are inactive (disabled).
(FORC-
Yellow I/O forces are active (enabled). I/O
E) (2)
force values may or may not exist.
Flashing One or more input or output Enable forces, or remove the individual I/O from
yellow addresses have been forced to an being forced.
On or Off condition, but the forces
have not been enabled.

(Cont’d)

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(Cont’d)

Status Condi-
Indicator: tion: Interpretation Recommended Actions
I/O State Off There are no devices in the I/O Normal operation - no action is required.
(I/O) (3) configuration of the controller.
The controller does not contain a
project.
Green The controller is communicating with
all of the devices in its I/O
configuration.
Flashing One or more devices in the 1. Verify that all I/O modules in your project are
green controller’s I/O configuration are not installed in the same order.
responding. 2. Verify that all devices have been updated to the
latest major and minor firmware revisions.
3. Use RSLogix 5000 programming software
Online help to determine which I/O module is not
responding.
Flashing The controller is not communicating
red with any devices.
A fault has occurred on the
controller.
Controller Off No power is applied. Normal operation - No action is required.
Status
Green The controller is OK.
(OK) (4)
Flashing The controller is storing a project to
green or loading a project from the SD
card.
Red The controller detected a
nonrecoverable major fault and
cleared the project from its memory.
Flashing The controller requires a firmware 1. Download the latest firmware from
red update. http://support.rockwellautomation.com.
2. To install the latest firmware, do one of the
following:
• Use the Control Flash utility.
• Use Auto Flash.
• Use your Compact Flash card.
For additional information, see the CompactLogix
Controllers Installation Guide, publication 1768-
IN004.
A major recoverable fault occurred
on the controller.
A nonrecoverable major fault
occurred on the controller.
A controller firmware update is in
process.
An embedded I/O module firmware
update is in process - CompactLogix
5370 L1 controllers only.
Dim green Save to Flash at power-down.
to red

(Cont’d)

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(Cont’d)

Status Condi-
Indicator: tion: Interpretation Recommended Actions
Ethernet Off The port is not initialised; it does not
Network have an IP address and is operating
Status in BOOTP or DHCP mode.
(NS) (5) Green The port has an IP address, and CIP
connections are established.
Flashing The port has an IP address, but no
green CIP connections are established.
Red The port has detected that the
assigned IP address is already in
use.
Flashing The port is performing its power-up
red/green self test.
Ethernet Off No link.
Link Port administratively disabled.
Status
(LINK Port disabled because rapid ring
1) (6) / fault condition was detected (Link2).
Ethernet Green A 100 Mbps link (half- or full-duplex)
Link exists, no activity.
Status
(LINK A 10 Mbps link (half- or full-duplex)
2) (7) exists - no activity.
Ring network is operating normally,
and the controller is the active
supervisor.
Ring network has encountered a
rare partial network fault, and the
controller is the active supervisor.
Flashing A 100 Mbps link exists and there is
green activity.
A 10 Mbps link exists and there is
activity.
SD Card Off There is no activity to the SD card.
Activity
Flashing The controller is reading from or
(SD) (8)
green writing to the SD card.
Flashing The SD card does not have a valid
red file system.

1.1.1-2 Preparation for PLC Communication - Configure PC

Network Communications
Note! Some computers may have problems connecting due to the firewall settings
on the local computer. If necessary, disable the firewall protection.
Note! Some computers may have problems due to the Wireless Network
Connection. If necessary, disable the Wireless Network Connection.
(Cont’d)

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(Cont’d)

Configure the PC IP Address

a) Open the Start menu (1) on the PC, and select Settings (2) and then
Network Connections (3) to open the Network Connections window (4).

1 Start menu
2 Settings
3 Network
Connections
4 Network
connections
window
.

(Cont’d)

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(Cont’d)

Note! The Local Area Connection (5) is only an example. If multiple area
connections are listed in the Network Connections window (4), select the
required network connection.
b) In the Network Connections window (4), right-click the Local Area
Connection (5), and select Properties (6).

6
4 Network
connections
window
5 Local Area
Connection
6 Properties
.

(Cont’d)

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(Cont’d)

c) In the Local Area Connection Properties window (7), select the

Internet Protocol (TCP/IP) (8). Click the Properties button (9).

8
9

7 Local Area
Connection
Properties window
8 Internet Protocol
(TCP/IP)
9 Properties
.

(Cont’d)

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(Cont’d)

Note! If the firewall protection system only allows a certain range of IP addresses,
make sure that the IP address you specify in the IP address field (12) is within that
range.
d) Select the Use the following IP address radio button (10), and the Use
the following DNS server addresses radio button (11).
e) In the IP address field (12), enter an IP address using the following format:
192.168.1.XX, where XX is a number between 248 and 251 not already
assigned to any PC or PLC connected to the same network.
f) In the Subnet mask field (13), enter the subnet mask as indicated in the
illustration.
g) Click OK (14).

10

10.0.100.XX
192.168.1.XX
255.255.255.0

12
11
13

14
10 Use the following 12 IP address field
IP address radio 13 Subnet mask field
button 14 OK
11 Use the following
DNS server
addresses radio
button
.

1.1.1-3 Preparation for PLC Communication - Set IP Address

To set the IP address for the PLC, see Procedure 1.1.1.1-1 PLC and Ethernet
Modules - Set IP Address.

1.1.1-4 Preparation for PLC Communication - Configure

RSLinx
The RSLinx software enables communication between a PC and a PLC over
Ethernet.
(Cont’d)

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(Cont’d)

Before the PC and the PLC can start communicating, you need to specify their
network and IP addresses in RXLinx.
a) Open the Start menu on the PC, and select Programs (1), Rockwell
Software (2), RSLinx (3) and then RSLinx Classic (4).

1 2 3 4

1 Programs
2 Rockwell Software
3 RSLinx
4 RSLinx Classic
.

(Cont’d)

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(Cont’d)

b) In the RSlinx Classic Professional window (5), select the Configure

Drivers button (6).
c) In the CONFIGURE DRIVERS window (7), select Ethernet/IP Driver (8)
from the drop down menu.
d) Select the Add New button (9).

7 8 9

5 RSlinx Classic 7 CONFIGURE DRIVERS

Professional window
window 8 Ethernet/IP
6 Configure Drivers Driver
button 9 Add New button
.

(Cont’d)

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(Cont’d)

e) Accept the default driver name by clicking OK (10).

f) Enter the PC’s IP address in the Host Name field (11), and then select the Add
New button (12).

10

12

11

10 OK
11 Host Name field
12 Add New button
.

(Cont’d)

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(Cont’d)

g) Enter IP address 192.168.1.8 for the PLC in the Host Name field (13).
h) Click OK (14).

13

192.168.1.8
10.0.0.204

14
13 Host Name field
14 OK
.

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1.1.1-5 Preparation for PLC Communication - Register the EDS

File
a) Open the start menu and select EDS Hardware Installation Tool (1).

1 EDS Hardware
Installation Tool
.

b) Press the Add button (2).

2 Add button
.

(Cont’d)

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(Cont’d)

c) Browse to select EDS file.

d) Highlight Register a single file (3).

e) Press the Next button (4).

4
3 Register a single
file
4 Next button
.

(Cont’d)

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(Cont’d)

f) Verify selection then press the Next button (4).

4
4 Next button
4 Next button
.

g) Press the Next button (4).

4
4 Next button
.

(Cont’d)

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(Cont’d)

h) Complete the task by pressing the Next button (4).

4
4 Next button
.

i) Press the Finish button (5) to exit.

5
5 Finish button
.

(Cont’d)

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(Cont’d)

Collect EDS from Components

a) Open the Start menu (1) on the PC, and then select All Programs (2).

1 Start menu
2 All Programs
.

(Cont’d)

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(Cont’d)

b) Select Rockwell Software (3), RSLinx (4), and then RSLinx Classic (5).

3 Rockwell Software
4 RSLinx
5 RSLinx Classic
.

(Cont’d)

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(Cont’d)

c) Make sure that RSLinx is configured. See Procedure 1.1.1-4 Preparation for
PLC Communication - Configure RSLinx on page 76.
d) Right-click on the device (6) that you want EDS file from. Select Upload EDS
file from device (7).
e) Follow the Rockwell Automation EDS wizard until the end.
f) Repeat items d) and e) until all devices have an EDS file.

6 Device
7 Upload EDS file
from device
.

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1.1.1-6 PLC - Download Program

Machine Status Electrical supply disconnecting device in position I
(ON)
Special Equipment PC
Ethernet cable
SPC Reference 3241507-0200
3241500-0100

Note! To connect to the PLC using an Ethernet cable, the PC must first be
configured for this type of communication. See Procedure 1.1.1-4 Preparation for
PLC Communication - Configure RSLinx on page 76 and Procedure 1.1.1-5
Preparation for PLC Communication - Register the EDS File on page 81 for more
details.
a) Connect the Ethernet cable between a vacant connection port on the Ethernet
switch (1) and the PC (2).

2 1

1 Ethernet switch
2 PC
.

(Cont’d)

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(Cont’d)

b) Make sure the electrical supply disconnecting device is ON and that the
machine is in program step IDLE.
c) Access the software media.
d) Browse to the machine software, and copy the compressed program folder to
the PC desktop.
Extract the program file with the format *.ACD.
e) Double click on the program file to open it in RXLogix.
f) Make sure that the PLC program mode switch is in position rem (middle
position).
g) Use the Communications menu (3) in RSLogix, and select Go Online (4).

3 Communications
menu
4 Go Online
.

(Cont’d)

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(Cont’d)

h) The CONNECTED TO GO ONLINE window (5) should display.

Note! If you get a message saying FAILED TO GO ONLINE WITH THE
CONTROLLER, check the Ethernet cable connection from the PC to the switch,
and from the switch to the PLC, and then click OK. If you do not see the WHO
ACTIVE window (7), click WHO ACTIVE window (6). Manually browse, and
select 00, COMPACTLOGIX PROCESSOR, SA30 on IP 192.168.1.8. Click Go
Online (8).
Note! If you get a message asking to UPDATE FIRMWARE, select Update
firmware.
• Select firmware according to the table in Procedure 1.1-1 Electrical
Equipment - Load Firmware in PLC and Servo, and click Update,
PROCEED? Yes, CONTINUE? OK. The update is made in two steps.
Between each step and when finished, the control flash takes 300 seconds
to turn on. If the time runs out, Disabled BOOTP/DHCP is probably not
selected. Restart if time out occurs. See Procedure 1.1-1 Electrical
Equipment - Load Firmware in PLC and Servo.
• When both the OK LED and the Ethernet port NS LED stop flashing and
remain lit, the firmware update is completed.

5 7 6 8

5 CONNECTED TO GO 7 WHO ACTIVE window

ONLINE window 8 Go Online
6 WHO ACTIVE
.

(Cont’d)

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(Cont’d)

i) Click Download (9).

9
9 Download
.

(Cont’d)

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(Cont’d)

j) In the DOWNLOAD window (10), click the Download button (11).

k) When the download is complete, a Message (12) displays. Click Yes (13) to put
the PLC in RUN mode.
l) If the download is for a replacement PLC controller, continue with the procedure
below to set the nonvolatile memory.
Note! Settings that are not saved in the recipe are overwritten.
• HMI (if applicable) package counter values are always overwritten.
• The configuration page settings remain the same.

10

11

13 12
10 DOWNLOAD window 12 Message
11 Download button 13 Yes
.

(Cont’d)

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(Cont’d)

Set Nonvolatile Memory

a) Select the Communications menu (1), and then select Go Online (2).

1 Communications
menu
2 Go Online
.

(Cont’d)

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(Cont’d)

b) Select the Communications menu (1), and then select Program Mode (3).
c) In the RSLogix dialogue box (4), select the Yes button (5) to put the PLC in
PROGRAM mode.

5
1 Communications
menu
3 Program Mode
4 RSLogix dialogue box
5 Yes button
.

(Cont’d)

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(Cont’d)

d) In the RSLOGIX 5000 window (6), select the CONTROLLER PROPERTIES

button (7).
e) In the CONTROLLER PROPERTIES window (8), select the Nonvolatile
Memory tab (9).
f) Select the Load/Store button (10).

9 8 10

6 RSLOGIX 5000 8 CONTROLLER 10 Load/Store button

window PROPERTIES window
7 CONTROLLER 9 Nonvolatile
PROPERTIES button Memory tab
.

(Cont’d)

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(Cont’d)

g) In the NONVOLATILE MEMORY LOAD/STORE window (11), select On Corrupt

Memory (12) from the drop down list of the Load Image option (13).
h) In the NONVOLATILE MEMORY LOAD/STORE window (11), select Program
(Remote Only) (14) from the drop down list of the Load Mode option (15).
i) Select the Store button (16).

15 13 11 12 14

16
11 NONVOLATILE 14 Program (Remote
MEMORY LOAD/STORE Only)
window 15 Load Mode option
12 On Corrupt Memory 16 Store button
13 Load Image option
.

(Cont’d)

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(Cont’d)

j) Click Yes (17), and then click OK (18).

17

18
17 Yes
18 OK
.

(Cont’d)

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(Cont’d)

k) Click OK (19) to close CONTROLLER PROPERTIES window (8).

19
8 CONTROLLER
PROPERTIES window
19 OK button
.

(Cont’d)

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(Cont’d)

l) Select the Communications menu (1), and then select Go Online (2).
m) Select the Communications menu (1), and then select Run Mode (20) to put
the PLC in RUN mode.
Note! After a PLC program download, you may need to restart the TPOP to
restore the communication between the PLC and the HMI.

20

1 Communications
menu
2 Go Online
20 Run mode
.

1.1.1-7 PLC - Load Firmware in PLC and Ethernet Modules

CAUTION
Risk of damage to the equipment.
If a firmware update is interrupted by a power failure or a failure in the
communication between the device and the PC, the PLC CPU breaks down and
must be sent for repair.
(Cont’d)

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(Cont’d)

Note! The following procedure is valid for all PLC rack mounted or distributed
modules requiring firmware.
Firmware revision per device:

Ref. Name Firmware

A03K2010 Process- See
or L36 Software
ERM Package
1769-
L36ERM

a) When applicable, add firmware files (.dmk) in folder C:\Program Files (x86))
If another folder is used, add the folder in the Control Flash software using the
Browse button in the Catalog Number window.
b) Make sure that the PC is configured as described in Procedure 1.1.1-4
Preparation for PLC Communication - Configure RSLinx.
c)
.
Select Flash programming tools → Control Flash.
d) Press Next (1) in the CONTROLFLASH window.

1
1 Next
.

(Cont’d)

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(Cont’d)

e) Select the catalogue number of the target device, and press Next (1).

1
1 Next
.

f) Select the network path (2) to the target device.

g) Click OK (3).

2 Network path for

A03K2010
3 OK
.

(Cont’d)

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(Cont’d)

h) Select the firmware revision, and click Next (1).

1
1 Next
.

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1.1.1-8 PLC - Install Module

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 3241500-0200

When installing I/O modules or other modules, it is important that the bus
connectors (6) are securely locked together to ensure proper electrical connection.

a) Check that the bus lever (2) of the module to be installed is in the unlocked (fully
right) position. If the module to be installed is inserted between two other
modules, the right-hand-module bus lever also must be in the unlocked position.
b) Use the upper tongue-and-groove slot (3) and the lower tongue-and-groove
slot (4) to secure the modules together (or to a controller).
c) Move the module back along the tongue-and-groove slots until the bus
connectors (6) line up with each other.
d) Push down the upper mounting tabs (1), and push up the lower mounting
tabs (5).

1 2

5 4 3
1 Upper mounting tab 4 Lower tongue-and-
2 Bus lever groove slot
3 Upper tongue-and- 5 Lower mounting tab
groove slot 6 Bus connector
.

(Cont’d)

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(Cont’d)

e) Push the bus lever (2) back slightly to clear the positioning tab (7). Use your
fingers or a small screwdriver.
f) To allow communication between the controller and module, move the bus
lever (2) fully to the left until it clicks. Ensure it is locked firmly in place.
g) If the module to be installed is inserted between two other modules, the right-
hand-module also must be locked as described in items e) and f).
h) Install an end cap terminator (8) to the last module in the system by using the
tongue-and-groove slots as before.
i) Lock the end cap bus terminator (9) by pushing it into place.

8
2 Bus lever
7 Positioning tab
8 End cap terminator
9 End cap bus
terminator
.

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1.1.1-9 PLC - Remove Module

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 3241500-0200

a) Pull up the upper mounting tabs (1) and pull down the lower mounting tabs (7)
by using, for example, a small blade screwdriver.
b) Move the bus lever (2) of the module to be removed to the unlocked (fully right)
position. If the module to be removed is inserted between two other modules,
the right-hand-module bus lever also must be in the unlocked position.
c) If the module to be removed is the last module in the system, it has an end cap
terminator (4) attached. Remove the end cap terminator (4) by unlocking (fully
right) the end cap terminator lever (3), and slide it along the upper tongue-and-
groove slot (5) and the lower tongue-and-groove slot (6).
d) Remove the module by sliding it along the upper tongue-and-groove slot (5) and
the lower tongue-and-groove slot (6).

1 2

7 6 5 3
4

1 Upper mounting tab 4 End cap terminator 6 Lower tongue-and-

2 Bus lever 5 Upper tongue-and- groove slot
3 End cap terminator groove slot 7 Lower mounting tab
lever
.

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1.1.1-10 PLC Power Supply - Change Fuse

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
Consumables Fine-Wire fuse 3.15A
SPC Reference 3241500-0200

a) Disconnect Compact Logix system power, and correct the conditions causing
the short circuit.
b) Remove the fuse housing cover (1) by placing a slotted screwdriver under the
tab (2).
c) Remove the front access fuse using a fuse puller or similar device. Be careful
not to damage the printed circuit board and surrounding electronics.
d) Replace the front access fuse. Center the replacement fuse over the fuse clip,
and press down. If you use a tool, apply pressure to the metal end caps only,
not the center of the fuse.
e) Assemble the fuse housing cover.
f) Reconnect Compact Logix system power.

1 Fuse housing cover

2 Tab
.

Note! Dispose of the electrical components and batteries in special waste

management systems. Follow local regulations.
.

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1.1.1-11 PLC Power Supply - Change Module

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 3241500-0200

a) Open the door (2), and disconnect the power cables (4).
b) Disconnect the ground cable (3).
c) Change the power supply modules. See Procedure 1.1.1-9 PLC - Remove
Module and Procedure 1.1.1-8 PLC - Install Module.
d) Connect the ground cable (3).
e) Connect the power cables (4) to the power supply terminals (1) according to the
Electrical Manual.

4 3
1 Power supply terminal
2 Door
3 Ground cable
4 Power cable
.

Note! Dispose of the electrical components and batteries in special waste

management systems. Follow local regulations.
.

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1.1.1-12 PLC - Attach Module

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 3241500-0200

When attaching I/O modules or other modules, it is important that the bus
connectors are securely locked together to ensure proper electrical connection.

a) Disconnect the power.

b) Check that the bus lever (4) of the module to be installed is in the unlocked
(fully right) position.
c) Use the upper tongue-and-groove slot (1) and the lower tongue-and-groove
slot (2) to secure the modules together (or to a controller).
d) Move the module back along the tongue-and-groove slots until the bus
connectors (3) line up with each other.

4
4
3

2
1 Upper tongue-and- 2 Lower tongue-and- 3 Bus connector
groove slot groove slot 4 Bus lever
.

(Cont’d)

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(Cont’d)

e) Use your fingers or a small screwdriver to push the bus lever back slightly to
clear the positioning tab (5).
f) To allow communication between the controller and module, move the bus lever
fully to the left until it clicks. Ensure it is locked firmly in place.
g) Attach an end cap terminator (6) to the last module in the system by using the
tongue-and groove slots. See Item d).
h) Lock the end cap bus terminator (7) by pushing it into place.
i) Detach the module in the reverse order.

6
5 Positioning tab
6 End cap terminator
7 End cap bus
terminator
.

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1.1.1-13 PLC Input/Output Module - Disconnect/Connect

Terminal Block
Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 3241500-0200

a) Remove the upper retaining screw (1) and the lower retaining screw (2).
b) Pull the terminal block to disconnect.
c) Assemble the terminal block, and tighten the retaining screws finger tight
(0.46 Nm (4.1 in-lbs)).

2
1 Upper retaining screw
2 Lower retaining screw
.

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1.1.1.1 PLC and Ethernet Modules

.

1.1.1.1-1 PLC and Ethernet Modules - Set IP Address

Machine Status Electrical supply disconnecting device in position I (ON)
Special Equipment PC
Ethernet cable

Connection with Ethernet Cable

Connect the Ethernet cable between a vacant connection port on the Ethernet
switch (1) and the PC (2).

2 1

1 Ethernet switch
2 PC
.

(Cont’d)

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(Cont’d)

Change IP Address for Ethernet/IP Modules with MAC Address

If the processor (3) is replaced, you need to set the IP address.

a) Connect the Ethernet cable from the PC to the PLC processor (3), and disable
any PC firewall.
b) Start the program BootP/DHCP server. If it is the first time the program is run,
the NETWORK SETTING window (4) opens automatically; otherwise, you must
open it from Tools→Network Settings.
c) Enter 255.255.255.0 in the Subnet Mask field (5).
d) Enter 192.168.1.1 in the Gateway field (6).
e) Press OK (7).

4
5
6

3 7
3 Processor 5 Subnet Mask field
4 NETWORK SETTING 6 Gateway field
window 7 OK
.

(Cont’d)

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(Cont’d)

f) Check the label of the component, and mark the corresponding MAC address
on the BootP list. There might be several MAC addresses in the list.
g) Mark one of the entries of the type BootP (8), and click the Add to Relation
List (9).
h) Enter the PLC IP address (10); 192.168.1.8 and press OK (11). The entry is
copied to the Relation List (12).

12

10

11

8 BootP
9 Add to Relation
List button
10 IP address
11 OK
12 Relation List
.

(Cont’d)

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(Cont’d)

i) If you can see the message SENT 192.168.1.8 TO ETHERNET

ADDRESS..... in the Status bar (13), and the IP address (14) in the
REQUEST HISTORY window (15), the IP address is set. If not, repeat the
procedure from item b).
j) Select the MAC address in the relation list. Click the DISABLE
BOOTP/DHCP (16). The Status bar (13) should say "COMMAND
SUCCESSFUL". If not, repeat the procedure.
k) Click DISABLE BOOTP/DHCP (16).
l) Close the BOOTP/DHCP window, and choose save changes No.

14

15

16

13

13 Status bar
14 IP address
15 REQUEST HISTORY
window
16 Disable
BOOTP/DHCP
.

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1.1.2 Frequency Converter

See Section 11.14 Frequency Converter.

1.1.3 Servo Drive

See Section 11.13 Servo Drive.

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1.1.4 NAT Router

1.1.4-1 NAT Router - Set
Machine Status Electrical supply disconnecting device in position I
(ON)

a) Connect a cable from your laptop to the LAN Input on the router.
b) Open a web browser.
c) Make sure that no proxy settings are active. In Microsoft Internet Explorer,
select Tools→Internet Options.
d) Select the Connections tab (1), and click LAN settings (2). Cancel the
selection in the Use automatic configuration script checkbox (3).

1 2 3

1 Connections tab 3 Use automatic

2 LAN settings configuration
script checkbox
.

e) Type address https://192.168.1.1.

f) Login using the following user name and password.
• User Name = admin
• Password = mGuard

(Cont’d)

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(Cont’d)

g) Go to Management→Configuration Profiles.
h) Browse the software package, and extract the compressed configuration file
onto the laptop.
i) Select the Browse button (4), then select the configuration file.
j) Select the Upload button (5).

5 4
4 Browse button
5 Upload button
.

k) Click Restore (6) on the same line as the configuration profile uploaded.
Note! An Active symbol (green) precedes the entry for the configuration profile
in use.

6
6 Restore
.

(Cont’d)

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(Cont’d)

l) NAT routing is set up.

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1.1.4-2 NAT Router Several Machines - Set

Machine Status Electrical supply disconnecting device in position I (ON)
SPC Reference 3423205-0200
3245318-0200

If there is more than one Straw Applicator 30 installed in the same line (or on the
same network), proceed as described below.
a) Go to Network→Interfaces, and select the General tab (1).
b) Enter a unique IP address from the range 10.0.6x.1 (where x = 1 to 9) in the
External IP address field (2).
c) Click the Apply button (3). A new window displays confirming the change.
Press Continue.

1 2

3
1 General tab
2 External IP
address field
3 Apply button
.

(Cont’d)

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(Cont’d)

d) Go to Network→NAT, and select the Masquerading tab (4).

e) Enter a unique IP address from the range 10.0.1.170 to 10.0.1.220 in the
External network field (5) on the first line under 1:1 NAT.
f) Enter the IP address 10.0.6x.0 (where x is same as in item b)) in the External
network field (7) on the second line under 1:1 NAT
g) Click the Apply button (6).

4 5

6 7
4 Masquerading tab
5 External network
field
6 Apply button
7 External network
field
.

(Cont’d)

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(Cont’d)

h) On the TPOP press IP-address PLC (8) .

i) Press the IP-address set buttons (9) in sequential order and enter the same
unique IP-address as in step e).
j) Press the confirm button (10) .

9
10
8 IP-address PLC
9 IP-address set buttons
10 Confirm button
.

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1.1.4-3 NAT Router - Troubleshoot

Machine Status Electrical supply disconnecting device in position I
(ON)

There are seven status indicators on the NAT router and one RESET button.

2 3 4

5 6 7 8

1 RESET button 5 P2 LED

2 P1 LED 6 ERR LED
3 STAT LED 7 FAULT LED
4 MOD LED 8 INFO LED

LED Colour State Meaning

P1 LED (2) Green On Power supply 1 is active.
P2 LED (5) Green Off Redundant supply not provided.
STAT LED (3) Green Flashing Heartbeat. The device is correctly connected
and operating.
ERR LED (6) Red Flashing System error. Restart the device:
• Press the RESET button (1), and keep it
pressed for for 1.5 seconds.
• Alternatively, briefly disconnect the device
power supply, and then connect it again.
Begin the recovery procedure if the error
continues to occur. See Recovery Procedure
on page 123.
STAT LED (3) + Green and red Flashing Boot process. When the device has been
ERR LED (6) connected to the power supply, the LED
changes to the heartbeat state after a few
seconds.
FAULT LED (7) Red On The alarm output is open due to an error at
“low” signal. (The alarm output is interrupted
during a restart.)
MOD LED (4) Green Off Connection with modem not provided.

(Cont’d)

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(Cont’d)

LED Colour State Meaning

INFO LED (8) Green Off VPN connection not provided.
LAN and WAN LEDs Green On The LAN/WAN LEDs are located in the
LAN/WAN sockets (10/100 and duplex LED).
Ethernet status: Shows the status of the
LAN/WAN ports. When the device is
connected to the relevant network, the LEDs
light continuously to indicate the presence of a
network connection over LAN or WAN. The
LEDs go out briefly when data packets are
being transferred.

Recovery Procedure
a) Press the RESET button (1) slowly six times.
b) After about two seconds, the STAT LED (3) lights green.
c) Press the RESET button (1) again slowly six times.
d) If successful, the STAT LED (3) lights green. The device restarts after two
seconds and switches to Stealth mode.

It can then be accessed again at the following address: https://192.168.1.1/

Note! If unsuccessful, the ERR LED (6) lights red.
e) Set the NAT router according to Procedure 1.1.4-1 NAT Router - Set on page
116.

1 RESET button
3 STAT LED
6 ERR LED
.

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1.1.5 Safety System

1.1.5-1 Safety System - Change Modules
Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)

See Procedure 11.9-1 Safety PLC - Change and Procedure 11.11-2 Safety Relay
Expansion Module - Change.

1.1.5.1 Pluto Manager

See Section 11.10 Pluto Manager.

1.1.5.2 Safeguard
See Section 11.8 Safeguard.

1.1.5.3 Emergency Stop

See Section 11.7 Emergency Stop.

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1.1.6 Safety Devices

1.1.6-1 Overvoltage Protector - Change Fuse
Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 3241501-0200

When one or more of the phases are subject to an overvoltage, the overvoltage
protector (1) breaks the power supply. The OVERVOLTAGE TRIPPED alarm on the
HMI indicates this event.
a) When a fuse has tripped, the colour in the indication window (2) changes from
green to red.
b) Change all tripped fuses.

2
1

2
1

1 Overvoltage protector
2 Indication window
.

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1.1.6-2 Miniature Circuit Breaker - Reset Fuse

The fuse is tripped when the switch is in OFF position (1).

To reset the switch, turn it to the ON position (2).

1 2
1 Switch OFF
2 Switch ON
.

1.1.6.1 Residual Current Device (All Countries except USA and

Canada)
.

1.1.6.1-1 Residual Current Device - Check Function

Machine Status Electrical supply disconnecting device in position I
(ON)

Pass criteria
The residual current device must trip immediately when the TEST button (6) is
pressed.

(Cont’d)

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(Cont’d)

DANGERI
DANGER

Hazardous voltage.
Electrical shock causes death or serious injury. Change the residual current
device (4) if it does not trip immediately.
Note! Test the function of the residual current device monthly. Always test the
residual current device (4) before using the wall socket (3).
a) Make sure that the switch (5) is in position ON (1).
b) Press the TEST button (6).
c) The residual current device must trip immediately; the switch goes to position
OFF (2).
d) Turn the switch to position ON (1).

1 2

4 3
1 Switch in position ON 4 Residual current
2 Switch in position OFF device
3 Wall socket 5 Switch
6 TEST button
.

1.1.6.2 Residual Current Device (USA and Canada)

.

1.1.6.2-1 Residual Current Device - Check Function

Machine Status Electrical supply disconnecting device in position I (ON)

Pass criteria
• The LED indicator (4) goes off when the TEST button (2) is
pressed.
• The LED indicator (4) is lit when the RESET button (3) is
pressed.

(Cont’d)

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(Cont’d)

The wall socket (1) has a built-in residual current device.

DANGERI
DANGER

Hazardous voltage.
Electrical shock causes death or serious injury. Change the wall socket (1) if the
residual current device does not trip immediately.
Note! Test the function of the residual current device monthly. Always test the
residual current device before using the wall socket (1).
a) Press the TEST button (2). The LED indicator (4) must go off.
b) Press the RESET button (3). The LED indicator (4) must be lit.

4
1 Wall socket
2 TEST button
3 RESET button
4 LED indicator
.

1.1.6.3 Multi Circuit Protector (All Countries except USA and

Canada)
.

1.1.6.3-1 Multi Circuit Protectors - Change

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)

DANGERI
DANGER
Hazardous voltage.
Shocks, burns, or causes death.
Follow lockout procedure before maintenance. See Chapter Safety Precautions.
(Cont’d)

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(Cont’d)

Note! To ensure adequate heat dissipation, install the device vertically with the input
terminals (5) and the input terminals (7) at the bottom, and the output terminals (1)
and the output terminals (2) at the top. Leave a clearance of at least 50 mm above
and below the device.
a) Record the positions and the colours of the wires.

1 2

8 4
7 5

6
1 Output terminal 5 Input terminal
2 Output terminal 6 Plastic cover
3 Label 7 Input terminal
4 DIP switch 8 Potentiometer
.

(Cont’d)

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(Cont’d)

b) Record the settings of the DIP switches (4) and the potentiometers (8).
c) Loosen the screws of the output terminals (1), the output terminals (2), the input
terminals (5), and the input terminals (7). Remove the wires.
d) Replace the unit.
e) Assemble in the reverse order.
f) Remove the plastic cover (6).
g) Set the correct values of the potentiometers (8) and DIP switches (4).
h) Install the plastic cover (6).
i) Move the label (3) of the replaced unit (if applicable).
j) Set according to Procedure 1.1.6.3-2 Multi Circuit Protectors - Set.

1 2

8 4
7 5

6
1 Output terminal 5 Input terminal
2 Output terminal 6 Plastic cover
3 Label 7 Input terminal
4 DIP switch 8 Potentiometer
.

Note! Dispose of the electrical components and batteries in special waste

management systems. Follow local regulations.
.

1.1.6.3-2 Multi Circuit Protectors - Set

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)

DANGERI
DANGER
Hazardous voltage.
Shocks, burns, or causes death.
Follow lockout procedure before maintenance. See Chapter Safety Precautions.
Note! An orange LED (3) indicates that the alarm for this parameter is bypassed.
Make sure that all the LEDs are green.
(Cont’d)

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a) Make sure the two DIP switches (2) are set to the ON (down) position.
b) Set the potentiometers (1) according to the fuse panel label by turning the
potentiometers (1).
c) Set the electrical supply disconnecting device in position I (ON), and make sure
that all LEDs are lit green. If not, press the ON/OFF/RST button (4) below the
corresponding LED, and keep it pressed until it lights green.

3 3 3 3

4 4

2
4
4

1 1 1 1
1 Potentiometer
2 DIP switch
3 LED
4 ON/OFF/RST button
.

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1.1.6.4 Digital Multi Circuit Protector (USA and Canada)

4 5 6 7

14
8
9
13 10
12 11
3

1 Power Input Terminals 6 Over-temperature 10 Mode Key

2 Branch Output Output 11 Up Key
3 Status Indicators 7 External Tripping 12 Down Key
4 Tripping Alarm Output Output 13 Reset Key
5 Alarm Output 8 Seven-segment 14 Communications
Display Terminals
9 Unit Indicators

Name Function
Power Input Terminals (1) (+V), (-V) Connect to the input line.
Branch Output (2) (+V), (-V) Connect to the load lines.
Up to four branch outputs can be connected.
Status Indicators (3) Indicate the connection and cutoff status for each branch output.
Cut off: Red.
Connected: Green.
Lit green Normal connection status.
Flashing Connection standby status during the startup sequence.
green
Lit red Cutoff status for an abnormality.
Flashing red Cutoff status for a redundant protection circuit with Class 2
specifications.

(Cont’d)

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(Cont’d)

Name Function
Not lit Forced cutoff or operation stopped.
Tripping Alarm Output (4) (+, -) Output (transistor: OFF) when the error tripping operation
functions.
Alarm Output (5) (+, -) Output (transistor: OFF) when a set value for alarm detection is
exceeded.
Over-temperature Output (6) (+, -) Output (transistor: OFF) when a set value for over-temperature
detection is exceeded.
External Tripping Output (7) (+, -) The tripping operation can be executed with an external input
signal.
Seven-segment Display (8) Displays measured values and set values.
(Red)
Unit Indicators (9) V
(Orange) A Lit when the output current is being displayed.
Flashes when the peak output current is being displayed.
kh Lit when the run time is being displayed.
°C Lit when the temperature is being displayed.
s Lit when setting the sequence time.
1 to 4 Lit or flashes when displaying branch output information.
Mode Key (10) Used to change the parameter being displayed or to reset the
peak hold current value.
Up Key (11) Used to move to different setting modes or to increase a set value.
Down Key (12) Used to move to different setting modes or to decrease a set
value.
Reset Key (13) (RST) Used when connecting branch outputs for tripping operation.
Communications (RD, SD, SG) Connect to the communications lines
Terminals (14) (RS-232C).
.

1.1.6.4-1 Digital Multi Circuit Protector - Configure

Machine Status Electrical supply disconnecting device in position I (ON)

Configuration
To configure a digital multi circuit protector (S8M):
Note! The digital multi circuit protector automatically enters Setting mode when
turned ON for the first time.
a) Go to the Mode Selector menu.
b) Enter setting mode and adjust all relevant parameters.
c) Return to Mode Selector menu.
d) Enter the Test Mode.
e) Activate all used branch outputs.
f) Return to Mode Selector menu.
g)
.
Select Run mode.

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(Cont’d)

Mode Selector Menu

Mode Selection menu How to navigate

Select Run Mode

Run Mode
(RUN) +

Press and keep it pressed for three seconds.

Select Setting Mode

Setting Mode
(SET) +

Press and keep it pressed for three seconds.

Select Test Mode

Test
(TST) +

Press and keep it pressed for three seconds.

Select Protection Level

(PRT)

Initialise Parameters

(INI)

(Cont’d)

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Setting Mode
a) Navigate the different parameters by using the UP key (4) and the DOWN
key (5).
Note! Several parameters belong to different branch outputs (2).
b) Select the correct parameters by pressing the MODE key (3).
c) Adjust the parameter value by using the UP key (4) and the DOWN key (5).
d) To confirm the setting, press the MODE key (3). The seven-segment display (1)
flashes with the new setting and then returns to the parameter list.
e) Press both the UP key (4) and the DOWN key (5) and keep them pressed for
three seconds to return to the Mode Selector menu.

1
2

5 4 3

1 Seven-segment
display
2 Branch output
3 MODE key
4 UP key
5 DOWN key
.

(Cont’d)

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Test Mode
The different branch outputs are activated from the Test Mode menu. Enter the
Test Mode menu from the Mode Selector menu.

a) The flashing ON display (3) indicates that the digital multi-circuit protector (1) is
ready to connect branch output 1 (2).
b) To connect branch output 1 (2), press the MODE key (4).
Note! The status indicator 1 (7) lights when connected.
c) The display changes to OFF (8) to indicate that the digital multi-circuit
protector (1) is ready to disconnect the branch output.
Note! If the MODE key (4) is pressed again, branch output 1 (2) is
disconnected.
d) Use the UP key (5) and the DOWN key (6) to cycle between the different
branch outputs.
e) Press both the UP key (5) and the DOWN key (6), and keep them pressed for
three seconds to return to the Mode Selector menu.

1 2 3

6 5 4
7 8

1 Digital multi-circuit 3 ON display 6 DOWN key

protector 4 MODE key 7 Status indicator 1
2 Branch output 1 5 UP key 8 OFF display
.

(Cont’d)

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(Cont’d)

Parameters to Change

LED Indicators
Seven-segment Branch output Unit
Parameter display indicator indicator Setting
Current tripping value Seven-segment display A Current value, see fuse
(C-V) Only relevant circuits lit. panel label.

Parameter Default Values

LED Indicators
Seven-segment Branch output Unit
Parameter display indicator indicator Setting range Default value
Abnormal current Only relevant A 0.5 to 3.8 A 3.8 A
tripping value (C-V) circuits lit
Abnormal current Standard or Standard
tripping type (C-T) instantaneous
Overcurrent alarm 0.5 to 3.8 A 3.8 A
value (A-V)
Overcurrent alarm Standard or Standard
type (A-T) instantaneous
Undervoltage Not lit V 18.0 V to 26.4 V 20 V
alarm value (V-U)
Overvoltage alarm 20.0 to 28.8 28.8 V
value (V-O)
Runtime alarm kh 1 to 99.9 kh 0.0 kh*
value (TIM)
Over-temperature °C 25 °C to 80 °C (77 80 °C* (176 °F)
output (TMP) °F to 176 °F)
Startup sequence Only relevant s 0 s to 99.9 s 0s
(UPS) circuits lit
Shutdown 0 s to 99.9 s 0s
sequence (DWS)
External Tripping Only relevant None Valid/Invalid Valid (Enabled)
Input (TRG) circuits lit
Unit number Not lit None 0 to 314.8 kbps or 09.6 kbps
(UNO) 9.6 kbps
Baud rate
(BPS)
Bit length 7 or 8 bits 7 bits
(LEN)
Stop bits 1 or 2 bits 2 bits
(BIT)
Parity None, Even or Even
(PTY) Odd

(Cont’d)

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(Cont’d)

LED Indicators
Seven-segment Branch output Unit
Parameter display indicator indicator Setting range Default value
Send wait time — 00 ms to 999 ms 0 ms
(SWT)
Clear the run time None — —
(CLR)

* If the run-time value is set to 0.0 kh, the runtime alarm function is disabled.

1.1.6.4-2 Digital Multi Circuit Protector - Reset Alarms

Machine Status Electrical supply disconnecting device in position I
(ON)

When an alarm goes off, eliminate the cause of the alarm. Press the RESET key (1)
and keep it pressed for at least three seconds. The display shows RESET (2), and
the alarm is reset.

Note! The over-temperature output is automatically reset when the temperature

drops below the set value. All other alarms must be reset manually.

1
1 RESET key
2 RESET

(Cont’d)

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(Cont’d)

Example
The following example shows the display when branch output 1 was cut off because
an abnormal current was detected (short circuit). If an error occurs, first determine
the cause of the error, and then eliminate the cause.

The seven-segment display (2) alternately shows error code A11 and the measure
current.
The branch output 1 indicator (1) and the unit indicator A (3) flash along with the
measured current.

Status indicator 1 (4) is lit red.

1 2 3

4
1 Branch output 1
indicator
2 Seven-segment
display
3 Unit indicator A
4 Status indicator 1
.

(Cont’d)

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(Cont’d)

Alarm List
Note! If more than one alarm occurs at the same time, the alarms are displayed in
order of priority.
Note! Order of priority: A10, A11, A20, A21, A22, A23, A30.

1 2
1 RESET key
2 MODE key

Error Code Meaning Probable cause Remedy

A10 Abnormal voltage tripping The power supply voltage Check the power supply
exceeded 28.8 V. voltage.
A11 Abnormal current tripping The branch output's current Check whether the connected
exceeded the current tripping device is correct, and check
value. whether the set value is
appropriate.
A20 Overvoltage alarm The input voltage exceeded Check the power supply
the overvoltage alarm value. voltage, and the set value.
A21 Undervoltage alarm The input voltage dropped
below the undervoltage alarm
value.
A22 Overcurrent alarm The branch output's current Check whether an excessive
exceeded the overcurrent load is connected and, check
alarm value. whether the set value is
appropriate.
A23 Run time alarm The run time exceeded the Reset the run time. If the run
run time value. time alarm is not needed, set
the alarm value to 0.0.
A30 Over-temperature output The internal temperature of Check for a high ambient
the S8M exceeded the over- temperature and check the
temperature output value. setting of the over-
temperature output value.
Take steps to reduce the
temperature in the control
panel.

(Cont’d)

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(Cont’d)

Error Display List

Error Code Meaning Probable cause and remedy

E98 RAM Error System errors.
E97 EEPROM read error When one of these error codes is
E96 displayed, contact an OMRON
EEPROM write error
representative regarding the error.
E94 A/D conversion error

1.1.6.4-3 Digital Multi Circuit Protector - Troubleshoot

Machine Status Electrical supply disconnecting device in position I (ON)

Before requesting repair for the Multi Circuit Protector, go through these
troubleshooting steps.

Stage Observed problem Possible cause Remedy

Installation The Multi Circuit Protector The bottom latch of the Make sure that the Multi
was installed on a DIN Multi Circuit Protector is Circuit Protector has been
Rail, not mounted correctly. pressed until the bottom
but the bottom of the Unit is latch clicks.
not attached.
Parameter setting The desired alarm value is The setting is not allowed Change the protection
not being displayed. in the present protection level setting.
level.
The set value was The new setting was not After pressing the UP and
changed, but the change saved. DOWN keys to change the
was not accepted. set value, press the MODE
key, and verify that the
setting flashes and is
saved.
When the Multi Circuit The undervoltage and Switch to Setting Mode
Protector was switched to overvoltage settings have and, check the settings.
Run Mode after setting the probably been reversed.
overvoltage and
undervoltage alarm, the
alarm output is turned ON
and cannot be cleared.
Equipment setup The display is flashing ON A flashing ON display If the MODE key is
in Test Mode, but power is indicates that the Multi pressed, the output is
not being supplied by the Circuit Protector is waiting connected, and power is
outputs. to turn ON the outputs. supplied. When power is
being supplied, OFF
flashes on the display.
The Multi Circuit Protector If the power is turned OFF Either connect all branch
was turned OFF in Test in Test Mode, all the outputs in Test Mode or
Mode, and there was no branch outputs are cut off connect each branch
power from the outputs for safety reasons. output individually.
when the Multi Circuit
Protector was turned ON
again.

(Cont’d)

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(Cont’d)

Stage Observed problem Possible cause Remedy

When the output is Check whether the Check for problems such
connected in Test Mode, it STATUS INDICATOR is lit as output wiring problems.
is cut off immediately and red. The current can be If no problems are found,
cannot be connected higher than the tripping press the RESET key and
again. current. keep it pressed for at least
three seconds.
Operation The displayed temperature The Multi Circuit Protector
is clearly different from the detects the internal
ambient temperature. temperature of the Unit,
which can be 5 °C to 10 °C
(41 °F to 50 °F) higher than
the ambient temperature.
An alarm was output. The The Multi Circuit Protector The alarm can be cleared
cause of the alarm was does not disregard by pressing the RESET
eliminated, but the alarm temporary errors, so the key for at least three
display cannot be cleared. alarm display is retained seconds.
even after the cause of the
alarm is cleared.
The peak output current The current has probably Clear the peak output
value is not displayed and exceeded the measurable current value in Run Mode.
the display shows “- - -”. range.
The circuit was not The abnormal current Either change the
designed for a current that tripping type (detection abnormal current tripping
high, but the circuit is cut method) is probably set to type from instantaneous to
off when power is supplied. “instantaneous.” With standard, or raise the
instantaneous detection, current tripping value.
an abnormal current is
detected quickly, and the
circuit can be cut off due to
excessive current during
equipment operation.
There are probably To spread out the
multiple devices connected connections to the devices
to the output. The more (delay the connection of
devices that are some devices), use the
connected, the higher the startup sequence function
operating current. of the Multi Circuit
Protector.
Branch output cut off The connection cannot be To protect the internal If RST is displayed when
reset immediately after it is circuits of the Multi Circuit the RESET key is pressed
cut off. Protector, at least 15 for at least three seconds,
seconds must pass before the cutoff output can be
a cut-off output can be reset when 15 seconds has
reset. passed since the output
was cut off.
The output was reset, but it The original cause of Eliminate the cause of the
was immediately cut off tripping can still exist. After cutoff, and press the
again. resetting the error, a large RESET key, and keep it
current can flow again. pressed for at least three
seconds.
Maintenance The run-time alarm went The Multi Circuit Protector Clear the run time.
off, so the equipment was continues adding to the run
checked, and other parts time. The run time must be
were replaced, but the reset to 0 to clear the
alarm could not be cleared. alarm.

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1.1.7 Control Devices and Sensors

1.1.7-1 Control Devices and Sensors - Set Proximity Sensor
Machine Status Electrical supply disconnecting device in position I (ON)

a) Move the cylinder to its end position.

b) Move the sensor in one direction until the LED indicator (2) goes off. Mark the
position (1).
c) Move the sensor in the opposite direction until the LED indicator (2) goes off.
Mark the position (3).
d) Centre (4) the sensor in-between the positions (1) and (3) and tighten the screw.

1 2 3

4
1 LED indicator goes off
2 LED indicator
3 LED indicator goes off
4 Centre
.

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1.1.8 PLMS SNP (Variant)

1.1.8-1 PLMS SNP - Select
Machine Status Electrical supply disconnecting device in position I
(ON)

a) On the TPOP, log on as “tptechnician” or “supervisor”, see Procedure 1.2.2.1-2

User Management - Log On as a User on page 174.
b) Press the Configuration button (4) to display the Configuration window.
c) Press the PLMS type button (1).
d) Select SNP from the list.
e) Confirm the setting with the Confirmation button (2) or press the Cancel
button (3) to abort.

2 3 4
1 PLMS type button
2 Confirmation
button
3 Cancel button
4 Configuration
button
.

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1.1.8-2 SNP Module - Change

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 3241507-0100
3245318-0100

1 SNP module
A01K2121

a) Disconnect the cables to the SNP module (1).

b) To release the module from the hanger (2), simultaneously push the SNP
module (1) down and pull the lower part outwards.

1 SNP module
A01K2121
2 Hanger
.

(Cont’d)

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(Cont’d)

c) Attach the new SNP module (1) to the hanger (2) and push the SNP module
towards the electrical cabinet (3).
d) Connect the cables to the SNP module.

1 SNP module
A01K2121
2 Hanger
3 Electrical cabinet
.

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1.1.8-3 SNP Module - Set

Machine Status Electrical supply disconnecting device in position I (ON)
Special Equipment Ethernet communication cable
Rockwell program BootP/DHCP
SPC Reference 3241507-0100
3245318-0100

a) Connect the cables to the RS485 connection (4) and the power connection (5)
on the SNP module, according to the Electrical Manual.
b) Set the 8-bit dip switch (1), according to the illustration.
c) Connect the Ethernet cable from the PC to the Ethernet connection (3), and, if
necessary, disable any PC firewall.

A0 1
A1
A2
A3
A4
A5 2
A6
6
A7 3 4 5
SNP module from below SNP module from above

1 Dip switch
2 Dip switch (not used)
3 Ethernet connection
4 RS485 connection
5 Power connection
6 RS485 connection (not
used)
.

(Cont’d)

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(Cont’d)

d) Start the program BootP/DHCP server. If it is the first time the program runs, the
NETWORK SETTINGS window (7) displays. If it is not the first time, go to the
Tools menu and select Network Settings.
e) Enter 255.255.255.0 in the SUBNET MASK field (8).
f) Enter 192.168.1.1 in the GATEWAY field (9).
g) Press the OK button (10).

7
8
9

10
7 NETWORK SETTINGS
window
8 SUBNET MASK field
9 GATEWAY field
10 OK button
.

(Cont’d)

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(Cont’d)

h) Mark one of the entries of the type BootP (12) and click the Add to relation
list button (13).
Note! It takes approximately 30 seconds for the SNP gateway to show up in the
list after it is turned on.
i) Enter the SNP gateway IP address (14); 192.168.1.191, and press the OK
button (10). The entry is copied to the relation list (11).

13

12

11 191

14
191

10

10 OK button
11 Relation list
12 BootP
13 Add to relation
list button
14 IP address
.

(Cont’d)

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(Cont’d)

j) If you can see the message “SENT 192.168.1.191 TO ETHERNET

ADDRESS.....” in the status bar (16), and the IP address (14) is visible in the
REQUEST HISTORY window (15), the IP address is set. If not, repeat the
procedure from item d).
k) Close the BootP/DHCP and choose save changes NO.

14 15

16
14 IP address
15 REQUEST HISTORY
window
16 Status bar
.

1.1.8-4 PLMS SNP Data Collection - Check

a) Unzip the compressed file in the PLMS - Software folder on the Software CD.
b) Inspect the document in the SNP5 folder to see which SA30 alarms are logged
for each SNP bit. Since there are more alarms in the SA30 than there are SNP
bits, the alarms are clustered according to the document.
Make sure the flexbox is updated with the latest available installation files for the
downstream equipment (DE).
.

1.1.9 Door
1.1.9.1 Filter Fan
.

1.1.9.1-1 Filter and Fan - Check

Machine Status Electrical supply disconnecting device in position I
(ON)
SPC Reference 2844519-0400
2844519-0400

Note! If the machine is equipped with a cooling unit, the door has no filter fan.
(Cont’d)

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(Cont’d)

Pass criteria
• The fan is running without noise from worn parts.
• The filter is clean.

a) Remove the cover (1) according to the illustration.

1 Cover
.

(Cont’d)

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(Cont’d)

b) Make sure that the fan runs without any noise from worn parts. Change the fan
if there is noise due to worn parts. See Section 1.1.9.1-3 Fan - Change on page
153.
c) Turn the electrical supply disconnecting device to position O (OFF).
d) Open the louvered grill (2).
e) Check the following on the filter (3):
• If the filter is clogged or dirty, clean the filter.
• If the filter is damaged, change the filter. See Section 1.1.9.1-2 Filter -
Change on page 152.

2 Louvered grill
3 Filter
.

1.1.9.1-2 Filter - Change

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2844518-0400
2844519-0400

Note! If the machine is equipped with a cooling unit, the door has no filter fan.
(Cont’d)

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(Cont’d)

a) Remove the cover (1). See Section 1.1.9.1-1 Filter and Fan - Check on page
150.
b) Open the louvered grill (2) as shown in the illustration.
c) Change the filter (3).

1 3

1 Cover
2 Louvered grill
3 Filter
.

1.1.9.1-3 Fan - Change

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2844518-0400

Note! If the machine is equipped with a cooling unit, the door has no filter fan.
(Cont’d)

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(Cont’d)

The fan is mounted with a simple snap-on into the mounting hole. No tools are
needed.
a) Disconnect all electrical cables from the fan.
b) Remove the cover (1). See Section 1.1.9.1-1 Filter and Fan - Check on page
150.
c) Change the fan device (2).
d) Assemble in the reverse order.

2
1

1 Cover
2 Fan device
.

1.1.10 Cooling Unit

1.1.10-1 Cooling Unit - Clean
Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 3424524-0100

Note! The Cooling Unit is a variant.

DANGERI
DANGER
Hazardous voltage.
Shocks, burns, or causes death.
Be careful when working inside the electrical cabinet. For personal protection, follow
the local regulations.

CAUTION
Risk of damage to the equipment.
While the doors of the electrical cabinet are open, the cooler does not work.
Make sure to close the doors of the electrical cabinet after finishing work inside.
(Cont’d)

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(Cont’d)

a) Remove the front cover (1) from the cooling unit (2).

1 2
1 Front cover
2 Cooling unit
.

b) Disconnect the cable (3) from the display (4).

4 3
3 Cable
4 Display
.

(Cont’d)

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(Cont’d)

c) Disconnect the earth cable (5).

5 Earth cable
.

d) Remove the four screws (6)

6
6 Screw
.

(Cont’d)

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(Cont’d)

e) Remove the cover (7).

7
7 Cover
.

f) Use an air jet gun (8) to clean the condenser (9), the fans (10), and the
compressor (11).
g) Assemble in the reverse order.

9
8

10

11
8 Air jet gun
9 Condenser
10 Fan
11 Compressor
.

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1.1.10-2 Cooling Unit - Check

Machine Status Electrical supply disconnecting device in position I
(ON)
SPC Reference 3424524-0100

Note! The Cooling Unit is a variant.

DANGERI
DANGER
Hazardous voltage.
Shocks, burns, or causes death.
Be careful when working inside the electrical cabinet. For personal protection, follow
local regulations.

CAUTION
Risk of damage to the equipment.
While the doors of the electrical cabinet are open, the cooler does not work.
Make sure to close the doors of the electrical cabinet after finishing work inside.
Note! Be careful when removing the front cover (1) to avoid damaging the cable
connected to the display.
a) Remove the front cover (1) from the cooling unit (2), and make sure that the
condenser (3) is clean. Clean the condenser (3) if necessary. See Procedure
1.1.10-1 Cooling Unit - Clean.
b) Put the front cover (1) back on the cooling unit (2).

1 2 3
1 Front cover
2 Cooling unit
3 Condenser
.

(Cont’d)

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(Cont’d)

c) Press button (4) and button (5) simultaneously, and keep them pressed for at
least five seconds. The cooling unit launches test mode and runs diagnostics for
about five minutes. After finishing, the cooling unit turns off and changes to
normal operation.
d) Check the cooling function of the cooling unit.
e) Check the compressor and the fans in the cooling unit for abnormal noise.

4 5

4 Button
5 Button
.

1.1.10-3 Cooling Unit - Change

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
Main air valve LOCKED in OFF position
SPC Reference 3424524-0100

Note! The Cooling Unit is a variant.

(Cont’d)

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(Cont’d)

CAUTION
Ergonomic hazard.
Risk of personal injury due to strain when lifting heavy objects. The cooling unit is
heavy.
Avoid twisting the body, especially when bending forward while lifting the cooling
unit. Two persons recommended while assembling the cooling unit.
Use a trolley when transporting the cooling unit.

CAUTION
Risk of damage to the equipment.
The cooling unit bracket can deform.
If resting the cooling unit on the floor, use two wooden planks that are higher than
the edge of the cooling unit bracket as support.
a) Disconnect the drainage connection (1).

1
1 Connection
.

(Cont’d)

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(Cont’d)

b) Remove the cooling unit (2) from the cabinet (3).

2 Cooling unit
3 Cabinet
.

(Cont’d)

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(Cont’d)

c) Lift the cooling unit a few inches.

d) Disconnect the cooling unit power supply (4).
e) Remove the two hoses (7) from the front cooling unit openings (5) by the two
hose clips (6).
f) Change the cooling unit, and assemble in the reverse order.
g) Change the cooling unit parameters. See Section 1.1.10-5 Cooling Unit - Set on
page 163.

5
6
4
7

4 Power supply
5 Opening
6 Hose clip
7 Hose
.

1.1.10-4 Cooling Unit - Set Temperature

Machine Status Electrical supply disconnecting device in position I
(ON)
SPC Reference 3424524-0100

Note! The Cooling Unit is a variant.

(Cont’d)

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(Cont’d)

a) Press the SET button (1), and keep it pressed for five seconds.
b) Press the PROGRAMMING button (2) or the PROGRAMMING button (3) until
the display (4) shows St.
c) Press the SET button (1).
d) Press the PROGRAMMING button (2) or the PROGRAMMING button (3) until
the display (4) shows Cod.
e) To change the value on the display (4), press the PROGRAMMING button (2).
Set the value to 22.
f) Press the SET button (1).
g) To change the temperature setting, press the PROGRAMMING button (2) or the
PROGRAMMING button (3). Set the temperature to 35 °C (95 °F).
h) Press the SET button (1), and keep it pressed for five seconds. When the
display (4) shows Acc, the changes are saved.
The cooling unit runs automatically when the electrical supply is on.

2 1

4 3
1 SET button
2 PROGRAMMING
button
3 PROGRAMMING
button
4 Display
.

1.1.10-5 Cooling Unit - Set

Machine Status Electrical supply disconnecting device in position I (ON)

Note! The Cooling Unit is a variant.

(Cont’d)

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(Cont’d)

WARNING
Refrigerant gas.
Cooling media R134A. See the Safety Precautions.
Note! The temperature is preset at the factory to 35 °C (95 °F) to save energy. Do
not set the temperature lower than necessary.
a) Press the SET button (3), and keep it pressed for five seconds.
Note! The controller is now in programming mode. If no buttons are pressed
within 30 seconds, the display (1) first flashes, then the controller switches back
to display mode. Esc in the display indicates that any changes made have not
been saved.
b) To step between the parameters according to the Parameter Table, press the
UP (°C) button (2) or the DOWN (°F) button (4).
c) To select the displayed parameter for editing, press the SET button (3). The
current value of the parameter is displayed.
d) Press the UP (°C) button (2) or the DOWN (°F) button (4). COD appears in the
display (1). To continue, enter the code
• Keep the UP (°C) button (2) pressed until authorisation code 22 displays.
• Press the SET button (3) to confirm.

1 2 3

4
1 Display
2 UP (°C) button
3 SET button
4 DOWN (°F) button
.

(Cont’d)

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(Cont’d)

e) Press the UP (°C) button (2) or the DOWN (°F) button (4), and keep them
pressed until the required value appears, according to the Parameter Table.
f) Press the SET button (3) to confirm.
g) Repeat items b) to f) to set more parameters.
Note! There is no need to reenter authorisation code 22.
h) Press the SET button (3), and keep it pressed for five seconds to exit the
programming mode. Acc appears in the display (1) to indicate that the changes
have been saved.

1 2 3

4
1 Display
2 UP (°C) button
3 SET button
4 DOWN (°F) button
.

Parameter Table
Operat-
ing
Display Parameter setting Description
St Internal enclosure 35* The internal enclosure temperature setting is
temperature set point Ti preset at the factory to 35 °C (95 °F) and can be
altered within a range of 20 °C to 55 °C (68 °F to
131 °F).
Fi Filter mat monitoring 99* To enable filter mat monitoring, set the display to
a minimum of 10 K above the temperature
difference that is shown in programming mode
FI. Filter mat monitoring is disabled at the
factory (99 = off).
Ad Master-slave identifier 0* Not applicable.
CF Switch between °C/°F 0* The temperature display can be switched
between °C (0) and °F (1). The LED displays the
current unit of temperature.
H1 Setting for switching 5* The cooling unit is preset in the factory to a
difference (hysteresis) switching hysteresis of 5 K. Only change this
parameter after consultation.

(Cont’d)

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(Cont’d)

Operat-
ing
Display Parameter setting Description
H2 Differential for error 5* If the internal enclosure temperature exceeds
message A2 the set value of more than 5 K, then error
message A2 (internal enclosure temperature too
high) appears on the display terminal. If
necessary, the differential can be altered here
within the range of 3 K to 15 K.
A1 1 Enclosure door open
A2 0* Internal temperature of enclosure too high
A3 0* Filter monitoring
A4 0* Ambient temperature too high/low
A5 0* Icing hazard
A6 0 PSAH pressure switch
A7 0 Evaporator coil
A8 0 Condensate warning
A9 0 Condenser fan blocked or defective
A10 Error messages 0 Evaporator fan blocked or defective
A11 0 Compressor
A12 0 Condenser
A13 0 Ambient temperature sensor
A14 0 Icing temperature sensor
A15 0 Condensate warning temperature sensor
A16 0 Internal temperature sensor
A17 0 Phase monitoring
A18 0* EPROM
A19 0* LAN/Master-Slave
ECO Eco-mode operation 1* Eco-mode OFF: 0 / Eco-mode ON: 1
PSO Changing the 0*
authorisation code

* Default setting

1.1.10-6 Cooling Unit - Error Handling

SPC Reference 3424524-0100

Note! The Cooling Unit is a variant.

(Cont’d)

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(Cont’d)

The basic controller (1) on the cooling unit supervises and regulates the cooling
system. The message on the display (2) shows the status of the cooling system.

1 2

1 Basic controller
2 Display

3 Door switch,
A01B0400

Electrical supply disconnecting device in position O (OFF) or I (ON) depending on

the Alarm.

Alarm Status Action

A01 Open door. The • Check the position of the door and the door
cooling system switch (3).
turns off after 15
• Close the door to the electrical cabinet.
seconds.
A02 Temperature too • Check the temperature setting.
high inside the • Check the condenser, and clean if
electrical cabinet.
necessary.
• Check the filter mat, and replace if
necessary.
• Check the heat loss to be dissipated. It must
not exceed the useful cooling output of the
cooling unit.

(Cont’d)

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(Cont’d)

Alarm Status Action

A03 Soiled filter mat. • Check the filter mat, and replace if
necessary.
• Reset the Basic controller manually after
correcting the error. See Section Basic
Controller - Reset.
A04 Ambient • Check the ambient temperature setting, and
temperature too rise/lower if necessary.
high/low.
A05 Icing hazard. • Check the evaporator fan, and replace if
necessary.
• Check the enclosure interior temperature,
and raise if necessary.
A06 High pressure in • Check the ambient temperature, and lower if
the cooling necessary.
circulation.
• Check the condenser, and clean if
necessary.
• Check the filter mat, and replace if
necessary.
• Check the condenser fan, and replace if
necessary.
• Check the E-valve, and repair if necessary.
• Check pressure-operated switch, and
replace if necessary.
• Reset the Basic controller manually after
correcting the error. See Section Basic
Controller - Reset.
A07 Lack of coolant in • Check the sensor in front of, or behind
evaporator coil. condenser, and repair if necessary.
• Reset the Basic controller manually after
correcting the error. See Section Basic
Controller - Reset.
A08 Condensate • Check condensate discharge, and repair if
warning. necessary.
• Check the evaporation unit, and replace if
necessary.
A09 Condenser fan • Check if the condenser fan is blocked, and
error. clear the blockage if necessary.
• Check condenser fan, and replace if
necessary.
A10 Evaporator fan • Check if the evaporator fan is blocked, and
error. clear the blockage if necessary.
• Check evaporator fan, and replace if
necessary.
A11 Compressor • Check the compressor, and replace if
error. necessary.
A12 Condenser • Replace the condenser temperature sensor.
temperature
sensor error.

(Cont’d)

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(Cont’d)

Alarm Status Action

A13 Ambient • Replace the ambient temperature sensor.
temperature
sensor error.
A14 Icing • Replace the icing temperature sensor.
temperature
sensor error.
A15 Condensate • Replace the icing temperature sensor.
warning
temperature
sensor error.
A16 Internal • Replace the icing temperature sensor.
temperature
sensor error.
A17 Phase • Replace two phases.
monitoring error.
A18 EPROM error. • Update software.
A19 LAN/master and • Check settings and cable.
slave not
connected.
A20 Error display not • To see the error that was not shown, check in
shown. the log file.
E0 Connection • Switch off power supply, switch on again
problem between after two seconds.
the display and
• Check the cable, and replace the boards if
the controller
necessary.
board.
OL Overload error. • Ambient parameters or heat loss outside the
applicable limits.
b07 Cooling circuit • Correct sensor position.
leak error.
rSt Manual device • Reset the Basic controller manually after
reset required. correcting the error. See Section Basic
Controller - Reset.

Basic Controller - Reset

a) Press the programming buttons (1) and (2) at the same time, and keep them
pressed for five seconds.

2
1 Programming button
2 Programming button
.

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1.2 TPOP HMI

1.2.1 Cooling Air Intake
1.2.1-1 Cooling Air Intake - Check Filter and Fan
Machine Status Electrical supply disconnecting device in position I
(ON)
SPC Reference 2582040-0100

a) To access the back of the HMI panel, open the door.

b) Make sure that the fan (1) runs without any noise from worn parts.
c) Check the function of the fan (1). Change if necessary. See Section 1.2.1-3
Cooling Air Intake - Change Fan on page 171.
d) Clean the filter (2) if clogged, or change if damaged. See Section 1.2.1-2
Cooling Air Intake - Change Filter on page 171.

1 Fan
2 Filter
.

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1.2.1-2 Cooling Air Intake - Change Filter

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2582040-0100

a) Open the door to access the back of the HMI panel.

b) Loosen the screws (1), and remove the cover (2).
c) Check while the is running, that is running without any noise from worn parts.
Check also the function of the . Change if necessary.
d) Check the condition of the filter (3). Clean it if clogged, or change it if it is
damaged.
e) Assemble in the reverse order.

1
1 Screw (4 pcs)
2 Cover
3 Filter
.

Note! Recycle or dispose of the filter according to local regulations.

.

1.2.1-3 Cooling Air Intake - Change Fan

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2582040-0100

DANGERI
DANGER
Hazardous voltage.
Risk of immediate danger to life through electrical shock.
Make sure that the electrical supply disconnecting device is switched off.
(Cont’d)

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1.2 TPOP HMI 1 Electric Equipment

(Cont’d)

a) Open the door to access the back of the HMI panel.

b) Turn the lock (1), and open the HMI panel cover (2).
c) Disconnect all electrical cables to the fan (4).
d) Loosen the four screws (3), and change the fan (4).
e) Assemble in the reverse order.

3 4

1 Lock
2 Cover
3 Screw
4 Fan
.

Note! Recycle or dispose of the fan according to local regulations.

.

1.2.2 TPOP Control Panel

1.2.2.1 User Management
.

1.2.2.1-1 User Management - Description

The TPOP includes certain sections which have restricted access and are password
protected. Access is permitted and defined by the user profile and the password
used to log on. See the table below for a description of each of the available user
profiles and the corresponding level of access.

Note! The default machine operator has no user log on profile or access to the
restricted areas of the TPOP.
(Cont’d)

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(Cont’d)

User Profile User Name Password Access Description

TP service tptechnician not Access to:
technician provided • production control settings and
functions
• maintenance control settings and
functions
• create and delete recipes
• software installation and
configuration
• shutdown
• diagnostic
• full access to the configuration
window
Supervisor supervisor shiftsup Access to:
• user administration
• production control settings and
functions
• maintenance control settings and
functions
• create and delete recipes
• software installation and
configuration
• shutdown
• diagnostic
• partial access to the configuration
window
Service technician custtech Access to:
technician • production control settings and
functions
• maintenance control settings and
functions
• create and delete recipes
• software installation and
configuration
• partial access to the configuration
window
Power pwroperator expertop Access to:
operator • production control settings and
functions
Operator - - -
(default user
with no log on)

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1.2 TPOP HMI 1 Electric Equipment

1.2.2.1-2 User Management - Log On as a User

Machine Status Electrical supply disconnecting device in position I
(ON)

This procedure describes how to log on to the TPOP and to access the restricted
password protected sections of the TPOP. The level of access permitted is defined
by the user profile. See Section 1.2.2.1-1 User Management - Description on page
172.
Note! After 15 minutes of TPOP inactivity, the user is automatically logged out.
a) On the TPOP, press the Setup button (1).
b) In the Setup window, press the User management button (2).
c) In the User management window, press the Log on button (3) to display the
Log in window (4).

1 2 3

1 Setup button
2 User management
button
3 Log on button
4 Log in window
.

(Cont’d)

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(Cont’d)

d) Press the User button (5) to display the keyboard (6).

e) Use the keyboard (6) to type your user name, and then press the Enter
button (7).

5 User button
6 Keyboard
7 Enter button
.

(Cont’d)

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(Cont’d)

f) Press the Password button (8) to display the keyboard (6).

g) Use the keyboard (6) to type your password, and then press the Enter
button (7).
h) Press the Enter button (9) to confirm the data entry.
The user is now logged on to the TPOP with the corresponding level of access.

9
8

6 Keyboard
7 Enter button
8 Password button
9 Enter button
.

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1.2.2.1-3 User Management - Change User Password

Machine Status Electrical supply disconnecting device in position I (ON)

CAUTION
Risk of unplanned machine stoppage.
If the default passwords are changed and subsequently forgotten, the TPOP
software must be reinstalled before access to the restricted sections of the TPOP is
restored.
The user with the profile “supervisor” has the authority to set and change the
passwords for the user profiles of “technician” and “pwroperator”. To change the
password of either the user profiles proceed as follows:

a) Log on to the TPOP as the user profile “supervisor”. See Procedure 1.2.2.1-2
User Management - Log On as a User on page 174.
b) In the User management window, press either of:
• Enable PWRoperator change password button (1) for the user profile
“pwroperator”.
• Enable technician change password button (2) for the user profile
“technician”.

1 2
1 Enable
PWRoperator
change password
button
2 Enable technician
change password
button
.

(Cont’d)

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1.2 TPOP HMI 1 Electric Equipment

(Cont’d)

c) Press the Log off button (3).

d) Log on to the TPOP using the user profile chosen in item b). See Procedure
1.2.2.1-2 User Management - Log On as a User on page 174.
e) The Change password button (4) is now enabled in the User Management
window, press the Change password button (4) to display the Change
password window (5).

3 4 5

3 Log off button

4 Change password
button
5 Change password
window
.

(Cont’d)

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(Cont’d)

f) Press the Old password button (6) to display the keyboard (8).
g) Use the keyboard (8) to type the current password, then press the Enter
button (9).
h) Press the New password button (7) to display the keyboard (8).
i) Use the keyboard (8) to type the new password, then press the Enter
button (9).

6 Old password button

7 New password button
8 Keyboard
9 Enter button
.

(Cont’d)

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1.2 TPOP HMI 1 Electric Equipment

(Cont’d)

j) Press the Confirm password button (10) to display the keyboard (8).
k) Use the keyboard (8) to type and repeat the new password, and then press the
Enter button (9).

10

8 Keyboard
9 Enter button
10 Confirm password
button
.

(Cont’d)

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(Cont’d)

l) Press the Enter button (11) to finalise the password change procedure.
If necessary, repeat the procedure to change the password for the other user profile.
The password for the user profile “supervisor” can be changed by logging on as the
“supervisor” and selecting the Change password button in the User management
window.

11

11 Enter button
.

1.2.2.1-4 User Management - Change User Settings

Machine Status Electrical supply disconnecting device in position I (ON)

a) On the TPOP, log on as “supervisor”. See Section 1.2.2.1-2 User Management -

Log On as a User on page 174.
b) In the button bar, press the Setup window (1) to display the Setup window.
c) Press the User management button (2).

1
1 Setup window
2 Usermanagementbut-
ton
.

(Cont’d)

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1.2 TPOP HMI 1 Electric Equipment

(Cont’d)

d) Press the Log out button (3) to log out, the Log in button (4) to log in, or the
Change password button (5) to change password (if available).
Note! After 15 minutes of inactivity on the TPOP, the user is automatically
logged out.

3 4 5
3 Log out button
4 Log in button
5 Change
password button
.

1.2.2.1-5 User Management - Add Language

Machine Status Electrical supply disconnecting device in position I
(ON)

a) On the TPOP, log on as “tptechnician” or “supervisor” or “technician”. See

Section 1.2.2.1-2 User Management - Log On as a User on page 174.
b) In the button bar, press the Setup button (2) to display the Setup window.
c) Press the Language button (1).

1 2
1 Language button
2 Setup button
.

(Cont’d)

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(Cont’d)

d) The selectable languages (3) are shown. Press the Language button (5) to add
a new language.
e) Press the Add language button (4) multiple times until the desired language is
shown. The selected language is now loaded and selectable.

3 4 5

3 Selectable languages
4 Add language button
5 Language button
.

1.2.2.2 Install
.

1.2.2.2-1 Install - Load Firmware

Machine Status Electrical supply disconnecting device in position I (ON)
Special Equipment PC and Secure Digital card reader
Secure Digital card
Software media delivered with the machine

Note! Use a formatted, empty Secure Digital card.

Ref. Name Firmware

A08A2010 Operator Panel 15", See Software Package
2711P-T15C4D8-TP

(Cont’d)

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1.2 TPOP HMI 1 Electric Equipment

(Cont’d)

a) Identify the correct firmware revision to be flashed and copy the “autorun.exe”
file and the “Upgrade” folder from the software media to the Secure Digital card.
b) Shut down the TPOP. See Procedure 1.2.2.3-1 Machine Setup - Shut Down
TPOP on page 192.
c) Insert the Secure Digital card at the back of the TPOP panel and wait for the
upgrade window to pop up.
d) Press the Upgrade button.
e) Press the Yes button.
f) The update will run for a few minutes and the TPOP panel will reboot. Wait for
the upgrade to complete.
g) Calibrate the touch sensor area of the TPOP. See Procedure 1.2.2.3-9 Machine
Setup - Calibrate Touch Screen on page 215.
h) Remove the Secure Digital card.
i) Set the IP address. See Procedure 1.2.2.3-3 Machine Setup - Set IP Address
and Subnet Mask Address on page 197.
j) Reset the TPOP. See Procedure 1.2.2.3-7 Machine Setup - Reset TPOP on
.
page 213.

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1.2.2.2-2 Install - Download Program Using a PC

Machine Status Electrical supply disconnecting device in position I (ON)
Special Equipment PC
Ethernet cable
Software media delivered with the machine
FT View ME 5.00 plus with ME Transfer Utility 6.10

Note! Use this alternative only if the memory media option is not present.
Note! After a program download, the default passwords are reset. See Procedure
1.2.2.1-1 User Management - Description on page 172.
Note! To connect the PLC using an Ethernet cable, the PC must first be configured
for this type of communication.
a) Connect the Ethernet cable between a vacant connection port on the Ethernet
switch (1) and the PC (2).
b) Insert the software media into the PC.
c) Browse to the software media and copy the program file included in the folder to
the PC desktop.

1 Ethernet switch,
A01X2110
2 PC
.

(Cont’d)

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1.2 TPOP HMI 1 Electric Equipment

(Cont’d)

d) Open the Start menu (3) on the PC. Select Programs (4), Rockwell
Software (5), Factory Talk View (6), Tools (7), and then Me Transfer
Utility (8).

3 4 5 6 7 8
3 Start menu
4 Programs
5 Rockwell Software
6 Factory Talk View
7 Tools
8 Me Transfer
Utility
.

(Cont’d)

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(Cont’d)

e) In the Transfer Utility window (9), select the Download tab (10).
f) Select the correct destination terminal (11).
g) Select the Browse button (12).

9 10 12

11
9 Transfer Utility
window
10 Download tab
11 Destination terminal
12 Browse button
.

(Cont’d)

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1.2 TPOP HMI 1 Electric Equipment

(Cont’d)

h) Browse and select the program file (13), and then select the Open button (14).

13

14
13 Program file
14 Open button
.

(Cont’d)

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(Cont’d)

i) In the Transfer Utility window (9), make sure that the check boxes (18),
(20), and (21) are selected.
Note! If the TPOP panel has been exchanged, also check Replace
communications check box (19).
j) Select the Download button (15).
k) Select the Yes button (16) if the dialogue box appears.
l) When the Downloading window (17) appears, wait until the downloading
process is completed.

9
15

21

20
19
18

17

9 Transfer Utility 17 Downloading 20 Run application at

window window start-up check box
15 Download button 18 Delete Log Files 21 Download as: check
16 Yes button (not in check box box
illustration) 19 Replace
communications
check box
.

(Cont’d)

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1.2 TPOP HMI 1 Electric Equipment

(Cont’d)

m) When the Transfer Utility window (22) appears, the download procedure
is completed. Select the OK button (23) to go back to the configuration window.
Note! If the buttons on the HMI should not work properly after the download,
reset the TPOP according to procedure 1.2.2.3-7 Machine Setup - Reset TPOP
on page 213.

22 23

22 Transfer Utility
window
23 OK button
.

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1.2.2.2-3 Install - Download Program Using a Secure Digital Card

Machine Status Electrical supply disconnecting device in position I (ON)
Special Equipment PC and Secure Digital card reader
Secure Digital card
Software media delivered with the machine
Tetra Pak PVP Installer

Note! Use a formatted, empty Secure Digital card.

a) Copy all files in the TPOP program folder from the software media to the root of
the Secure Digital card.
b) Delete all projects (*.mer-files) from the TPOP panel if not empty. See
Procedure 1.2.2.3-4 Machine Setup - Delete Application Program on page 203.
c) Insert the SD card into the TPOP panel. Wait for the update to continue. The
download of files will start automatically.
d) When the message "PRESS ANY KEY TO CONTINUE..." appears, the
download is finished. Removed the SD card from the TPOP panel.
e) Press File→Close on the TPOP, or press the "X" in the upper right corner to
continue. The panel reboots.
Note! If the buttons on the HMI should not work properly after the download,
reset the TPOP according to procedure 1.2.2.3-7 Machine Setup - Reset TPOP
on page 213.
f) Continue with 1.2.2.3-5 Machine Setup - Load Application Program on page
207.

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1.2.2.3 Machine Setup

.

1.2.2.3-1 Machine Setup - Shut Down TPOP

Machine Status Electrical supply disconnecting device in position I
(ON)

a) On the TPOP, log on as “tptechnician” or “supervisor”. See Section 1.2.2.1-2

User Management - Log On as a User on page 174.
b) In the button bar, press the Setup button (1) to display the Setup window.
c) Press the Shut down button (2) to shut down the control panel.

2 1
1 Setup button
2 Shut down button
.

d) Press the Confirmation button (3) to shut down, or the Cancel button (4) to
cancel.

3 4
3 Confirmation button
4 Cancel button
.

(Cont’d)

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(Cont’d)

e) The Configuration window appears.

1.2.2.3-2 Machine Setup - Disable Screen Saver

Machine Status Electrical supply disconnecting device in position I (ON)

a) On the TPOP, log on as “tptechnician” or “supervisor”. See Procedure 1.2.2.1-2

User Management - Log On as a User on page 174.
b) Shut down the TPOP. See Procedure 1.2.2.3-1 Machine Setup - Shut Down
TPOP on page 192.
c) In the Configuration window, press the Terminal Settings button (1) .

1 Terminal Settings
button
.

(Cont’d)

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(Cont’d)

d) Select Display (2) and press the Enter button (3).

2 Diagnostic Setup
Display
File Management
Font Linking
Input Devices
Networks and Communications
Print Setup
Startup Options
System Event Log
System Information
Time/Date/Regional Settings 3

Close
[F8]

2 Display
3 Enter
.

e) Select Screen Saver (4) and press the Enter button (3).

4 Display Intensity
Display Temoerature
Screen Saver
Cursor

Close
[F8]

3 Enter
4 Screen Saver
.

(Cont’d)

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(Cont’d)

f) Select Disabled (5) and press the OK button (6).

5
Intensity
Disabled

5 minutes

10 minutes

10% 15 minutes
Screen
Saver
[F2] 20 minutes

25 minutes

30 minutes

Advanced OK Cancel
Settings
[F7] [F8]
[F2]

6
5 Disabled
6 OK button
.

g) Press the Close button (7) twice to exit to the Configuration window.

Display Intensity Diagnostic Setup

Display Temoerature Display
Screen Saver File Management
Cursor Font Linking
Input Devices
Networks and Communications
Print Setup
Startup Options
System Event Log
System Information
Time/Date/Regional Settings

Close Close
[F8] [F8]

7 7
7 Close button
.

(Cont’d)

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(Cont’d)

h) Select Yes (8) on option Delete log files before running.

i) Press the Run Application button (9).

8 Yes
9 Run Application
button
.

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1.2.2.3-3 Machine Setup - Set IP Address and Subnet Mask

Address
Machine Status Electrical supply disconnecting device in position I (ON)

a) On the TPOP, log on as “tptechnician” or “supervisor”. See Procedure 1.2.2.1-2

User Management - Log On as a User on page 174.
b) Shut down the TPOP. See Procedure 1.2.2.3-1 Machine Setup - Shut Down
TPOP on page 192.
c) In the Configuration window, press the Terminal settings button (1).

1 Terminal settings
button
.

d) Select Networks and communications (2) and press the Enter button (3).

Alarms
Diagnostic Setup
Display
File Management
Font Linking
Input Devices
Networks and Communications
Print Setup
Startup Options
2 System Event Log
System Information
Time/Date/Regional Settings

Close
3
[F8]

2 Networks and
communications
3 Enter button
.

(Cont’d)

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(Cont’d)

e) Select Network connections (4) and press the Enter button (3) .

KEP Server Serial Port ID's

Network Connections
RSLinx Enterprise Communications

Close
[F8]
3

3 Enter button
4 Network
connections
.

f) Select Network Adapters (5) and press the Enter button (3).

Device Name
Network Adapters
Network Identification

Close
3
[F8]

3 Enter button
5 Network Adapters
.

(Cont’d)

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(Cont’d)

g) Select KS88411: Micrel KS8841 Ethernet Drive (6) and press the
IP address button (7).

KS88411: Micrel KS8841 Ethernet Drive

Name Servers IP Address Settings Close

[F1] [F2] [F3] [F8]

7
6 KS88411: Micrel
KS8841 Ethernet
Drive
7 IP address button
.

h) Select No underneath the Use DHCP button.

i) Press the IP address button (8).

IP Address Use DHCP

[F1] [F4]

8 Yes
Subnet Mask
[F2] No

Gateway
[F3]

Mac ID: OK Cancel

[F7] [F8]

8 IP address button
.

(Cont’d)

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(Cont’d)

j) Use the keyboard (9) and type the HMI IP address, 192.168.1.12, and then
press the Enter button (10).

10

9 Keyboard
10 Enter button
.

k) Press the Subnet mask button (11).

IP Address Use DHCP

[F1] [F4]

Yes
Subnet Mask
[F2] No

11 Gateway
[F3]

Mac ID:
OK Cancel
[F7] [F8]

11 Subnet mask button

.

(Cont’d)

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(Cont’d)

l) Use the keyboard (9) and type the subnet mask address, 255.255.255.0, and
then press the Enter button (10).

10

9 Keyboard
10 Enter button
.

m) Press the Gateway button (12).

IP Address Use DHCP

[F1] [F4]

Yes
Subnet Mask
[F2] No

Gateway
[F3]

12
Mac ID:
OK Cancel
[F7] [F8]

12 Gateway button
.

(Cont’d)

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(Cont’d)

n) Use the keyboard (9) and type the gateway address, 192.168.1.1, and then
press the Enter button (10).

10

9 Keyboard
10 Enter button
.

o) Press the OK button (13).

IP Address Use DHCP

[F1] 192.168.1.12 [F4]

Yes
Subnet Mask
255.255.255.0
[F2] No

Gateway 192.168.1.1
[F3]

Mac ID: OK Cancel

[F7] [F8]

13
13 OK button
.

(Cont’d)

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(Cont’d)

p) Press the OK button (14).

14
14 OK button
.

q) Repeatedly press the Close button (15) until the configuration window appears.
r) Reset the TPOP according to the instructions described in Procedure 1.2.2.3-7
Machine Setup - Reset TPOP on page 213.

Close
[F8]

15
15 Close button
.

1.2.2.3-4 Machine Setup - Delete Application Program

Machine Status Electrical supply disconnecting device in position I (ON)

Before a new application program can be installed, all files associated with the old
program must be deleted to make space in the memory for the new program.
Proceed as follows:
(Cont’d)

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(Cont’d)

a) Shut down the TPOP. See Procedure 1.2.2.3-1 Machine Setup - Shut Down
TPOP on page 192.
b) In the Configuration window, press the Terminal settings button (1).

1 Terminal settings
button
.

c) Select File management (2) and press the Enter button (3).

2 Diagnostic Setup
Display
File Management
Font Linking
Input Devices
Networks and Communications
Print Setup
Startup Options
System Event Log
System Information
Time/Date/Regional Settings
3

Close
[F8]

2 File management
3 Enter button
.

(Cont’d)

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(Cont’d)

d) Select Delete Files (4) and press the Enter button (3).

4
Copy files
Delete files

Close
[F8]

3 Enter button
4 Delete Files
.

e) Select Delete Applications (5) and press the Enter button (3).

5
Delete applications
Delete fonts
Delete log files

Close
[F8]

3 Enter button
5 Delete
Applications
.

(Cont’d)

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(Cont’d)

f) Select appropriate application program (6) to be deleted and press the Delete
button (7).

Internal Storage
7
Source Delete
[F1] External Storage 1 [F2]

6 External Storage 2

*_A.mer
*_B.mer
*_C.mer

Close
[F8]

6 Application program
7 Delete button
.

g) Confirm by pressing the Yes button (8).

8 Yes button
.

h) Delete any other application program, repeat items f) to g), and then press the
Close button.
i)
.
Repeatedly press the Close button until the configuration window appears.

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1.2.2.3-5 Machine Setup - Load Application Program

Machine Status Electrical supply disconnecting device in position I (ON)

a) Shut down the TPOP. See Procedure 1.2.2.3-1 Machine Setup - Shut Down
TPOP on page 192.
b) In the Configuration window, press the Load Application button (1).

1 Load application
button
.

(Cont’d)

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(Cont’d)

c) Use the arrow buttons (4) to select the application (2) to be loaded, see the
table below, and press the Load button (3).

*_A.mer = Group A *_B.mer = Group B *_C.mer = Group C

English 01 English 01 English 01
Swedish 02 Czech 17 Arabic 21
German 03 Serbian 19 Persian 22
French 04 Croatian 31 Malay 23
Spanish 05 Slovenian 32 Japanese 24
Italian 06 Slovak 33 Simplified Chinese 25
Portuguese 07 Romanian 35 Thai 28
Danish 08 Bulgarian 36 Korean 30
Greek 09 Bosnian 37 Traditional Chinese 53
Finnish 11 Hungarian 52 Vietnamese 54
Polish 18 Macedonian 38 - -
Dutch 26 Russian 12 - -
Norwegian 27 Latvian 13 - -
Icelandic 29 Estonian 14 - -
Turkish 20 Lithuanian 15 - -
Brazilian Portuguese 50 - - - -

3
Internal Storage
Source Load
[F1] External Storage 1 [F2]

2 External Storage 2

*_A.mer
*_B.mer
*_C.mer

Cancel
[F8]

2 Application
3 Load button
4 Arrow button
.

(Cont’d)

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(Cont’d)

d) When the message “DO YOU WANT TO REPLACE THE TERMINAL’S CURRENT
COMMUNICATION CONFIGURATION WITH THE APPLICATION’S
COMMUNICATION CONFIGURATION?” appears, press the Yes button (5) to
confirm.

Do you want to replace the terminal’s current communication

configuration with the application’s communication configuration?

5 Yes button
.

e) After loading, press the Terminal settings button (6).

6 Terminal
settings button
.

(Cont’d)

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(Cont’d)

f) Select the Startup Options (7) and press the Enter button (8).

Diagnostic Setup
Display
File Management
Font Linking
7 Input Devices
Networks and Communications
Print Setup
Startup Options
System Event Log
System Information
Time/Date/Regional Settings
8

Close
[F8]

7 Startup Options
8 Enter button
.

g) Select Run Current Application (9) and press the Run options
button (10).

Do not start Factory Talk View ME Station

Go to Configuration Mode
9
On Startup Configuration Mode options
[F1] [F2]

Run Current Application 10

Run options
[F3]

OK Cancel
[F7] [F8]

9 Run Current
Application
10 Run options button
.

(Cont’d)

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(Cont’d)

h) Select Yes (11) on option Delete Log Files On Every Power Cycle.
i) Confirm by pressing the OK button (12).

311

Replace RS Linx
Enterprise
Communications
[F1]

Delete Log Files

On Every Power Cycle
[F2]

12
OK Cancel
[F7] [F8]

11 Yes
12 OK button
.

j) Press the OK button and repeatedly the Close button until the Configuration
.
window appears.

1.2.2.3-6 Machine Setup - Set Start-Up Language

Machine Status Electrical supply disconnecting device in position I (ON)

a) Shut down the TPOP. See Procedure 1.2.2.3-1 Machine Setup - Shut Down
TPOP on page 192.
b) In the Configuration window, press the Application settings
button (1).

1 Application
settings button
.

(Cont’d)

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(Cont’d)

c) Select Startup language (2).

d) Press the Enter button (3) to confirm.

2 Startup language
3 Enter button
.

e) Select Start in last runtime language radio button (4) to make the
TPOP select the active language after every reboot.
f) Press the OK button (5) to confirm.

4 Start in last
runtime language
5 OK button
.

(Cont’d)

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(Cont’d)

g) Press the Close button (6) to exit.

6 Close button
.

1.2.2.3-7 Machine Setup - Reset TPOP

Machine Status Electrical supply disconnecting device in position I (ON)

a) Shut down the TPOP. See Procedure 1.2.2.3-1 Machine Setup - Shut Down
TPOP on page 192.
b) In the Configuration window, press the Reset button (1).

1
1 Reset button
.

(Cont’d)

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1.2 TPOP HMI 1 Electric Equipment

(Cont’d)

c) Press the Yes button (2) to confirm.

Do you want to reset the terminal?

2 Yes No
No
[F7] [F8]
[F8]

2 Yes button
.

1.2.2.3-8 Machine Setup - Run Application

Machine Status Electrical supply disconnecting device in position I
(ON)

a) In the Configuration window, select Yes (1) on option Delete log files
before running.
b) Press the Run application button (2).

1 Yes
2 Run application
button
.

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1.2.2.3-9 Machine Setup - Calibrate Touch Screen

Machine Status Electrical supply disconnecting device in position I (ON)

a) Shut down the TPOP. See Procedure 1.2.2.3-1 Machine Setup - Shut Down
TPOP on page 192.
b) In the configuration window, press the Terminal Settings button (1).

1 Terminal Settings
button
.

c) Select Input Devices (2) and press the Enter button (3).

Diagnostic Setup
2 Display
File Management
Font Linking
Input Devices
Networks and Communications
Print Setup
Startup Options
System Event Log
System Information
Time/Date/Regional Settings 3

Close
[F8]

2 Input Devices
3 Enter button
.

(Cont’d)

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(Cont’d)

d) Select Touch Screen (4) and press the Enter button (3).

4 Keyboard/ Keypad
Mouse
Touch Screen
String Pop-Up

Close
[F8]

3 Enter button
4 Touch Screen
.

e) Select Calibration (5) and press the Enter button (3).

5
Calibration
Double Tap Sensitivity

Close
[F8]

3 Enter button
5 Calibration
.

(Cont’d)

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(Cont’d)

f) Follow the instructions on the touch screen to calibrate it. Using a pointed object
(not too pointed) touch the middle of the cross that will appear at the screen
centre and on each corner of the screen.

g) Touch the screen again within 30 seconds to confirm the new calibration, or wait
30 seconds to reset the previous calibration.
h)
.
Repeatedly press the Close button until the configuration window appears.

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1.2 TPOP HMI 1 Electric Equipment

1.2.2.3-10 Machine Setup - Set Date, Time and Regional Settings

Machine Status Electrical supply disconnecting device in position I
(ON)

a) Shut down the TPOP. See Procedure 1.2.2.3-1 Machine Setup - Shut Down
TPOP on page 192.
b) In the Configuration window, press the Terminal settings button (1).

1 Terminal settings
button
.

c) Select Time/Date/Regional settings (2) and press the Enter button (3).

Alarms
Diagnostic Setup
Display
Desktop Access Setup
File Management
Font Linking
Input Devices
File Integrity Check
Networks and Communications
Print Setup
Startup Options
System Event Log
System Information
Time/Date/Regional Settings

3
2 Close
[F8]

2 Time/Date/Re-
gional settings
3 Enter button
.

(Cont’d)

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(Cont’d)

d) Select Time zone (4) and press the Enter button (3).

Date
Regional Settings
Time
Time Zone

3
Close
[F8]

3 Enter button
4 Time zone
.

e) Scroll the list and select the Correct time zone (5), and press the OK
button (6).

(GMT) Greenwich Mean Time

___________________________________
___________________________________
___________________________________

5 ___________________________________
___________________________________
___________________________________
___________________________________
___________________________________
___________________________________
___________________________________
___________________________________

Daylight
OK Cancel
Savings
[F7] [F8]
[F1]

6
5 Correct time zone
6 OK button
.

(Cont’d)

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(Cont’d)

f) Select Time (7) and press the Enter button (3).

Date
Regional Settings
Time
Time Zone

3
Close
[F8]

3 Enter button
7 Time
.

(Cont’d)

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(Cont’d)

g) Set the current time as follows:

• press the Hour button (8) and insert the hour using the keyboard (11), and
then press the Enter button (12).
• press the Minute button (9) and insert the minutes using the
keyboard (11), and then press the Enter button (12).
• press the Seconds button (10) and insert the seconds using the
keyboard (11), and then press the Enter button (12).
h) Press the OK button (6).

Enter time in 24 hour format:

16 45 30

Hour Minute Seconds

[F1] [F2] [F3]

8 10
OK Cancel
[F7] [F8]
9

6
11

12

6 OK button
8 Hour button
9 Minute button
10 Seconds button
11 Keyboard
12 Enter button
.

(Cont’d)

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(Cont’d)

i) Select Date (13) and press the Enter button (3).

Date
Regional Settings
Time
Time Zone

13

3
Close
[F8]

3 Enter button
13 Date
.

(Cont’d)

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(Cont’d)

j) Set the current date as follows:

• press the Year button (14) and insert the year using the keyboard (11),
then press the Enter button (12).
• press the Month button (15) and insert the month using the keyboard (11),
then press the Enter button (12).
• press the Day button (16) and insert the day using the keyboard (11), then
touch the Enter button (12).
k) Press the OK button (6), and then repeatedly press the Close button until the
Configuration window appears.

2007 5 25

Year Month Day

[F1] [F2] [F3]

14 16
OK Cancel
15 [F7] [F8]

6
11

12

6 OK button
11 Keyboard
12 Enter button
14 Year button
15 Month button
16 Day button
.

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1.2.2.3-11 Machine Setup - Font Linking

Machine Status Electrical supply disconnecting device in position I
(ON)

a) Shut down the TPOP. See Procedure 1.2.2.3-1 Machine Setup - Shut Down
TPOP on page 192.
b) In the configuration window, press the Terminal Settings button (1).

1 Terminal Settings
button
.

c) Select Font Linking (2) and press the Enter button (3).

2 Font Linking
3 Enter button
.

(Cont’d)

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(Cont’d)

d) Select font Arial (4) and press the Show Links button (5).

5
4

4 Arial
5 Show Links button
.

e) Press the Edit Link button (6).

6
6 Edit Link button
.

(Cont’d)

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(Cont’d)

f) Select font Arial Unicode MS (7) and press the Add Font button (8).

7 Arial Unicode MS
8 Add Font button
.

g) Repeatedly press the Close button (9) until the configuration window appears.

9 Close button
.

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1.2.2.4 Configuration
.

1.2.2.4-1 Configuration - Change PLMS Communication

Machine Status Electrical supply disconnecting device in position I (ON)
Program step IDLE

a) On the TPOP, log on as “tptechnician” or “supervisor”. See Procedure 1.2.2.1-2

User Management - Log On as a User on page 174.
b) Press the Configuration button (6) to display the Configuration window.
c) Press the PLMS icon (1) to change the communication type (2).
d) Use the Arrow buttons (3) to change the Confirmation button (4) according
to the current type of filling machine.
e) Confirm the setting with the Confirmation button (4) or press the
Cancel button (5) to abort.

2 3 4 5 6
1 PLMS icon
2 Communication type
3 Arrow button
4 Confirmation button
5 Cancel button
6 Configuration
button
.

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1.2.2.4-2 Configuration - Change Package Type

Machine Status Electrical supply disconnecting device in position I
(ON)
Program step IDLE

a) On the TPOP, log on as “tptechnician” or “supervisor”. See Procedure 1.2.2.1-2

User Management - Log On as a User on page 174.
b) Press the Configuration button (6) to display the Configuration window.
c) Press the Type of package handling icon (1) to change the package
type (2).

The Quick change option (TBA/TPA) activates the possibility to change

package type in the recipe.
d) Use the Arrow buttons (3) to change the package type (2).
e) Confirm the setting with the Confirmation button (4) or press the
Cancel button (5) to abort.

2 3 4 5 6
1 Type of package
handling icon
2 Package type
3 Arrow buttons
4 Confirmation button
5 Cancel button
6 Configuration
button
.

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1.2.2.4-3 Configuration - Set Line Communication

Machine Status Electrical supply disconnecting device in position I (ON)
Program step IDLE

a) On the TPOP, log on as “tptechnician” or “supervisor”. See Procedure 1.2.2.1-2

User Management - Log On as a User on page 174.
b) Press the Configuration button (6) to display the Configuration window.
c) Press the Line communication icon (1).
d) Choose type of line communication (2) if the machine uses photocells, relays, or
other.
e) Use the Arrow buttons (3) to change the type of line communication (2).
f) Confirm the setting with the Confirmation button (4) or press the
Cancel button (5) to abort.

2 3 4 5 6
1 Line communica-
tion icon
2 Type of line
communication
3 Arrow button
4 Confirmation button
5 Cancel button
6 Configuration
button
.

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1.2.2.4-4 Configuration - Identify Main Conveyor Specification

Machine Status Electrical supply disconnecting device in position I
(ON)
Program step IDLE

a) Press the Configuration button (1) to display the Configuration window.

b) Identify the Main Conveyor (2) IP Address (3) setting. See Section 10.6 IP
Addresses.

The Main Conveyor (2) is only monitored and not possible to select.

2
3

1
1 Configuration
button
2 Main Conveyor
3 IP Address
.

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1.2.2.4-5 Configuration - Change Infeed Conveyor Specification

Machine Status Electrical supply disconnecting device in position I (ON)
Program step IDLE

a) On the TPOP, log on as “tptechnician” or “supervisor”. See Procedure 1.2.2.1-2

User Management - Log On as a User on page 174.
b) Press the Configuration button (1) to display the Configuration window.
c) Press the Infeed Conveyor button (2).
d) Use the Arrow buttons (3) to select the correct drive and end station:
• 5 - 65 m/min.
• 39 m/min.
• 33 m/min.
• 25 m/min.
• Not Installed.
e) Confirm the setting with the Confirmation button (4) or press the
Cancel button (5) to abort.

2 3 4 5 6
1 Configuration
button
2 InfeedConveyorbut-
ton
3 Arrow buttons
4 Confirmation button
5 Cancel button
.

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1.2 TPOP HMI 1 Electric Equipment

1.2.2.4-6 Configuration - Change Discharge Conveyor

Specification
Machine Status Electrical supply disconnecting device in position I
(ON)
Program step IDLE

a) On the TPOP, log on as “tptechnician” or “supervisor”. See Procedure 1.2.2.1-2

User Management - Log On as a User on page 174.
b) Press the Configuration button (1) to display the Configuration window.
c) Press the Discharge Conveyor button (2).
d) Use the Arrow buttons (3) to select the correct drive and end station:
• 5 - 65 m/min.
• 39 m/min.
• 33 m/min.
• 25 m/min.
• Not Installed.

e) Confirm the setting with the Confirmation button (4) or press the
Cancel button (5) to abort.

3 4 5 1
1 Configuration
button
2 Discharge Convey-
or button
3 Arrow buttons
4 Confirmation button
5 Cancel button
.

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1.2.2.4-7 Configuration - Change IP Address

Machine Status Electrical supply disconnecting device in position I (ON)
Program step IDLE

a) On the TPOP, log on as “tptechnician” or “supervisor”. See Procedure 1.2.2.1-2

User Management - Log On as a User on page 174.
b) Press the Configuration button (11) to display the Configuration window.
c) Press the IP address icon (17).
d) To change the IP address, choose one of the Field 1 button (4) to Field4
button (1). The Field 1 button (4) corresponds to Address part 1 (16), the
Field2 button (3) corresponds to Address part 2 (15), and so on.
e) To set the value (7) use the Arrow buttons (8) or the keypad (12).
f) Confirm the value with the Confirmation button (9) or press the
Cancel button (10) to abort.
g) When the change are completed, confirm the setting with the
Confirmation button (5) or press the Cancel button (6) to abort.

17

16
15
14
13

1
2

3 4 5 6 7 8 9 10 11 12
1 Field 4 button 8 Arrow button 13 Address part4
2 Field3 button 9 Confirmation button 14 Address part3
3 Field 2 button 10 Cancel button 15 Address part 2
4 Field1 button 11 Configuration 16 Address part 1
5 Confirmation button button 17 IP address on WAN
6 Cancel button 12 Keypad port of router
7 Value
.

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1.2 TPOP HMI 1 Electric Equipment

1.2.2.4-8 Configuration - Set Second Discharge Unit Option

Machine Status Electrical supply disconnecting device in position I
(ON)
Program step IDLE

Note! The SA30 must be configured for Line Controller.

a) On the TPOP, log on as “tptechnician” or “supervisor”. See Procedure 1.2.2.1-2
User Management - Log On as a User on page 174.
b) Press the Configuration button (6) to display the Configuration window.
c) Press the Second discharge unit icon (1).
d) Enable with the Select button (2) or disable with the Deselect button (3).
e) Confirm the setting with the Confirmation button (4) or press the
Cancel button (5) to abort.

2 3 4 5 6
1 Second discharge
unit icon
2 Select button
3 Deselect button
4 Confirmation button
5 Cancel button
6 Configuration
button
.

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1.2.2.4-9 Configuration - Select Cooling Unit Option

Machine Status Electrical supply disconnecting device in position I (ON)
Program step IDLE

a) On the TPOP, log on as “tptechnician” or “supervisor”. See Procedure 1.2.2.1-2

User Management - Log On as a User on page 174.
b) Press the Configuration button (6) to display the Configuration window.
c) Press the Cooling unit icon (1).
d) Enable with the Select button (2) or disable with the Deselect button (3).
e) Confirm the setting with the Confirmation button (4) or press the
Cancel button (5) to abort.

2 3 4 5 6
1 Cooling unit icon
2 Select button
3 Deselect button
4 Confirmation button
5 Cancel button
6 Configuration
button
.

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1.2 TPOP HMI 1 Electric Equipment

1.2.2.4-10 Configuration - Set iLine XT Option

Machine Status Electrical supply disconnecting device in position I
(ON)
Program step IDLE

a) On the TPOP, log on as “tptechnician” or “supervisor”. See Procedure 1.2.2.1-2

User Management - Log On as a User on page 174.
b) Press the Configuration button (8) to display the Configuration window.
c) Press the iLine XT icon (1).
d) Press the iLine XT activation icon (3).
e) Enable with the Select button (4) or disable with the Deselect button (5).
f) Confirm the setting with the Confirmation button (6) or press the
Cancel button (7) to abort.
g) Press the iLine XT installation icon (2).
h) Enable with the Select button (4) or disable with the Deselect button (5).
i) Confirm the setting with the Confirmation button (6) or press the
Cancel button (7) to abort.

1
2
3

4 5 6 7 8
1 iLine XT icon 5 Deselect button
2 iLine XT 6 Confirmation
installation icon button
3 iLine XT 7 Cancel button
activation icon 8 Configuration
4 Select button button
.

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1.2.2.4-11 Configuration - Set Laser Guided Vehicle Option

Machine Status Electrical supply disconnecting device in position I (ON)
Program step IDLE

Note! The iLine XT must be installed and activated in order to use the LGV. See
Procedure 1.2.2.4-10 Configuration - Set iLine XT Option on page 236.
a) On the TPOP, log on as “tptechnician” or “supervisor”. See Procedure 1.2.2.1-2
User Management - Log On as a User on page 174.
b) Press the Configuration button (6) to display the Configuration window.
c) Press the LGV activation icon (1).
d) Enable with the Select button (2) or disable with the Deselect button (3).
e) Confirm the setting with the Confirmation button (4) or press the
Cancel button (5) to abort.

1 2 3 4 5 6
1 LGV activation 4 Confirmation
icon button
2 Select button 5 Cancel button
3 Deselect button 6 Configuration
button
.

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1.2 TPOP HMI 1 Electric Equipment

1.2.2.4-12 Configuration - Set Energy Saving Option

Machine Status Electrical supply disconnecting device in position I
(ON)
Program step IDLE

Note! The iLine XT must be installed and activated in order to use the Energy
Saving. See Procedure 1.2.2.4-10 Configuration - Set iLine XT Option on page 236.
a) On the TPOP, log on as “tptechnician” or “supervisor”. See Procedure 1.2.2.1-2
User Management - Log On as a User on page 174.
b) Press the Configuration button (6) to display the Configuration window.
c) Press the Energy saving icon (1).
d) Enable with the Select button (2) or disable with the Deselect button (3).
e) Confirm the setting with the Confirmation button (4) or press the
Cancel button (5) to abort.

2 3 4 5 6
1 Energy saving icon 5 Cancel button
2 Select button 6 Configuration
3 Deselect button button
4 Confirmation
button
.

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1.2.2.4-13 Configuration - Set Conveyor Encoder

Machine Status Electrical supply disconnecting device in position I (ON)
Program Step IDLE

a) On the TPOP, log on as “tptechnician” or “supervisor”. See Procedure 1.2.2.1-2

User Management - Log On as a User on page 174.
b) Press the Configuration button (1) to display the CONFIGURATION window.
c) Press the Conveyor Encoder icon (2).
d) Press the Conveyor encoder direction (3).
e) Select encoder direction (clockwise or anti-clockwise) with the Select
buttons (4).
f) Confirm the setting with the Confirmation button (5) or press the
Cancel button (6) to abort.

2 4 5 6 1
1 Configuration 4 Select button
button 5 Confirmation
2 Conveyor Encoder button
icon 6 Cancel button
3 Conveyor encoder
direction
.

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1.2 TPOP HMI 1 Electric Equipment

1.2.2.4-14 Configuration - Set Straw Detector Integrated

Machine Status Electrical supply disconnecting device in position I
(ON)
Program step IDLE

a) On the TPOP, log on as “tptechnician” or “supervisor”. See Procedure 1.2.2.1-2

User Management - Log On as a User on page 174.
b) Press the Configuration button (6) to display the Configuration window.
c) Press the Straw detector icon (1).
d) Enable with the Select button (2) or disable with the Deselect button (3).
e) Confirm the setting with the Confirmation button (4) or press the Cancel
button (5) to abort.
f) Press the Angled/Parallel Camera icon (7).
Note! Parallel camera intended for PoMF, but also works for PoB.
g) Select angled or parallel camera.
h) Confirm the setting with the Confirmation button (4) or press the Cancel
button (5) to abort.

2 3 4 5 6
71
1 Straw detector 4 Confirmation
icon button
2 Select button 5 Cancel button
3 Deselect button 6 Configuration
button
7 Angled/Parallel
Camera icon
.

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1.2.2.5 Recipes
.

1.2.2.5-1 Recipes - Set Recipe

Machine Status Electrical supply disconnecting device in position I (ON)
Program step IDLE or PREHEATING

a) On the TPOP, log on as “tptechnician” or “supervisor” or “technician”. See

Procedure 1.2.2.1-2 User Management - Log On as a User on page 174.
b) Press the Recipe button (1) to display the Recipe window.
c) Press the Open button (2) to open an existing recipe or the
New recipe button (3) to create a new recipe.

2
3

1
1 Recipe button
2 Open button
3 New recipe button
.

Open an Existing Recipe

Choose a recipe in the list by using the arrow buttons (3), and press the
Confirmation button (1) to select the recipe. To abort the selection, press the
Cancel button (2).

1 2 3
1 Confirmation
button
2 Cancel button
3 Arrow button

(Cont’d)

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1.2 TPOP HMI 1 Electric Equipment

(Cont’d)

Create a New Recipe

a) Press the New recipe button (1) to open the Recipe window.

1
1 New recipe button
.

b) Press an icon to change the corresponding setting. Available settings are the
buttons (2) to (8). If an icon is coloured grey, the setting is not available.
For a guideline for the applicator unit angle (7) settings, see Section
10.1 Straw Angle Settings on page 579.
Note! Always select the Straw type (3).

2 3

8
4
7
5
6

2 Package size 5 Straw Diameter

3 Straw type (TB/TBA only)
4 Straw length 6 Straw colors
(TB/TBA only) (Transperan-
t/Light/Dark)
7 Angle of
applicator unit
8 Package type (for
Quick change
configuration only)
.

(Cont’d)

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(Cont’d)

c) Press the Confirmation button (9).

d) Type the recipe name with the keyboard and press Enter (10).
Note! It is not possible to save more than eight recipes.

10

9 Confirmation button
10 Enter button
.

e) Press the Next window button (11) to view the next recipe window.

11

11 Next window button

.

(Cont’d)

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1.2 TPOP HMI 1 Electric Equipment

(Cont’d)

f) Press an icon to change the corresponding setting. Available settings are the
buttons (12) to (16). If an icon is coloured grey, the setting is not available.
g) Press the Next window button (18) or the Previous window button (17) to
switch between the recipe windows.
h) Use the keypad (19) or the Arrow buttons (21) to change the settings.
i) Confirm setting with the Confirmation button (20).

15 16

14
13
12
17
18

19

21 20
12 Position of straw on 17 Previous window
package button
13 Glue position lower 18 Next window button
14 Glue position upper 19 Keypad
15 Glue duration lower 20 Confirmation
button
16 Glue duration upper
21 Arrow button
.

(Cont’d)

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(Cont’d)

j) Press an icon to change the corresponding setting. Available settings are the
buttons (22) to (37). If an icon is coloured grey, the setting is not available.
Note! To activate and make the Second discharge unit (35) visible in the
HMI. See Procedure 1.2.2.4-8 Configuration - Set Second Discharge Unit
Option on page 234.
k) Press the Previous window button (25) to switch to the previous
recipe windows.
l) Use the Keypad (26) or the Arrow buttons (27) to change the settings.

22 23 24

35

36 37
34 25
33

26

32 31 30 29 28 27
22 Package length 28 Distance between 31 Distance between 34 Infeed speed
under the the left edge of the right edge of factor (optional)
influence of the the package and the package and 35 Second discharge
blow nozzle the straw (TB/TBA the straw (TB/TBA unit (optional)
23 Straw presence only) only) 36 Outfeed queue
24 Straw angle 29 Distance between 32 Distance between alarm activation
25 Previous window the bottom edge of the top edge of the delay (TPA only)
button the package and package and the 37 Outfeed queue
26 Keypad the straw (TB/TBA straw (TB/TBA only) alarm
27 Arrow button only) 33 Discharge speed deactivation
30 Distance between factor delay (TPA only)
the straw and the
package surface
(TB/TBA only)
.

(Cont’d)

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1.2 TPOP HMI 1 Electric Equipment

(Cont’d)

Save a Recipe
When changes have been made to a recipe, the Recipe icon (1) shows in the
upper left corner of the screen. This means that the recipe needs to be saved before
the new settings are activated.

a) Press the Recipe button (2).

b) Save the recipe according to one of the procedures below.

1 2
1 Recipe icon
2 Recipe button
.

Save Current Recipe

c) Press the Save button (3) to save the current recipe.
d) Press the Confirmation button (5) to save the current recipe, or press the
.
Cancel button (6) to abort the saving.
Save Recipe with a New Name

e) Press the Save as button (4) to save the recipe with a new name.
f) Edit the values in the first recipe window. See Procedure Create a New Recipe,
item b) to c) on page 242.
g) Type the recipe name with the keyboard and press Enter.

5
3 4

3 Save button
4 Save as button
5 Confirmation button
6 Cancel button
.

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1.2.2.6 Maintenance
.

1.2.2.6-1 Maintenance - Set Apply Unit

Machine Status Electrical supply disconnecting device in position I (ON)

a) On the TPOP, log on as “tptechnician” or “supervisor” or “technician”. See

Procedure 1.2.2.1-2 User Management - Log On as a User on page 174.
b) Press the Maintenance button (2) to display the Maintenance window.
c) Press the Apply unit button (1).

1 2
1 Apply unit button
2 Maintenance button
.

(Cont’d)

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(Cont’d)

d) In the Apply unit maintenance window it is possible to set the glue

duration (3), the glue position (4), the pick position (5), and the bleed
hotmelt (6).
e) Press one of the icons to show the corresponding setting display. The setting
display looks similar for glue duration and glue position. To set pick position,
see Procedure 1.2.2.6-2 Maintenance - Set Pick Position on page 249. To bleed
hotmelt, see Procedure 5.2-3 Hotmelt Equipment Nordson - Bleed System on
page 449.
f) Use the Arrow buttons (8) to set the desired value (7).
g) Confirm the setting with the Confirmation button (10) or press the
Cancel button (9) to abort.

3
4
6
5

7 8 9 10
3 Glue duration 8 Arrow button
4 Glue position 9 Cancel button
5 Pick position 10 Confirmation
6 Bleed hotmelt button
7 Value
.

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1.2.2.6-2 Maintenance - Set Pick Position

Machine Status Electrical supply disconnecting device in position I (ON)
Program step PREHEATING
Special Equipment Templates: 3057744-0100, 3013617-0100 (for
TB/TBA), 3013619-0100 (for TPA/TT)

a) On the TPOP, log on as “tptechnician” or “supervisor” or “technician”. See

Procedure 1.2.2.1-2 User Management - Log On as a User on page 174.
b) Press the Maintenance button (2) to display the Maintenance window.
c) Press the Apply unit button (1).

1 2
1 Apply unit button
2 Maintenance button
.

(Cont’d)

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1.2 TPOP HMI 1 Electric Equipment

(Cont’d)

d) Press the Pick position icon (4).

e) Press the Select button (3) and the Confirmation button (5).
f) The feed wheel will turn to the correct pick position.
g) Press the Select button (3) when it turns green.
h) Open the doors to the machine.

5
3 Select button
4 Pick position icon
5 Confirmation
button
.

(Cont’d)

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(Cont’d)

i) Attach the template (7) on the frame section (8) to keep the bearing housing (6)
fixed.

TB/TBA

6
7

8
TPA/TT
6 Bearing housing
7 Template
8 Frame section
.

(Cont’d)

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(Cont’d)

j) CAUTION
Possible equipment damage.
Do not move the stellar knobs once the position template fits in the feed wheel,
as the template and the feed wheel will be damaged.
Turn the stellar knob (15) until the position template (11) fits. The pins (10) shall
fit in the bushings (12) and the pins (13) in the cavities (9) in the feed wheel. If
desired, it is also possible to screw the knurled screw (14) into the threaded
hole (16).

11
9

10

12
16

15 14 13
9 Cavity
10 Pin
11 Position template
12 Bushing
13 Pin
14 Knurled screw
15 Stellar knob
16 Threaded hole
.

(Cont’d)

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(Cont’d)

k) Confirm the setting by pressing the Confirmation button (5), or press the
Deselect button (17) if no change was made.

17 5
5 Confirmation
button
17 Deselect button
.

l) Remove the templates.

m) Close the doors.
n) Press the RESET button (18) to restore the safety circuit and wait until the
audible alarm has produced a warning signal.
o) Reset the door alarm on the TPOP.

18
18 RESET button
.

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1.2 TPOP HMI 1 Electric Equipment

1.2.2.6-3 Maintenance - Set Discharge Unit

Machine Status Electrical supply disconnecting device in position I
(ON)
Program step PREHEATING

Note! The Discharge unit must be configured (selected) for the machine (see the
configuration window). Otherwise this will not be visible.
a) On the TPOP, log on as “tptechnician” or “supervisor” or “technician”. See
Procedure 1.2.2.1-2 User Management - Log On as a User on page 174.
b) In the button bar, press the Maintenance button (1) to display the
Maintenance window.
c) Press the Discharge unit button (2).
d) In the Discharge unit maintenance window, it is possible to set the
discharge conveyor speed (3) and the discharge conveyor length (4).
e) Press one of the icons to show the corresponding setting display (5).
f) Use the Arrow buttons (6) to set the desired value.

4 5 6
1 Maintenance button 4 Discharge conveyor
2 Discharge unit length
button 5 Setting display
3 Discharge conveyor 6 Arrow button
speed
.

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1.2.2.6-4 Maintenance - Set Infeed Unit Parameters

Machine Status Electrical supply disconnecting device in position I (ON)
Program step PREHEATING

Note! The Infeed unit must be configured (selected) for the machine (see Procedure
configuration window). Otherwise this will not be visible.
a) On the TPOP, log on as “tptechnician” or “supervisor” or “technician”. See
Procedure 1.2.2.1-2 User Management - Log On as a User on page 174.
b) In the button bar, press the Maintenance button (1) to display the
Maintenance window.
c) Press the Infeed unit button (2).
d) If the machine is equipped with an infeed conveyor, it is possible to set infeed
conveyor speed (3) and the infeed conveyor length (4).
e) Press one of the icons to show the corresponding setting display (5).
f) Use the Arrow buttons (6) to set the desired value.

4 5 6
1 Maintenance button 4 Infeed conveyor length
2 Infeed unit button 5 Setting display
3 Infeed conveyor speed 6 Arrow button
.

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1.2 TPOP HMI 1 Electric Equipment

1.2.2.6-5 Maintenance - Set Conveyor Unit Parameters

Machine Status Electrical supply disconnecting device in position I
(ON)
Program step PREHEATING

a) On the TPOP, log on as “tptechnician” or “supervisor” or “technician”. See

Procedure 1.2.2.1-2 User Management - Log On as a User on page 174.
b) Press the Maintenance button (5) to display the MAINTENANCE window.
c) Press the Conveyor unit button (1).
d) In the PACKAGE UNIT MAINTENANCE window, it is possible to synchronize the
speed parameters (3) and set the queue alarm activation delay (4).
e) The second discharge unit (2) is available if the machine has been
configured for second discharge. See Procedure 1.2.2.4-8 Configuration - Set
Second Discharge Unit Option on page 234.

1
2

1 Conveyor unit
button
2 second discharge
unit
3 Synchronize speed
parameters
4 Queue alarm
activation delay
5 Maintenance button
.

(Cont’d)

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(Cont’d)

Synchronize Speed Parameters

Note! Synchronization is mandatory during installation.
a) Press the Synchronize speed parameters icon (1).
b) Press the Select button (2).
c) Press the Confirmation button (3).
When the conveyor shaft head (4) has passed the sensor (5), show the time
bar (6) 50%.conveyor shaft head (4)

2
6

5 4
1 Synchronize speed 4 Conveyor shaft head
parameters icon 5 Sensor W40B2180
2 Select button 6 Time bar
3 Confirmation
button
.

(Cont’d)

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(Cont’d)

d) When the conveyor shaft head (4) has passed the sensor (7), show the time
bar (6) 100%. The conveyor stops when the conveyor shaft head (4) is outside
the machine.

7
4
4 Conveyor shaft head
6 Time bar
7 Sensor W40B2182
.

(Cont’d)

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(Cont’d)

Set Second Discharge Unit

a) Press the Second discharge unit icon (1).
b) Enable with the Select button (2) or disable with the Deselect button (3).
c) Confirm the setting with the Confirmation button (4) or press the Cancel
button (5) to abort.

2 3 4 5
1 Second discharge
unit icon
2 Select button
3 Deselect button
4 Confirmation
button
5 Cancel button
.

Queue Photocell Selection

Each conveyor on a line with parallel DE interfaces is equipped with a queue
photocell. This setting selects the photocell for the current recipe. This setting
applies only with LC automation types.

(Cont’d)

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(Cont’d)

a) Press the Queue photocell selection icon (1).

b) Select the appropriate photocell from the list, use the Arrow buttons (2).
c) Confirm the setting with the Confirmation button (3) or press the Cancel
button (4) to abort.

2 3 4
1 Queue photocell
selection icon
2 Arrow buttons
3 Confirmation
button
4 Cancel button
.

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1.2.2.6-6 Maintenance - Set Material Maintenance

Machine Status Electrical supply disconnecting device in position I (ON)
Program step PREHEATING

Note! The SA30 must be configured for iLine XT.

a) On the TPOP, log on as “tptechnician” or “supervisor” or “technician”. See
Procedure 1.2.2.1-2 User Management - Log On as a User on page 174.
b) In the button bar, press the Maintenance button (2) to display the
Maintenance window.
c) Press the Material maintenance button (1).

2
1 Material
maintenance button
2 Maintenance button
.

(Cont’d)

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(Cont’d)

d) Press the Interlocking stop icon (3).

e) To set the Interlocking stop alarm as yellow, press the Select button (4), or
press the Deselect button (5) to set the interlocking stop alarm as blue.
f) Confirm the setting with the Confirmation button (6).

4 5 6
3 Interlocking stop
4 Select button
5 Deselect button
6 Confirmation button
.

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1.2.2.6-7 Maintenance - Set Straw Detector Integrated

Machine Status Electrical supply disconnecting device in position I (ON)
Program step PREHEATING

a) On the TPOP, log on as “tptechnician” or “supervisor” or “technician”. See

Procedure 1.2.2.1-2 User Management - Log On as a User on page 174.
b) Press the Maintenance button (1) to display the Maintenance window.
c) Press the Straw detector button (2).

2 1
1 Maintenance button
2 Straw detector
button
.

(Cont’d)

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(Cont’d)

d) In the Straw detector maintenance window, it is possible to set data for

reject unit (3) and (4), to save images (6), and to make FTP server settings (5).
Select the icon to open the corresponding window or setting display.

3 4

6 5
3 Package length 5 FTP server
under the settings
influence of the 6 Save images to FTP
blow nozzle server
4 Distance between
detector and
reject unit
.

(Cont’d)

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1 Electric Equipment 1.2 TPOP HMI

(Cont’d)

Set the Reject Unit

a) Select the icon for Package length under the influence of the blow
nozzle (1) to change the settings.
b) Change the current value (2) with the Arrow buttons (4) or with the keypad (7).
The new value will be displayed at (3).
c) Confirm the setting with the Confirmation button (5) or press the
Cancel button (6) to abort.

2 3 4 5 6 7
1 Package length 4 Arrow button
under the 5 Confirmation
influence of the button
blow nozzle 6 Cancel button
2 Current value 7 Keypad button
3 New value
.

(Cont’d)

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1.2 TPOP HMI 1 Electric Equipment

(Cont’d)

d) Select the icon for Distance between detector and reject unit (8) to
change the settings.
e) Select the new value (3) with the Arrow buttons (4) or with the keypad (7).
f) Confirm the setting with the Confirmation button (5) or press the
Cancel button (6) to abort.

3 4 5 6 7
3 New value 7 Keypad button
4 Arrow button 8 Distance between
5 Confirmation detector and
button reject unit
6 Cancel button
.

Save Image to FTP Server

Note! This function is for troubleshooting only. With the function enabled, it is not
possible to analyse all packages.

(Cont’d)

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1 Electric Equipment 1.2 TPOP HMI

(Cont’d)

a) To change the setting, select the Save images to FTP server icon (4).
b) Enable with the Select button (1) or disable with the Deselect button (2).
c) Confirm the setting with the Confirmation button (3).

1 2 3 4
1 Select button
2 Deselect button
3 Confirmation
button
4 Save images to FTP
server icon
.

(Cont’d)

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1.2 TPOP HMI 1 Electric Equipment

(Cont’d)

Set the FTP Server

a) In the FTP server maintenance window, it is possible to set FTP server
mode (1), to save selection (2), and to set FTP server data, such as FTP picture
format (3), FTP IP address (4), FTP port number (5), FTP user name (6), and
FTP password (7). Select the icon to open the corresponding window or setting
display.
b) Press the Exit button (8) to return to the Straw detector maintenance
window.

5
1
6
2
7
3
4 8

1 FTP server mode 6 FTP user name

2 Save selection (numeric)
3 FTP picture format 7 FTP password
(numeric)
4 FTP IP address
8 Exit button
5 FTP port number
.

(Cont’d)

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1 Electric Equipment 1.2 TPOP HMI

(Cont’d)

Set FTP Server Mode

a) To change the setting, select the FTP server mode icon (1).
b) Press the Select button (2) for passive mode and the Deselect button (3) for
active mode.
c) Confirm the setting with the Confirmation button (4) or press the
Cancel button (5) to abort.

2 3 4 5
1 FTP server mode
2 Select button
3 Deselect button
4 Confirmation
button
5 Cancel button
.

(Cont’d)

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1.2 TPOP HMI 1 Electric Equipment

(Cont’d)

Set Save Selection for FTP Server

a) To change the setting, select the icon for FTP save selection (1).
b) Enable the function with the Select button (2) or disable with the Deselect
button (3).
c) Confirm the setting with the Confirmation button (4) or press the
Cancel button (5) to abort.

2 3 4 5
1 FTP save selection
2 Select button
3 Deselect button
4 Confirmation
button
5 Cancel button
.

Set Picture Format for FTP Server

Note! For fault finding only. When a picture is sent by FTP from the detector, the
following packages will not be evaluated. Turn off the function after use.

(Cont’d)

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1 Electric Equipment 1.2 TPOP HMI

(Cont’d)

a) To change the setting, select the FTP picture format icon (1).
b) Change format with the Arrow buttons (2).
c) Confirm the setting with the Confirmation button (3) or press the
Cancel button (4) to abort.

2 3 4
1 FTP picture
format icon
2 Arrow button
3 Confirmation
button
4 Cancel button
.

(Cont’d)

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1.2 TPOP HMI 1 Electric Equipment

(Cont’d)

Set IP Address for FTP Server

Note! The IP address should be identical to the IP address for the computer
receiving the images.
a) Select the FTP IP address icon (1).
b) To change the IP address, choose one of the Part buttons 2) to 5). The Part
1 (5) button corresponds to Address part 1 (9), the Part 2 (4) corresponds
to Address part 2 (8), and so on.

2
3

4 5 6 7 8 9
1 FTP IP address icon 5 Part 1
2 Part 4 6 Address part 4
3 Part 3 7 Address part 3
4 Part 2 8 Address part 2
9 Address part 1
.

(Cont’d)

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1 Electric Equipment 1.2 TPOP HMI

(Cont’d)

c) To set the value (12) use the Arrow buttons (13) or the keypad (16).
d) Confirm the value with the Confirmation button (14) or press the
Cancel button (15) to abort.
e) When the change are completed, confirm the setting with the
Confirmation button (10) or press the Cancel button (11) to abort.

10 11 12 13 14 15 16
10 Confirmation button
11 Cancel button
12 Value
13 Arrow button
14 Confirmation button
15 Cancel button
16 Keypad button
.

(Cont’d)

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1.2 TPOP HMI 1 Electric Equipment

(Cont’d)

Set Port Number, User Name, or Password for FTP Server

a) To change the setting, select the corresponding icon for FTP Port number (1),
FTP User name (2), or FTP Password (3).
b) Change the current value (5) with the Arrow buttons (6) or with the keypad (9).
The new value will be displayed at (4).
c) Confirm the setting with the Confirmation (7) button or press the
Cancel button (8) to abort.

1
2
3

4 5 6 7 8 9
1 FTP Port number 5 Current value
2 FTP User name 6 Arrow button
(numeric) 7 Confirmation
3 FTP Password 8 Cancel button
(numeric)
9 Keypad button
4 New value
.

(Cont’d)

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1 Electric Equipment 1.2 TPOP HMI

(Cont’d)

Receive Images on FTP Server

a) Connect the detector to the computer through the ethernet switch (10) in the
electrical cabinet.

10
10 Ethernet switch
A01X2110
.

b) Open the FTP Server program on the PC.

c) Set the FTP Server program to listen to the port specified in Section Set Port
Number, User Name, or Password for FTP Server on page 274.
d) Set a short welcome message.
e) Bind the FTP Server program to the IP address specified in Section Set IP
Address for FTP Server on page 272.
Note! The IP address on the PC must be the same as the IP address used for
the FTP Server and the FTP Server program.
f) Create a user with the user name and the password specified in Section Set
Port Number, User Name, or Password for FTP Server on page 274.
g) Set full permission to the user.
h)
.
Set a home directory for the user where the images are received.

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1.2 TPOP HMI 1 Electric Equipment

1.2.3 Barcode Scanner

1.2.3-1 Barcode Scanner Cable - Change
Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
Main air valve ON
SPC Reference 3119157-0100

a) Remove the screw (1) and the cable strain relief plate (2).
b) Remove the cover (3).
c) Remove the cable connector (4) from the barcode scanner (5) together with the
plastic boot (6) and the rubber gasket (7).
d) Open the plastic boot (6), and remove it from the cable connector (4).
e) Remove the rubber gasket (7) from the cable connector (4).
f) Change the cable, and assemble in the reverse order.

3
7
2
4

6
1 Screw 5 Barcode scanner
2 Cable strain relief 6 Plastic boot
plate 7 Rubber gasket
3 Cover
4 Cable connector
.

Note! Dispose of the electrical components and batteries in special waste

management systems. Follow local regulations.
.

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1 Electric Equipment 1.2 TPOP HMI

1.2.3-2 Barcode Scanner - Configure and Test Barcode Scanner

Machine Status Electrical supply disconnecting device in position I (ON)
SPC Reference 3119157-0100

To setup the barcode scanner to work with the HMI, perform the following
configuration and testing procedures in the given order.

Configuration
a) Reset the barcode scanner to the default factory settings by scanning the
following barcode. Wait five seconds.

Barcode for factory setting

.

b) Set the scanner for use with USB Keyboard ALT mode by scanning the following
barcode. Wait five seconds.

Barcode to enable aiming system

Barcode for Tetra Pak operator sheet

.

c)
.
Perform the Configuration Test.

(Cont’d)

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1.2 TPOP HMI 1 Electric Equipment

(Cont’d)

Configuration Test
a) On the HMI, press the Production control button (1), and then the
Material control button (2), and select a material (3).
b) Press the ID button (4) to bring up the keyboard (5).

1 Production
control button
2 Material control
button
3 Material
4 ID button
5 Keyboard
.

c) To check that the barcode scanner is configured to terminate the scanning with
the tab command and not with the carriage return command, scan the
following barcode twice.
d) Check that the message in the scanner is

Code 128 Tab Test

e) Press CLR (6). If you do not get this message after scanning the barcode,
repeat the Configuration procedure.

Barcode test for tab terminator

6
5 Keyboard
6 CLR
.

(Cont’d)

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1 Electric Equipment 1.2 TPOP HMI

(Cont’d)

f) To check that the barcode scanner is configured to register barcodes with upper-
case letters, scan the following barcode.
g) Check that the message in the scanner is
CODE39TEST
h) Press CLR (6). If you do not get this message after scanning the barcode, repeat
the Configuration procedure.

Barcode test for all upper case characters

6
5 Keyboard
6 CLR
.

(Cont’d)

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1.2 TPOP HMI 1 Electric Equipment

(Cont’d)

i) To check that the barcode scanner is configured to register barcodes with

mixed in both upper case and lower case letters, scan the following barcode.
j) Check that the message in the scanner is
Code39test
k) Press CLR (6). If you do not get this message after scanning the barcode,
repeat the Configuration procedure.

Barcode test for mixed upper and lower case characters

6
5 Keyboard
6 CLR
.

(Cont’d)

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1 Electric Equipment 1.2 TPOP HMI

(Cont’d)

l) To check that the barcode scanner is configured to register barcodes that

require the replacement of separators with the special pipe text character (also
known as broken bar), scan the following barcode.
m) Check that the message in the scanner is
0197322510101005146120|789654

In particular, verify the special pipe text character positioned seventh from the
end.
n) Press CLR (6). If you do not get this message after scanning the barcode, repeat
the Configuration procedure.

Barcode for character replacement

6
5 Keyboard
6 CLR
.

(Cont’d)

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1.2 TPOP HMI 1 Electric Equipment

(Cont’d)

o) To check that the barcode scanner is configured to register barcodes that

require removal of parenthesis text characters, scan the following barcode.
p) Check that the message in the scanner is
0197322510101005146120789654
q) Press CLR (6) and ESC (7).
r) If you do not get this message after scanning the barcode, repeat the
Configuration procedure.
s) Press Exit (8).

Barcode for parenthesis removal

5 Keyboard
6 CLR
7 ESC
8 Exit
.

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 2 Conveyor Section

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 2 Conveyor Section

Description
SPC Reference 663302-0500

5
4

3
2
1 Conveyor
2 Belt brake
3 Adjustment plate
4 Top support
5 Height adjustment

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2 Conveyor Section Table of Contents

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

2.1 Conveyor......................................................... 287

2.1.1 Support Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
2.1.1-1 Support Rail - Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

2.2 Belt Brake ........................................................ 291

2.2-1 Belt Brake - Check Timing Belt . . . . . . . . . . . . . . . . . . . 291
2.2-2 Belt Brake - Change Timing Belt (TPA without
SD Integrated and TB/TBA/TT) . . . . . . . . . . . . . . . . . . .292
2.2-3 Belt Brake - Change Timing Belt (TPA with
SD Integrated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293
2.2-4 Belt Brake - Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
2.2-5 Belt Brake - Set Height (TPA with
SD Integrated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .297

2.3 Adjustment Plate ............................................... 299

2.3-1 Adjustment Plate - No Procedure Described . . . . . . . 299

2.4 Top Support ..................................................... 300

2.4-1 Top Support - Set Horizontal Position . . . . . . . . . . . . . 300
2.4-2 Top Support - Set Lateral Position . . . . . . . . . . . . . . . . 301

2.4.1 Support Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

2.4.1-1 Support Belt - Check Timing Belt . . . . . . . . . . . . . . . . . 302
2.4.1-2 Support Belt - Change Timing Belt . . . . . . . . . . . . . . . . 303
2.4.1-3 Support Belt - Set Timing Belt Tension . . . . . . . . . . . . 304

2.4.2 Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

2.4.2-1 Wheel - Check Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
2.4.2-2 Wheel - Change Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

2.5 Height Adjustment ............................................. 308

2.5-1 Height Adjustment - Set Height. . . . . . . . . . . . . . . . . . . 308
2.5-2 Height Adjustment - Set in Parallel. . . . . . . . . . . . . . . . 309
2.5-3 Height Adjustment - Change Timing Belt (with
SD Integrated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
2.5-4 Height Adjustment - Check Shock Absorber . . . . . . . 311
2.5-5 Height Adjustment - Change Shock
Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .313

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Table of Contents 2 Conveyor Section

2.5-6 Height Adjustment - Set Shock Absorber . . . . . . . . . . 314

2.5-7 Height Adjustment - Set Adjusting Screw . . . . . . . . . . 315
2.5-8 Height Adjustment - Check Cylinder . . . . . . . . . . . . . . 316
2.5-9 Height Adjustment - Change Cylinder . . . . . . . . . . . . . 317

2.6 Photocell Unit ................................................... 320

2.6-1 Photocell Unit - No Procedure Described . . . . . . . . . . 320

2.7 Second Discharge Unit ....................................... 321

2.7-1 Second Discharge Unit - No Procedure
Described . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .321

2.8 Encoder .......................................................... 322

2.8-1 CIP Sync Encoder - Set IP Address . . . . . . . . . . . . . . . 322

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2 Conveyor Section 2.1 Conveyor

2.1 Conveyor
The conveyor has twisted side plates at the first section on the infeed side, and on
the last section on the discharge side. The side plates are marked with numbers and
arrows corresponding to the product flow.

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2.1 Conveyor 2 Conveyor Section

2.1.1 Support Rail

2.1.1-1 Support Rail - Set
SPC Reference 2845848-0500
3013606-0300
3199517-0200

a) Put the package (1) in front of the belt brakes (2) and (6).
b) Loosen the screw (5).
c) Set the width between the lower parts of the support rail (3) and support rail (4).
It should be approximately the width of the package plus two to three mm play.
Set the railings as symmetrical as possible over the conveyor.
d) Tighten the screw (5).

5 6
1

4 3
1 Package 4 Support rail
2 Belt brake 5 Screw
3 Support rail 6 Belt brake
.

(Cont’d)

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2 Conveyor Section 2.1 Conveyor

(Cont’d)

e) Move the package (1) to the rail holder (7) and the rail holder (8).
f) Loosen the screw (9).
g) Set the rail holder (8) as close to the conveyor chain as possible.
h) Tighten the screw (9).
i) Loosen the screw (10).
Note! For TB/TBA; Set the distance A according to the illustration below. For
TPA/TT, set the support rail as close to the package as possible.
j) Set the rail holder (7) so that there is a distance A between the support rail (4)
and the package.
k) Tighten the screw (10).

8
7 9
A
1
10
4

A = 3 to 5 mm
1 Package 8 Rail holder
4 Support rail 9 Screw
7 Rail holder 10 Screw
.

(Cont’d)

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2.1 Conveyor 2 Conveyor Section

(Cont’d)

l) Move the package (1) to the rail holder (12) and the rail holder (13). Start with
the rail holders closest to the top support.
m) Loosen the screw (14).
n) Move the rail holder (13) so that the rear of the package (1) is positioned the
distance B from the side of the conveyor chain (11).
o) Tighten the screw (14).
p) Loosen the screw (15).
Note! The straw must not be in contact with the rail, until minimum one metre
after the applicator.
q) Adjust the rail holder (12) so that there is a distance C between the package (1)
and the support rail (4).
r) Move the package (1) to the next set of rail holders and repeat item m) to q).

1 1
11

B
C

11
4

12 13

14

15
B = 2 to 3 mm
C ≥ 10 mm
1 Package 13 Rail holder
4 Support rail 14 Screw
11 Conveyor chain 15 Screw
12 Rail holder
.

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2 Conveyor Section 2.2 Belt Brake

2.2 Belt Brake

2.2-1 Belt Brake - Check Timing Belt
SPC Reference 3008046-0200

Check the condition of the timing belts (1) and (2). Change, if necessary. See
Procedure 2.2-2 Belt Brake - Change Timing Belt (TPA without SD Integrated and
TB/TBA/TT) on page 292.

2
1 Timing belt
2 Timing belt

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2.2 Belt Brake 2 Conveyor Section

2.2-2 Belt Brake - Change Timing Belt (TPA without

SD Integrated and TB/TBA/TT)
SPC Reference 3008046-0200

a) Remove the screws (1) and the gable plates (2).

b) Change the timing belts (3).
c) Assemble in the reverse order.

1
2

1 Screw (8 pieces)
2 Gable plate
3 Timing belt
.

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2 Conveyor Section 2.2 Belt Brake

2.2-3 Belt Brake - Change Timing Belt (TPA with

SD Integrated)
Machine Status
SPC Reference 3008046-0200

a) Remove the screws (1), the gable plate (2), and change the timing belt (3).
b) Loosen the screw (5) and remove the toothed pulley (4) and the gable plate (6).
c) Repeat item a) with the lower half of the belt brake (7) and then assemble it in
reverse order.
d) Set the height as described in Procedure 2.2-4 Belt Brake - Set on page 294.
e) Repeat with the second belt brake.

2
3

1 Screw (4 pieces) 5 Screw

2 Gable plate 6 Gable plate
3 Timing belt 7 Lower half of belt
4 Toothed pulley brake
.

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2.2 Belt Brake 2 Conveyor Section

2.2-4 Belt Brake - Set

SPC Reference 3008046-0200

a) Check that the notch (1) in the shaft (2) is aligned with the bracket (3).
b) To adjust the bracket (3), loosen the screws (4) and slide the bracket (3) into
position. Tighten the screws (4).

3
4
1
2
1 Notch
2 Shaft
3 Bracket
4 Screw (4 pieces)
.

(Cont’d)

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2 Conveyor Section 2.2 Belt Brake

(Cont’d)

c) Loosen the lock nut (5).

d) Put a package (6) on the conveyor, between belt brake (7) and belt brake (8).
e) Hold the lock nut (5) and adjust the distance between the belt brakes by turning
the adjusting screw (9). The belt brakes should touch the package.
f) Move the belt brakes approximately 2 mm closer together.
g) Tighten the lock nut (5).

6 8
7

9 5

5 Lock nut
6 Package
7 Belt brake
8 Belt brake
9 Adjusting screw
.

(Cont’d)

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2.2 Belt Brake 2 Conveyor Section

(Cont’d)

h) Loosen the nut (10).

i) Adjust the position of the belt brake (8) with the adjusting screw (11). The
package (6) should be aligned with the support rail (12).
j) Tighten the nut (10).
k) Loosen the screw (13). Set the distance A between the package (6) and the
support rail (14).
l) Run a few packages in the machine. Fine tune, if needed.

14 8 12
13

12

A
6

11 10 14

A ≈ 2 mm
6 Package 12 Support rail
8 Belt brake 13 Screw
10 Nut 14 Support rail
11 Adjusting screw
.

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2 Conveyor Section 2.2 Belt Brake

2.2-5 Belt Brake - Set Height (TPA with SD Integrated)

SPC Reference 3008046-0200

a) Put a package (1) on the conveyor, between the belt brakes (2) and (3).

3
1
2

1 Package
2 Belt brake
3 Belt brake
.

(Cont’d)

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2.2 Belt Brake 2 Conveyor Section

(Cont’d)

b) Remove the screws (4).

c) Remove the gable plate (5) and the timing belt (6).
d) Loosen the screw (7).
e) Move the toothed pulley (8) along the shaft (9) until it is aligned with the thickest
part of the package.
f) Assemble in the reverse order.
g) Repeat with the second belt brake.

4 Screw (4 pieces) 7 Screw

5 Gable plate 8 Toothed pulley
6 Timing belt 9 Shaft
.

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2 Conveyor Section 2.3 Adjustment Plate

2.3 Adjustment Plate

2.3-1 Adjustment Plate - No Procedure Described
SPC Reference 2829416-0400

Variants with SD integrated

Variants without SD integrated

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2.4 Top Support 2 Conveyor Section

2.4 Top Support

2.4-1 Top Support - Set Horizontal Position
SPC Reference 2924675-0500
3178238-0300

Note! Set the height of the top support first. See Procedure 2.5-1 Height
Adjustment - Set Height on page 308.
a) Loosen the clamping elements (1).
b) Put a package (2) after the belt brake, on the conveyor, so that it touches the
belt brake pulleys (3) with its corners.
c) Set the horizontal position of the top support so that it touches the package.
d) Tighten the clamping elements (1).
e) Note the value of the scale (4) for future reference.

1 3

3
2

1 Clamping element
2 Package
3 Pulley
4 Scale
.

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2 Conveyor Section 2.4 Top Support

2.4-2 Top Support - Set Lateral Position

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
Main air valve LOCKED in OFF position
SPC Reference 2924675-0500
3178238-0300

Note! Valid for use with TBA200E and TBA250E packages only.
a) Set the support rail. See Procedure 2.1.1-1 Support Rail - Set on page 288.
b) Set the belt brake. See Procedure 2.2-4 Belt Brake - Set on page 294.
c) Put a package (1) on the conveyor up to the inner support rail (2).
d) Loosen the screws (3).
e) Adjust the top support (4) until it touches the package at distance A. Adjust
upwards or downwards with the adjusting screw (5) and sideways by pulling and
pushing.
f) Make sure that both scales (6) show the same distance.
g) Tighten the screws (3).
h) Run a few packages in the machine. Fine tune if needed.
i) Make the final settings according to Procedure 3.3.3-7 Pressure Arm - Set
Override on page 368.

5
5

2
3 A
2 3

A = 5 to 6 mm
1 Package 4 Top support
2 Support rail 5 Adjusting screw
3 Screw 6 Scale
.

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2.4 Top Support 2 Conveyor Section

2.4.1 Support Belt

2.4.1-1 Support Belt - Check Timing Belt
SPC Reference 3178235-0200
3210324-0200

a) Check the timing belt (1) for visible cracks or damage. Change, if necessary.
See Procedure 2.4.1-2 Support Belt - Change Timing Belt on page 303.
b) Check the tension of the timing belt. Set the tension, if necessary. See
Procedure 2.4.1-3 Support Belt - Set Timing Belt Tension on page 304.

1 Timing belt
.

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2 Conveyor Section 2.4 Top Support

2.4.1-2 Support Belt - Change Timing Belt

SPC Reference 3178235-0200
3210324-0200

a) Loosen the screws (1) and the setting screw (2).

b) Change the timing belt (3).
c) Set the tension of the timing belt (3). See Item b) in Procedure 2.4.1-3 Support
Belt - Set Timing Belt Tension on page 304.
d) Tighten the screws (1).

1
2

1 Screw
2 Setting screw
3 Timing belt
.

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2.4 Top Support 2 Conveyor Section

2.4.1-3 Support Belt - Set Timing Belt Tension

SPC Reference 3178235-0200
3210324-0200

a) Loosen the screws (1).

b) Adjust the tension of the timing belt (2) with the setting screw (3). Set distance A
comprising the disc springs (4).
c) Tighten the screws (1).

1
3

A
4
3

A ≈ 20 mm
1 Screw
2 Timing belt
3 Setting screw
4 Disc spring (16 pieces)
.

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2 Conveyor Section 2.4 Top Support

2.4.2 Wheel
2.4.2-1 Wheel - Check Parts
SPC Reference 3187923-0200

a) Loosen the screws (2) and the setting screw (1).

b) Remove the timing belt (5).
c) Rotate the toothed pulley (4) and check if there is a play in the ball bearing (3).
Change, if necessary. See Procedure 2.4.2-2 Wheel - Change Parts on page
306.
d) Assemble the timing belt (5).
e) Set the tension of the timing belt (5). See Procedure 2.4.1-3 Support Belt - Set
Timing Belt Tension on page 304.

3
1 2

1 Setting screw
2 Screw
3 Ball bearing
4 Toothed pulley
5 Timing belt
.

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2.4 Top Support 2 Conveyor Section

2.4.2-2 Wheel - Change Parts

SPC Reference 3187923-0200

a) Loosen the screws (1) and the setting screw (2).

b) Remove the timing belt (3).
c) Loosen the screw (4) and remove the pulley (5) from the bracket (6).

4 5 6

1
2
1 Screw
2 Setting screw
3 Timing belt
4 Screw
5 Pulley
6 Bracket
.

(Cont’d)

306 (728) Doc. No. MM-3541840-0101

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2 Conveyor Section 2.4 Top Support

(Cont’d)

d) Use a screwdriver or compressed air to remove the seal cover (7).

e) Change the seal cover (7), the retaining rings (8) and the retaining ring (9), the
ball bearing (10), and the seal ring (11).
f) Assemble in the reverse order.
g) Set the timing belt tension. See Procedure 2.4.1-3 Support Belt - Set Timing Belt
Tension on page 304.

11
10 8
8 9
7
7 Seal cover
8 Retaining ring
9 Retaining ring
10 Ball bearing
11 Seal ring
.

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2.5 Height Adjustment 2 Conveyor Section

2.5 Height Adjustment

2.5-1 Height Adjustment - Set Height
SPC Reference 3178236-0300

a) Put a package (1) under the top support (2) for reference.
b) Adjust the top support upwards or downwards with the two synchronized
adjusting screws (3).
c) Set the height of the top support to the package height minus 1 to 2 mm.

3 3

1 2
1 Package
2 Top support
3 Adjusting screw
.

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2 Conveyor Section 2.5 Height Adjustment

2.5-2 Height Adjustment - Set in Parallel

SPC Reference 3178236-0300

a) Loosen the screws (2).

b) Turn the adjusting screw (1) halfway between its end positions.
c) Tighten the screws (2).
d) Put a package (4) on the conveyor in front of adjusting screw (3), as shown in
illustration.
e) Turn the adjusting screw (3) until the top support touches the package (4).
f) Put a package (5) on the conveyor in front of adjusting screw (1), as shown in
illustration. If the package does not fit, first perform step g).

1
2 2

1 3

5 4
1 Adjusting screw
2 Screw
3 Adjusting screw
4 Package
5 Package
.

(Cont’d)

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2.5 Height Adjustment 2 Conveyor Section

(Cont’d)

g) Loosen the screws (8).

h) Adjust with the screw (9) until the top support equally touches package (4) and
package (5).
i) Tighten the screws (8).
j) Loosen the screws (7) and adjust until the height adjustment unit is parallel with
the conveyor (6).
k) Tighten the screws (7).

7
7 6
5 Package
6 Conveyor
7 Screw (8 pieces)
8 Screw
9 Adjusting screw
.

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2 Conveyor Section 2.5 Height Adjustment

2.5-3 Height Adjustment - Change Timing Belt (with

SD Integrated)
SPC Reference 3178236-0300

a) Remove the screw (1) and the belt tensioner (2).

b) Loosen the screws (3).
c) Move two of the screws (3) to the threaded holes (4). Tighten the screws to
separate the clamping element (5) from the wheel (6).
d) Remove the clamping element (5) and the wheel (6) from the shaft (7).
e) Change the timing belt (8).
f) Assemble in the reverse order.
g) Adjust the slack with the belt tensioner (2).

4 7 4 6
1

3 2

5
8

1 Screw 5 Clamping element

2 Belt tensioner 6 Wheel
3 Screw (4 pieces) 7 Shaft
4 Threaded hole 8 Timing belt
.

2.5-4 Height Adjustment - Check Shock Absorber

SPC Reference 2929774-0400
3178236-0300

Check the shock absorber (1) for wear or damage. Check that the shock absorber is
damping the top support properly. See Procedure 2.5-6 Height Adjustment - Set
Shock Absorber on page 314. Change, if necessary. See Procedure 2.5-5 Height
Adjustment - Change Shock Absorber on page 313.
(Cont’d)

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2.5 Height Adjustment 2 Conveyor Section

(Cont’d)

1 Shock absorber

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2 Conveyor Section 2.5 Height Adjustment

2.5-5 Height Adjustment - Change Shock Absorber

SPC Reference 2929774-0400
3178236-0300

a) Use the handle (1) to move the top support (2) out of the way.
b) Remove the nut (3).
c) Pull the shock absorber (4) downwards through the hole.
d) Change the shock absorber.
e) Assemble in the reverse order.

1
3

1 Handle
2 Top support
3 Nut
4 Shock absorber
.

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2.5 Height Adjustment 2 Conveyor Section

2.5-6 Height Adjustment - Set Shock Absorber

SPC Reference 2929774-0400
3178236-0300

a) Use the handle (5) to move the top support (4) out of the way.
b) Set the adjusting screw (3) as described in Procedure 2.5-7 Height Adjustment
- Set Adjusting Screw on page 315.
c) Loosen the nuts (1) to adjust the height of the shock absorber (2). Set distance
A with the end knob (6) fully compressed.

5
1 2 3
A

6
A = 1 to 2 mm
1 Nut 4 Top support
2 Shock absorber 5 Handle
3 Adjusting screw 6 End knob
.

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2 Conveyor Section 2.5 Height Adjustment

2.5-7 Height Adjustment - Set Adjusting Screw

SPC Reference 2929774-0400
3178236-0300

a) Use the handle (2) to move the top support (1) out of the way.
b) Adjust the height of the adjusting screw (5) with the nuts (4) until the top
support (1) and the feed wheel (3) are in parallel at A. The angle B towards the
horizontal plane should be approximately 10°.

4
A
1
3
B

A = 0°
B ≈ 10°
1 Top support
2 Handle
3 Feed wheel
4 Nut
5 Adjusting screw
.

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2.5 Height Adjustment 2 Conveyor Section

2.5-8 Height Adjustment - Check Cylinder

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2929774-0400
3178236-0300

a) Check that the cylinder (1) works properly. Change if necessary. See Procedure
2.5-9 Height Adjustment - Change Cylinder on page 317.

1 Cylinder
.

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2 Conveyor Section 2.5 Height Adjustment

2.5-9 Height Adjustment - Change Cylinder

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2929774-0400
3178236-0300

a) Disconnect the air supply (1) from the throttle check valve (2).
b) Remove the proximity sensor (3) from the cylinder (4).
c) Remove the silencer (5) from the cylinder (4).

5
3

1 2
1 Air supply 3 Proximity sensor
2 Throttle check valve 4 Cylinder
5 Silencer
.

(Cont’d)

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2.5 Height Adjustment 2 Conveyor Section

(Cont’d)

d) Remove the screws (6) on the bracket pivot mount (7).

e) Unscrew the rod end (8), and move the cylinder (4) to a workbench.

4 Cylinder 7 Pivot mount

6 Screw 8 Rod end
.

(Cont’d)

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2 Conveyor Section 2.5 Height Adjustment

(Cont’d)

f) Remove the screws (9), and remove the cylinder (4) from the bracket pivot
mount (7).
g) Remove the screw (10) and remove the clamping ring (11).
h) Change the cylinder (4) and assemble in the reverse order.
Note! Make sure that the proximity sensor (3) is placed identically to the old
cylinder.
i) Set the proximity sensor (3). See Section 1.1.7-1 Control Devices and Sensors -
Set Proximity Sensor on page 143.

11

10

9
3 Proximity sensor 9 Screw
4 Cylinder 10 Screw
7 Pivot mount 11 Clamping ring
.

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2.6 Photocell Unit 2 Conveyor Section

2.6 Photocell Unit

2.6-1 Photocell Unit - No Procedure Described
SPC Reference 2943553-0200

To be placed directly on upstream DE controlled conveyor. It is used to start the

infeed conveyor.

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2 Conveyor Section 2.7 Second Discharge Unit

2.7 Second Discharge Unit

2.7-1 Second Discharge Unit - No Procedure Described
SPC Reference 3088860-0200

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2.8 Encoder 2 Conveyor Section

2.8 Encoder
2.8-1 CIP Sync Encoder - Set IP Address
Machine Status Electrical supply disconnecting device in position I
(ON)
Program Step IDLE
SPC Reference 3413844-0100

Note! To set the last octet of the IP address (192.168.1.xxx) use the network
address switches on the encoder (1).
Note! CIP = Common Industrial Protocol
a) Set the three network address switches to 999 on the encoder (1).

x10

x100 x1

b) Cycle power to the encoder (1).

c) Set the three address switches according to table 10.6 IP Addresses.

x10

x100 x1

d) Cycle power to the encoder (1).

e) The encoder (1) will power up to with the correct IP address.

1
1 Encoder
.

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 3 Applicator Unit

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 3 Applicator Unit

Description
SPC Reference 663301-0500

1
3
7

9
2

5 4
1 Feed wheel unit 4 Frame 7 Spring holder
2 Cutting unit 5 Ladder band guide 8 Crankshaft
3 Squeezer 6 Guide console 9 Guide arm

(Cont’d)

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3 Applicator Unit

(Cont’d)

6
1
3
5
7

9 2

4
Valid for: OK Straw Quality Improvement 3503674-0100
1 Feed wheel unit 4 Frame 7 Spring holder
2 Cutting unit 5 Ladder band guide 8 Crankshaft
3 Squeezer 6 Guide console 9 Guide arm

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Table of Contents 3 Applicator Unit

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
3-1 Applicator Unit - Check . . . . . . . . . . . . . . . . . . . . . . . . . . 329
3-2 Applicator Unit - Set Angle . . . . . . . . . . . . . . . . . . . . . . . 330
3-3 Applicator Unit - Set Height and Straw
Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .331

3.1 Feed Wheel Unit ................................................ 333

3.1-1 Feed Wheel Unit - Check Ball Bearings . . . . . . . . . . . 333
3.1-2 Feed Wheel Unit - Change Ball Bearings . . . . . . . . . . 333
3.1-3 Feed Wheel Unit - Set . . . . . . . . . . . . . . . . . . . . . . . . . . . 338

3.1.1 Feed Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340

3.1.1-1 Feed Wheel - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
3.1.1-2 Feed Wheel - Change . . . . . . . . . . . . . . . . . . . . . . . . . . . 341

3.2 Cutting Unit...................................................... 344

3.2-1 Cutting Unit - Check Parts . . . . . . . . . . . . . . . . . . . . . . . 344
3.2-2 Cutting Unit - Change Parts . . . . . . . . . . . . . . . . . . . . . . 347

3.3 Squeezer ......................................................... 348

3.3.1 Crank Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
3.3.1-1 Crank Housing - Check Parts (TB/TBA) . . . . . . . . . . . 348
3.3.1-2 Crank Housing - Change Parts (TB/TBA). . . . . . . . . . 349
3.3.1-3 Crank Housing - Check Parts (TPA/TT) . . . . . . . . . . . 356
3.3.1-4 Crank Housing - Change Parts (TPA/TT) . . . . . . . . . . 357

3.3.2 Drive Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361

3.3.2-1 Drive Motor - No Procedure Described . . . . . . . . . . . 361

3.3.3 Pressure Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362

3.3.3-1 Pressure Arm - Check Parts (TB/TBA) . . . . . . . . . . . . 362
3.3.3-2 Pressure Arm - Change Parts (TB/TBA). . . . . . . . . . . 363
3.3.3-3 Pressure Arm - Set Height (TB/TBA) . . . . . . . . . . . . . . 364
3.3.3-4 Pressure Arm - Check Parts (TPA/TT) . . . . . . . . . . . . 365
3.3.3-5 Pressure Arm - Change Parts (TPA/TT) . . . . . . . . . . . 366
3.3.3-6 Pressure Arm - Set Height (TPA/TT) . . . . . . . . . . . . . . 367
3.3.3-7 Pressure Arm - Set Override . . . . . . . . . . . . . . . . . . . . . 368

3.4 Frame ............................................................. 372

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3 Applicator Unit Table of Contents

3.4.1 Frame Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372

3.4.1-1 Frame Housing - Check Timing Belt . . . . . . . . . . . . . . 372
3.4.1-2 Frame Housing - Change Timing Belt . . . . . . . . . . . . . 375

3.4.2 Belt Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379

3.4.2-1 Belt Tensioner - Check Parts . . . . . . . . . . . . . . . . . . . . . 379
3.4.2-2 Belt Tensioner - Change Parts. . . . . . . . . . . . . . . . . . . . 385
3.4.3 Drive Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
3.4.3-1 Drive Motor - Change Ball Bearing. . . . . . . . . . . . . . . . 387

3.4.4 Axle Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388

3.4.4-1 Axle Support - Change Ball Bearing . . . . . . . . . . . . . . 388

3.5 Ladder Band Guide ............................................ 389

3.5-1 Ladder Band Guide - Set . . . . . . . . . . . . . . . . . . . . . . . . 389
3.5-2 Ladder Band Guide - Change End Section and
Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .391

3.6 Guide Console .................................................. 393

3.6-1 Guide Console - Change Guide Arms . . . . . . . . . . . . . 393
3.6-2 Guide Console - Set Gun Holder . . . . . . . . . . . . . . . . . 395

3.7 Spring Holder ................................................... 398

3.7-1 Spring Holder - Check Parts . . . . . . . . . . . . . . . . . . . . . 398
3.7-2 Spring Holder - Change Compression
Springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .398
3.7-3 Spring Holder - Change Leaf Spring . . . . . . . . . . . . . . 401
3.7-4 Spring Holder - Set Leaf Spring . . . . . . . . . . . . . . . . . . 403

3.8 Crank Shaft ...................................................... 404

3.8-1 Crank Shaft - Check Parts . . . . . . . . . . . . . . . . . . . . . . . 404
3.8-2 Crank Shaft - Change Parts . . . . . . . . . . . . . . . . . . . . . . 410

3.9 Guide Arm ....................................................... 413

3.9-1 Guide Arm - No Procedure Described (TPA
without SD Integrated and TB/TBA/TT) . . . . . . . . . . . .413
3.9-2 Guide Arm - Set (TPA with SD Integrated) . . . . . . . . . 414

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Table of Contents 3 Applicator Unit

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3 Applicator Unit 3-1 Applicator Unit - Check

3-1 Applicator Unit - Check

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 663301-0500

Check the resistance in the applicator unit by turning the stellar knob (1) to the left,
as indicated in the illustrations below. It should be possible to turn it by hand without
any difficulties.

1 Stellar knob
.

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3-2 Applicator Unit - Set Angle 3 Applicator Unit

3-2 Applicator Unit - Set Angle

Machine Status Program Step PREHEATING
SPC Reference 663301-0500

Note! This is only a guideline setting. For finer adjustment of the straw angle,
operate the machine and run packages through the machine. Check the angle and
adjust accordingly.
Note! Check the mechanical settings match the settings in the recipe.
a) Loosen the screw (1), and turn the applicator unit to the angle chosen in the
recipe on the TPOP. Use the scale (2) to set the value.
b) Tighten the screw (1).

1 2

1 Screw
2 Scale
.

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 3-3 Applicator Unit - Set Height and
3 Applicator Unit Straw Position

3-3 Applicator Unit - Set Height and Straw Position

Machine Status Program Step PREHEATING
SPC Reference 663301-0500

Note! This is only a guideline setting. For finer adjustments of the straw height,
operate the machine and run packages through the machine. Check the height and
adjust accordingly.
a) Set the height of the straw position on the package by turning the adjusting
screw (2). Use the scale (1) for reference.
b) If possible, set the height of the straw so that the straw foil does not go outside
the package bottom.

2
1

1 Scale
2 Screw
.

(Cont’d)

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3-3 Applicator Unit - Set Height and
Straw Position 3 Applicator Unit

(Cont’d)

c) The height distance Y is recommended to be the same at the top and at the
bottom of the package. See (3) and (4) in the illustration below (TB/TBA/TPA).
d) To adjust the horizontal distance X of the straw, use the Straw Position function
on the TPOP. See Section 2.8 Setting Menu in the Operation Manual specific
for the machine. The distance X is recommended to be the same on both sides
of the straw. See (3) and (4) in the illustration below (TB/TBA/TPA).
e) For Tetra Top (TT), the straw should be positioned in the middle of the rounded
part of the corner. See (5) in the illustration below.

X
3 4 5

X Y

Y Y

X X
3 TB/TBA
4 TPA
5 TT
.

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3 Applicator Unit 3.1 Feed Wheel Unit

3.1 Feed Wheel Unit

3.1-1 Feed Wheel Unit - Check Ball Bearings
Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
Main air valve LOCKED in OFF position
SPC Reference 2929773-0300

Note! Check the cutting unit first. See Procedure 3.2-1 Cutting Unit - Check Parts
on page 344. Continue with the crankshaft. See Procedure 3.8-1 Crank Shaft -
Check Parts on page 404.
a) Remove the feed wheel as described in item a) to d) in Procedure 3.1-2 Feed
Wheel Unit - Change Ball Bearings on page 333.
b) Toggle the arm (1) back and forth and check for play in the ball bearings (2).
Change, if necessary. See Procedure 3.1-2 Feed Wheel Unit - Change Ball
Bearings on page 333.
c) Assemble in the reverse order.

2
1 Arm
2 Ball bearing
.

3.1-2 Feed Wheel Unit - Change Ball Bearings

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
Main air valve LOCKED in OFF position
Special Equipment Template TP No. 3166869
SPC Reference 2929773-0300

To change the ball bearings (1), proceed as follows:

(Cont’d)

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3.1 Feed Wheel Unit 3 Applicator Unit

(Cont’d)

a) Turn the bearing housing (2) to move the arms (3) to a position outside the feed
wheel slots.
b) Turn the stellar knob (4) until the knife (5) is in position outside the feed wheel.
c) Turn the stellar knob (6) to the left until the feed wheel (7) is released from the
shaft.
d) Press the leaf spring (8) outwards from the feed wheel (7) and pull up the feed
wheel.

6
7

1 4

8 3 2
1 Ball bearing 4 Stellar knob 7 Feed wheel
2 Bearing housing 5 Knife 8 Leaf spring
3 Arm 6 Stellar knob
.

(Cont’d)

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3 Applicator Unit 3.1 Feed Wheel Unit

(Cont’d)

e) Remove the screws (9) and (10), and remove the guide (11).
f) Assemble the template (12) and remove the screw (13).
g) Remove the template (12). Remove the screw (14).
h) Lift up the axle pin (15) from the eccentric (16).

i) CAUTION
Risk of personal injury.
The knife is very sharp. Be careful when working near the knife.
Remove the knife holding unit (17).

17
13
15
11
16

10
12
14

9 Screw 12 Template 15 Axle pin

10 Screw 13 Screw 16 Eccentric
11 Guide 14 Screw 17 Knife holding unit
.

(Cont’d)

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3.1 Feed Wheel Unit 3 Applicator Unit

(Cont’d)

j) Remove the screw (18) and the guide console (19).

19

18

18 Screw
19 Guide console
.

(Cont’d)

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3 Applicator Unit 3.1 Feed Wheel Unit

(Cont’d)

k) Remove the axle bolt (20) and the retaining ring (21).
l) Pull up the arm (22) from the shaft (23).
m) Use a puller to pull out the ball bearings (1).
n) Press in the new ball bearings.
o) Assemble in the reverse order.

23

1
20

21

22
1

1 Ball bearing
20 Axle bolt
21 Retaining ring
22 Arm
23 Shaft
.

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Doc. No. MM-3541840-0101 337 (728)
3.1 Feed Wheel Unit 3 Applicator Unit

3.1-3 Feed Wheel Unit - Set

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
Special Equipment Template TP No. 3166869
SPC Reference 2929773-0300

a) Loosen the screws (1).

b) Turn the stellar knob (2) to set the knife (3) into the feed wheel slot. If the knife
does not fit in the feed wheel slot, turn the feed wheel (4) until the knife fits.
c) Fit the template (5).

1 3

2
1 Screw 4 Feed wheel
2 Stellar knob 5 Template
3 Knife
.

(Cont’d)

338 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.1 Feed Wheel Unit

(Cont’d)

d) Adjust the feed wheel (4) so that the knife (3) is in the centre of the feed wheel
slot.
e) Tighten the screws (1).
f) Remove the template (5).
g) Turn the stellar knob (2). Check that the knife moves without touching the slot
edges.
h) Set the pick position. See Procedure 1.2.2.6-2 Maintenance - Set Pick Position
on page 249.

1 3

2
1 Screw 4 Feed wheel
2 Stellar knob 5 Template
3 Knife
.

®
Doc. No. MM-3541840-0101 339 (728)
3.1 Feed Wheel Unit 3 Applicator Unit

3.1.1 Feed Wheel

3.1.1-1 Feed Wheel - Check
Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2829443-0100
3503684-0100 (Valid for: OK Straw Quality
Improvement 3503674-0100)

a) Check the coating of the feed wheel (1). If less than 50% of the coating
remains, change the feed wheel (1). See Procedure 3.1.1-2 Feed Wheel -
Change on page 341.

1 Feed wheel
.

340 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.1 Feed Wheel Unit

3.1.1-2 Feed Wheel - Change

Special Equipment Template TP No. 3166869
SPC Reference 2829443-0100
3503684-0100 (Valid for: OK Straw Quality
Improvement 3503674-0100)

a) Turn the bearing housing (6) to move the arms (7) to a position outside the feed
wheel slots.
b) Turn the stellar knob (9) until the knife (2) is in position outside the feed wheel.
c) Fit the template (1).
d) Loosen the screws (4).
e) Turn the stellar knob (3) to the left until the feed wheel (5) is released from the
shaft.
f) Press the leaf spring (8) outwards from the wheel and pull up the feed wheel.

3
2 4 5

1
6

9 8
7
1 Template 4 Screw 7 Arm
2 Knife 5 Feed wheel 8 Leaf spring
3 Stellar knob 6 Bearing housing 9 Stellar knob
.

(Cont’d)

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Doc. No. MM-3541840-0101 341 (728)
3.1 Feed Wheel Unit 3 Applicator Unit

(Cont’d)

g) Remove the screws (4) and pull out the centre parts from the feed wheel.
h) Lift the centre parts into the new feed wheel and fit the screws (4) in position.
Tighten the screws loosely by hand.
i) Lift the feed wheel unit back into the machine.

4 Screw
.

(Cont’d)

342 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.1 Feed Wheel Unit

(Cont’d)

j) Tighten the stellar knob (3) until the feed wheel (5) fits in its correct position.
k) Adjust the feed wheel so that the knife (2) is in the centre of the slot.
l) Fit the template (1).
m) Tighten the screws (4) and remove the template (1).
n) Turn the feed wheel by hand to check that the knife moves without touching the
slot edges. Use the stellar knob (9).
o) Adjust the arms (7). See Procedure 3.2-1 Cutting Unit - Check Parts on page
344.

3
4 5

9
7
1 Template 5 Feed wheel
2 Knife 7 Arm
3 Stellar knob 9 Stellar knob
4 Screw
.

®
Doc. No. MM-3541840-0101 343 (728)
3.2 Cutting Unit 3 Applicator Unit

3.2 Cutting Unit

3.2-1 Cutting Unit - Check Parts
Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
Special Equipment Template TP No. 3166869
SPC Reference 2829431-0400
3503684-0100 (Valid for: OK Straw Quality
Improvement 3503674-0100)

CAUTION
Risk of personal injury.
The knife is very sharp. Be careful when working near the knife.
a) Check that the knife cuts the straws satisfactorily. If not, turn the stellar knob (1)
until the knife (2) is in position outside the feed wheel.
b) Assemble the template (3).
c) Remove the screw (4).

1
1 Stellar knob
2 Knife
3 Template
4 Screw
.

(Cont’d)

344 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.2 Cutting Unit

(Cont’d)

d) Remove the template (3) and remove the screw (5).

e) Remove the knife unit (6).
f) Check the knife (2) for wear or damage. Change, if necessary.
g) Remove the screw (7) and remove the knife (2).
h) Remove the screws (8) and (9) and the guide (10).
i) Check the side steerings (11) for wear or damage. Change, if necessary.

2
8
10 6

11
9
5

2 Knife 8 Screw
3 Template 9 Screw
5 Screw 10 Guide
6 Knife unit 11 Side steering
7 Screw (4 pieces)
.

(Cont’d)

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Doc. No. MM-3541840-0101 345 (728)
3.2 Cutting Unit 3 Applicator Unit

(Cont’d)

j) Remove the screws (12) and the bracket (13).

k) Check the bearing bushings (14) and (15), the shaft (16) and the axle pin (17)
for wear or damage. Change, if necessary.
l) Assemble in the reverse order.

12
13

15

16

17

14
12 Screw (3 pieces)
13 Bracket
14 Bearing bushing
15 Bearing bushing
16 Shaft
17 Axle pin
.

346 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.2 Cutting Unit

3.2-2 Cutting Unit - Change Parts

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
Consumables Mist lubrication oil
SPC Reference 2829431-0400
3503685-0100 (Valid for: OK Straw Quality
Improvement 3503674-0100)

CAUTION
Risk of personal injury.
The knife is very sharp. Be careful when working near the knife.
a) Perform item a) to j) in Procedure 3.2-1 Cutting Unit - Check Parts on page 344.
b) Change the knife (1), the bearing bushings (2) and (3), the shaft (4), the axle
pin (5), and the side steerings (6).
c) Apply a drop of oil between the shaft (4) and the bearing bushings (2). Use the
lubricant described in Section 10.4.2 Lubricants on page 601.
d) Assemble in the reverse order.

1 4

3
6

1 Knife
2 Bearing bushing
3 Bearing bushing
4 Shaft
5 Axle pin
6 Side steering
(4 pieces)
.

®
Doc. No. MM-3541840-0101 347 (728)
3.3 Squeezer 3 Applicator Unit

3.3 Squeezer
3.3.1 Crank Housing
3.3.1-1 Crank Housing - Check Parts (TB/TBA)
SPC Reference 2829432-0200

a) Hold the bearing housing (1) with one hand and rotate the gear wheel (2) with
the other. Check that the bearing housing moves smoothly and silent.
b) If not, the ball bearings need changing. See Procedure 3.3.1-2 Crank Housing -
Change Parts (TB/TBA) on page 349.

1 Bearing housing
2 Gear wheel
.

348 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.3 Squeezer

3.3.1-2 Crank Housing - Change Parts (TB/TBA)

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
Special Equipment Template TP No. 3013617
Dynamometric wrench
SPC Reference 2829432-0200

a) Turn the bearing housing (1) to move the arms (2) to a position outside the feed
wheel slots.
b) Remove the screws (3) and remove the pressure arm (4).

4
2
3

3
1

1 Bearing housing
2 Arm
3 Screw
4 Pressure arm
.

(Cont’d)

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Doc. No. MM-3541840-0101 349 (728)
3.3 Squeezer 3 Applicator Unit

(Cont’d)

c) CAUTION
Possible machine damage
At reassembly, tighten the screws (5) with a torque of 5 Nm. At the
recommended torque, the top of the screws (5) is approximately levelled with
the recess (distance A).
Loosen the screws (5) and remove the clamping elements (6).
d) Remove the gear wheels (7).

7 6 5
A ≈ 0 mm
5 Screw
6 Clamping element
7 Gear wheel
.

e) Use a pair of 90º bent internal retaining ring pliers to loosen the retaining
rings (8) and remove the bearing housing.

8 Retaining ring
.

(Cont’d)

350 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.3 Squeezer

(Cont’d)

f) Change the O-ring (9).

9 O-ring
.

g) Remove the retaining ring (10).

h) CAUTION
Risk of damage to equipment.
Use a puller to remove the ball bearings.
Remove the ball bearing (11) from the crank shaft (12).
i) Remove the retaining ring (13).
j) Remove the ball bearing (14) from the rocker arm (15).

10
11 12
14 13

15

10 Retaining ring
11 Ball bearing
12 Crank shaft
13 Retaining ring
14 Ball bearing
15 Rocker arm
.

(Cont’d)

®
Doc. No. MM-3541840-0101 351 (728)
3.3 Squeezer 3 Applicator Unit

(Cont’d)

k) Remove the retaining rings (16) and (17).

l) Remove the ball bearing (18).

16
17
18

16 Retaining ring
17 Retaining ring
18 Ball bearing
.

(Cont’d)

352 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.3 Squeezer

(Cont’d)

m) Remove the screw (19) and the switch bracket (20).

n) Remove the screws (21) from the bearing sleeve (22).
o) Remove the screws (23) from the bearing sleeve (24).

23

21

24

22
20
19
19 Screw
20 Switch bracket
21 Screw
22 Bearing sleeve
23 Screw
24 Bearing sleeve
.

p) Remove the nuts (25).

q) Remove the locking washers (26).

26

25

25 Nut
26 Locking washer
.

(Cont’d)

®
Doc. No. MM-3541840-0101 353 (728)
3.3 Squeezer 3 Applicator Unit

(Cont’d)

r) Press out the crank shafts (27).

s) Remove the ball bearings (28) and the sleeves (29) from the bearing
sleeve (22) and bearing sleeve (24).

24 29

22 28

27
22 Bearing sleeve
24 Bearing sleeve
27 Crank shaft
28 Ball bearing (2 pieces)
29 Sleeve
.

t) Remove the sealing rings (30) from each bearing sleeve.

u) Remove the retaining rings (31).
v) Remove the ball bearings (32).

30
31
32

30 Sealing ring (2 pieces)

31 Retaining ring
(2 pieces)
32 Ball bearing (2 pieces)
.

(Cont’d)

354 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.3 Squeezer

(Cont’d)

CAUTION
Risk of damage to equipment.
The ball bearings must be pressed onto the shafts. Use appropriate equipment.
w) Change all worn parts and assemble in reverse order.
Note! At reassembly, use the template (33) for guidance, then tighten the
clamping elements (6).

33
6
6 Clamping element
33 Template

®
Doc. No. MM-3541840-0101 355 (728)
3.3 Squeezer 3 Applicator Unit

3.3.1-3 Crank Housing - Check Parts (TPA/TT)

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2952607-0200

a) Rotate the bearing housing (1) by hand and check that it moves smoothly and
silent.
b) If not, the ball bearings needs changing. See Procedure 3.3.1-4 Crank Housing
- Change Parts (TPA/TT) on page 357.

1 Bearing housing
.

356 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.3 Squeezer

3.3.1-4 Crank Housing - Change Parts (TPA/TT)

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2952607-0200

a) Turn the bearing housing (1) to move the arms (2) to a position outside the feed
wheel slots.
b) Remove the screws (3) and remove the pressure arm (4).
c) Use a pair of 90º bent internal retaining ring pliers to loosen the retaining
rings (5) and remove the bearing housing (1).

4
3

2 1
2
3
5

1 Bearing housing
2 Arm
3 Screw
4 Pressure arm
5 Retaining ring
.

(Cont’d)

®
Doc. No. MM-3541840-0101 357 (728)
3.3 Squeezer 3 Applicator Unit

(Cont’d)

d) Remove the retaining ring (6) and pull up the ball bearing (7) from the crank
shaft (8).
e) Pull up the ball bearing (9) from the rocker arm (10).

6
7 8
9

10

6 Retaining ring
7 Ball bearing
8 Crank shaft
9 Ball bearing
10 Rocker arm
.

f) Remove the retaining rings (11) and (12).

g) Pull up the ball bearing (13) from the crank shaft.
h) Remove the screws (14) from the bearing sleeve (15).

11
13
12

14
15

11 Retaining ring
12 Retaining ring
13 Ball bearing
14 Screw
15 Bearing sleeve
.

(Cont’d)

358 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.3 Squeezer

(Cont’d)

i) Remove the nut (16) and the lock washer (17).

j) Remove the rocker arm (10) from the bearing sleeve (15) by pressing up the
rocker arm shaft (18).

10 10

15
15 17
18
16
10 Rocker arm
15 Bearing sleeve
16 Nut
17 Lock washer
18 Shaft
.

k) Remove the ball bearing (19) and the sleeve (20) from the bearing sleeve (15).

15

19 20

15 Bearing sleeve
19 Ball bearing
20 Sleeve
.

(Cont’d)

®
Doc. No. MM-3541840-0101 359 (728)
3.3 Squeezer 3 Applicator Unit

(Cont’d)

l) Remove the sealing ring (21) from the bearing sleeve (15).
m) Remove the retaining ring (22) and remove the ball bearing (23).

21 22

23

15

15 Bearing sleeve
21 Sealing ring
22 Retaining ring
23 Ball bearing
.

n) CAUTION
Risk of damage to equipment.
The ball bearings must be pressed onto the shafts. Use appropriate equipment.
Change all worn parts and assemble in the reverse order. The illustration below
shows an exploded view of the bearing sleeve.

21
22
23
24
20
19
15

15 Bearing sleeve 22 Retaining ring

19 Ball bearing 23 Ball bearing
20 Sleeve 24 Retaining ring
21 Sealing ring
.

360 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.3 Squeezer

3.3.2 Drive Motor

3.3.2-1 Drive Motor - No Procedure Described
SPC Reference 2829439-0400 valid for TB/TBA
2983879-0400 valid for TPA/TT

TB/TBA TPA/TT

®
Doc. No. MM-3541840-0101 361 (728)
3.3 Squeezer 3 Applicator Unit

3.3.3 Pressure Arm

3.3.3-1 Pressure Arm - Check Parts (TB/TBA)
Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 3013387-0200
3503682-0100

a) Turn the bearing housing (1) to move the arms (2) to a position outside the feed
wheel slots.
b) Remove the arms (2) by removing the screws (3).
c) Remove the screws (4).
d) Check the flange bushings (5), the compression springs (6), and the
brackets (7) for wear or damage. Change, if necessary. See Procedure 3.3.3-2
Pressure Arm - Change Parts (TB/TBA) on page 363.
e) Assemble the parts. See item c) to e) in Procedure 3.3.3-3 Pressure Arm - Set
Height (TB/TBA) on page 364.

7
5
2
6

5
1 2 3 4
Valid for: 3013387-0200

7
5
2
6

5
1 2 3 4
Valid for: 3503682-0100 (OK Straw Quality Improvement 3503674-0100)
1 Bearing housing 4 Screw (2 pieces) 6 Compression spring
2 Arm 5 Flange bushing (2 pieces)
3 Screw (4 pieces) 7 Bracket
.

362 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.3 Squeezer

3.3.3-2 Pressure Arm - Change Parts (TB/TBA)

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 3013387-0200
3503682-0100

a) Turn the bearing housing (1) to move the arms (2) to a position outside the feed
wheel slots.
b) Remove the arms (2) by removing the screws (3).
c) Remove the screws (4) from the bracket (7).
d) Use a screwdriver or a similar tool to remove the old flange bushings (5).
e) Press in the new flange bushings in the pressure arms.
f) Replace the compression springs (6) with new ones.
g) Assemble in the reverse order.
h) Do not tighten the screws (4) too hard; the arms (2) must be able to spring.

7
5
2
6

5
1 2 3 4
Valid for: 3013387-0200

7
5
2
6

5
1 2 3 4
Valid for: 3503682-0100 (OK Straw Quality Improvement 3503674-0100)
1 Bearing housing 4 Screw (2 pieces) 6 Compression spring
2 Arm 5 Flange bushing (2 pieces)
3 Screw (4 pieces) 7 Bracket (2 pieces)
.

®
Doc. No. MM-3541840-0101 363 (728)
3.3 Squeezer 3 Applicator Unit

3.3.3-3 Pressure Arm - Set Height (TB/TBA)

SPC Reference 3013387-0200
3503682-0100 (Valid for: OK Straw Quality
Improvement)

a) Turn the bearing housing (1) to move the arms (2) to a position outside the feed
wheel slots.
b) Loosen the screws (3).
c) Set the height of the arms according to the table and illustration below.
d) Tighten the screws (3).
e) Turn the bearing housing (1) a few revolutions to check that the arms can move
without touching the sides of the feed wheel.

Straw type Top to the left Top to the right

U straw A = B, C = D B = 1 to 2 mm, C = D
S straw A = B, C = D A = B, C = D
T straw A = B, C = D A = B, C = 1 to 2 mm
A

2 3
B

1
C

1 Bearing housing
2 Arm
3 Screw
.

364 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.3 Squeezer

3.3.3-4 Pressure Arm - Check Parts (TPA/TT)

SPC Reference 3013886-0200

a) Turn the bearing housing (1) to move the arms (2) to a position outside the feed
wheel slots.
b) Remove the arms (2) by removing the screws (3).
c) Remove the screws (4) and check the flange bushings (5), the springs (6), and
the brackets (7) for wear and damage. Change, if necessary.
d) Assemble in the reverse order.
e) Do not tighten the screws (4) too hard; the arms (2) must be able to spring.

7
5
2
2 3
6

5
1 4
1 Bearing housing
2 Arm
3 Screw
4 Screw
5 Flange bushing
6 Spring
7 Bracket
.

®
Doc. No. MM-3541840-0101 365 (728)
3.3 Squeezer 3 Applicator Unit

3.3.3-5 Pressure Arm - Change Parts (TPA/TT)

SPC Reference 3013886-0200

a) Turn the bearing housing (1) to move the arms (2) to a position outside the feed
wheel slots.
b) Remove the arms (2) by removing the screws (3).
c) Remove the screws (4).
d) Use a screwdriver or a similar tool to remove the old flange bushing (5).
e) Press in the new flange bushings in the pressure arms.
f) Replace the compression springs (6) with new ones.
g) Replace the brackets (7) with new ones.
h) Assemble in the reverse order.
i) Do not tighten the screws (4) too hard; the arms (2) must be able to spring.

7
5
2
2 3
6

5
1 4
1 Bearing housing
2 Arm
3 Screw
4 Screw (2 pieces)
5 Flange bushing
6 Spring
7 Bracket
.

366 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.3 Squeezer

3.3.3-6 Pressure Arm - Set Height (TPA/TT)

Machine Status
SPC Reference 3013886-0200

a) Turn the bearing housing (1) to move the arms (2) to a position outside the feed
wheel slots.
b) Adjust the height of the arms with the screws (3). Set the height of the arms in
the centre of the feed wheel slots.
c) Tighten the screws (3).
d) Turn the bearing housing (1) a few revolutions to check that the arms can move
without touching the sides of the feed wheel.

2 3

1
1 Bearing housing
2 Arm
3 Screw
.

®
Doc. No. MM-3541840-0101 367 (728)
3.3 Squeezer 3 Applicator Unit

3.3.3-7 Pressure Arm - Set Override

Machine Status Electrical supply disconnecting device in position I
(ON)
Special Equipment Template TP No. 3013391-0100 for TB/TBA
Template TP No. 3013902-0100 for TPA/TT
SPC Reference 3013387-0200 valid for TB/TBA
3013886-0200 valid for TPA/TT

a) Attach the lever (1) to the upper arm (2) by using the screw (3) and the
washer (4).

3 1 3
2 2
1

4
4

TB/TBA TPA/TT
1 Lever
2 Arm
3 Screw
4 Washer
.

(Cont’d)

368 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.3 Squeezer

(Cont’d)

b) Attach the pre-assembled template (5) onto the bearing housing (6). Use the
screw (7) to fixate the template.

5 5

6 6

7 7
TB/TBA TPA/TT
5 Template
6 Bearing housing
7 Screw
.

(Cont’d)

®
Doc. No. MM-3541840-0101 369 (728)
3.3 Squeezer 3 Applicator Unit

(Cont’d)

c) Loosen the screw (8) to adjust the height of the pin (9).
d) Tighten the screw (8) when the lever (1) and the pin (9) are at the same height.
e) Move the pin (9) until it touches the lever (1).
f) Loosen the screw (10) and move the scale (11) until it is aligned with the pin (9).
g) Tighten the screw (10) and make sure that the screw (12) is not tightened.
h) Run a few packages at low speed.
i) Check the maximum override on the scale (11).
j) Repeat item h) to i) a few times to get an average override.
k) Remove the lever and the template.

10 12
9 11

11
8

1
9 1
TB/TBA

10 12 11

9
1

TPA/TT
1 Lever 10 Screw
8 Screw 11 Scale
9 Pin 12 Screw
.

(Cont’d)

370 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.3 Squeezer

(Cont’d)

l) Crank the adjustment plate with the shaft (13) to set the measured override.
Check the scale (14) at the plate (15) and adjust accordingly. The override
should be 2 ±1 mm.
Note! To be able to increase the override even further, the insulating plate
needs to be removed. See Procedure 3.6-2 Guide Console - Set Gun Holder.

15 14 13
13 Shaft
14 Scale
15 Plate
.

®
Doc. No. MM-3541840-0101 371 (728)
3.4 Frame 3 Applicator Unit

3.4 Frame
3.4.1 Frame Housing
3.4.1-1 Frame Housing - Check Timing Belt
Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
Special Equipment Hook Spanner TP No. 90243-0164
Template TP No. 3166869-0000
SPC Reference 2829433-0400

WARNING
Burn Hazard.
The hotmelt unit can be very hot and there is risk of severe burns. Use caution when
working near the hotmelt unit.
a) Turn the stellar knob (1) to move the knife (3) to a position inside the feed
wheel.
b) Assemble the template (2).

1 Stellar knob
2 Template
3 Knife
.

(Cont’d)

372 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.4 Frame

(Cont’d)

c) Loosen the screw (4) and rotate the applicator unit approximately 45° to the left.
Cut the ladder band before turning.
Note! Remember the angle position. See the scale (5).

4 5

4 Screw
5 Scale
.

d) Check the timing belt (6) for wear or damage. Change, if necessary See
Procedure 3.4.1-2 Frame Housing - Change Timing Belt on page 375.

6 Timing belt
.

(Cont’d)

®
Doc. No. MM-3541840-0101 373 (728)
3.4 Frame 3 Applicator Unit

(Cont’d)

e) Turn the applicator unit back. Check the scale (5) to set the same angle as
before.
f) Tighten the screw (4).
g) Remove the template.

4 5

4 Screw
5 Scale
.

374 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.4 Frame

3.4.1-2 Frame Housing - Change Timing Belt

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
Special Equipment Hook Spanner TP No. 90243-0164
Template TP No. 3166869-0000
SPC Reference 2829433-0400

WARNING
Burn Hazard.
The hotmelt unit can be very hot and there is risk of severe burns. Use caution when
working near the hotmelt unit.
a) Turn the stellar knob (1) until the template (2) fits. The knife (3) should be
positioned inside the feed wheel.

1 Stellar knob
2 Template
3 Knife
.

(Cont’d)

®
Doc. No. MM-3541840-0101 375 (728)
3.4 Frame 3 Applicator Unit

(Cont’d)

b) Loosen the screw (4) and rotate the applicator unit approximately 45° to the left.
Cut the ladder band before turning.
Note! Remember the angle position. See the scale (5).

4 5

4 Screw
5 Scale
.

c) Loosen the screw (7) on the belt tensioner (8).

d) Turn the belt tensioner ¾ of a revolution to the right to release the belt tension.
Use a hook spanner (6).
Note! Turning the belt tensioner more than ¾ of a revolution will destroy the
torsion spring.
e) Tighten the screw (7).

6 Hook spanner
7 Screw
8 Belt tensioner
.

(Cont’d)

376 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.4 Frame

(Cont’d)

f) Remove the screws (14) and the bearing holder (15).

g) Remove the screws (11) and the axle support (10).
h) Change the ball bearing (13).
i) Remove the timing belt (9).
j) Put the new timing belt over the pulleys and check that it is properly positioned
over all the pulleys.

13

10

11

15 14
9 Timing belt
10 Axle support
11 Screw (3 pieces)
12 Retaining ring
13 Ball bearing
14 Screw (3 pieces)
15 Bearing holder
.

(Cont’d)

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Doc. No. MM-3541840-0101 377 (728)
3.4 Frame 3 Applicator Unit

(Cont’d)

k) Attach the bearing holder (15) with the screws (14).

l) Attach the axle support (10) with the screws (11).
m) Loosen the screw (7) to let the belt tensioner (8) tighten the timing belt.
n) Remove the template (2) and turn the stellar knob (1) approximately five
revolutions to even out the tension of the belt.
o) Tighten the screw (7).

1
11

10
2

8
15 14
1 Stellar knob 10 Axle support
2 Template 11 Screw (3 pieces)
7 Screw 14 Screw (3 pieces)
8 Belt tensioner 15 Bearing holder
.

(Cont’d)

378 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.4 Frame

(Cont’d)

p) Turn the applicator unit back. Make sure that the scale (5) has the same value
as before and tighten the screw (4).
q) Check that the knife is in the centre of the feed wheel slot. If not, adjust the feed
wheel unit. See Procedure 3.1-3 Feed Wheel Unit - Set on page 338.
r) Set the pick position. See Procedure 1.2.2.6-2 Maintenance - Set Pick Position
on page 249.

4 5

4 Screw
5 Scale
.

3.4.2 Belt Tensioner

3.4.2-1 Belt Tensioner - Check Parts
Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
Special Equipment Hook spanner TP No. 90243-0164
Template TP No. 3166869-0000
SPC Reference 3022735-0200

WARNING
Burn hazard.
The hotmelt guns can be very hot. Use caution when working near the hotmelt guns.
(Cont’d)

®
Doc. No. MM-3541840-0101 379 (728)
3.4 Frame 3 Applicator Unit

(Cont’d)

a) Turn the stellar knob (1) until the template (2) fits. The knife (3) should be
positioned inside the feed wheel slot.

1 Stellar knob
2 Template
3 Knife
.

b) Loosen the screw (4) and rotate the applicator unit approximately 45° to the left.
Cut the ladder band before turning.
Note! Remember the angle position. See the scale (5).

4 5

4 Screw
5 Scale
.

(Cont’d)

380 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.4 Frame

(Cont’d)

c) Loosen the screw (7) on the belt tensioner (8).

d) Turn the belt tensioner ¾ of a revolution to the right to release the belt tension.
Use a hook spanner (6).
e) Tighten the screw (7).
f) Remove the timing belt (10) from the belt tensioner (8).
g) Remove the screw (7) and the belt tensioner (8).
h) Check the turn spring (9) and the screw (7) for wear or damage. Change, if
necessary.

6 7

9
10

6 Hook spanner
7 Screw
8 Belt tensioner
9 Turn spring
10 Timing belt
.

(Cont’d)

®
Doc. No. MM-3541840-0101 381 (728)
3.4 Frame 3 Applicator Unit

(Cont’d)

i) Remove the lid (11).

j) Check the ball bearing (15), the retaining rings (12), (14) and (16), and the
thrust ball bearing (13) for wear or damage. Change, if necessary.
k) Put the lid (11) back on the belt tensioner.
l) Put the belt tensioner into place with the screw (7), but without yet tightening
the screw. Use the hole (17) for type S and T straws, and the hole (18) for type
U straws.

11
18 12

17
13
14
15
16

7 Screw 15 Ball bearing

11 Lid 16 Retaining ring
12 Retaining ring 17 Hole S/T-15
13 Thrust ball bearing 18 Hole U-22
14 Retaining ring
.

(Cont’d)

382 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.4 Frame

(Cont’d)

m) Turn the belt tensioner (8) ¾ of a revolution to the right. Use a hook spanner (6).
n) Tighten the screw (7).

8
6 Hook spanner
7 Screw
8 Belt tensioner
.

(Cont’d)

®
Doc. No. MM-3541840-0101 383 (728)
3.4 Frame 3 Applicator Unit

(Cont’d)

o) Put the timing belt (10) back over the belt tensioner (8) and check that it is
properly positioned over all the pulleys.
p) Loosen the screw (7) to let the belt tensioner (8) tighten the timing belt.
q) Tighten the screw (7).
r) Remove the template (2) and turn the stellar knob (1) approximately five
revolutions to even out the tension of the belt.
s) If necessary, repeat item p) to q) and turn the stellar knob (1) approximately five
revolutions to even out the tension of the belt.

10
2

8
1 Stellar knob
2 Template
7 Screw
8 Belt tensioner
10 Timing belt
.

(Cont’d)

384 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.4 Frame

(Cont’d)

t) Turn the applicator unit back. Make sure that the scale (5) has the same value
as before and tighten the screw (4).
u) Check that the knife is in the centre of the feed wheel slot. If not, adjust the feed
wheel unit. See Procedure 3.1-3 Feed Wheel Unit - Set on page 338.
v) Set the pick position. See Procedure 1.2.2.6-2 Maintenance - Set Pick Position
on page 249.

4 5

4 Screw
5 Scale
.

3.4.2-2 Belt Tensioner - Change Parts

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
Special Equipment Hook spanner TP No. 90243-0164
Template TP No. 3166869-0000
SPC Reference 3022735-0200

WARNING
Burn hazard.
The hotmelt guns can be very hot. Use caution when working near the hotmelt guns.

CAUTION
Risk of damage to equipment.
The nozzles are easily damaged. Handle the nozzles with care when removing the
gun modules.
a) To change parts, perform items a) to g) in Procedure 3.4.2-1 Belt Tensioner -
.
Check Parts on page 379.

(Cont’d)

®
Doc. No. MM-3541840-0101 385 (728)
3.4 Frame 3 Applicator Unit

(Cont’d)

b) Remove and change the turn spring (8) and the screw (1).
c) Remove the lid (2).
d) Change the retaining rings (3), (5), and (7), the ball bearing (6), and the thrust
ball bearing (4).
e) To assemble the belt tensioner, perform items k) to in Procedure 3.4.2-1 Belt
Tensioner - Check Parts on page 379.

1
2

4
5
6
7

1 Screw
2 Lid
3 Retaining ring
4 Thrust ball bearing
5 Retaining ring
6 Ball bearing
7 Retaining ring
8 Turn spring
.

386 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.4 Frame

3.4.3 Drive Motor

3.4.3-1 Drive Motor - Change Ball Bearing
Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 3013623-0300

a) Remove the three screws (1) and the washers (2).

b) Remove the bearing housing (3) and the retaining ring (4).
c) Change the ball bearing (5).
d) Assemble in the reverse order.

1 Screw 4 Retaining ring

2 Washer 5 Ball bearing
3 Bearing housing

®
Doc. No. MM-3541840-0101 387 (728)
3.4 Frame 3 Applicator Unit

3.4.4 Axle Support

3.4.4-1 Axle Support - Change Ball Bearing
Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 3358190-0100

a) Remove the three screws (1) and the washers (2).

b) Remove the bearing housing (3).
c) Change the ball bearing (4).
d) Assemble in the reverse order.

3
2
1

4
1 Screw
2 Washer
3 Bearing housing
4 Ball bearing
.

388 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.5 Ladder Band Guide

3.5 Ladder Band Guide

3.5-1 Ladder Band Guide - Set
SPC Reference 2987398-0200
3503676-0100

Valid for: 2987398-0200

a) Place the straw (1) so it touches the lower bracket (2).
b) Loosen the star handle (3) and adjust the height of the bracket (4) according to
distance A.
c) Tighten the star handle (3).

A
4

A = 1 to 2 mm
1 Straw
2 Bracket
3 Star handle
4 Bracket
.

(Cont’d)

®
Doc. No. MM-3541840-0101 389 (728)
3.5 Ladder Band Guide 3 Applicator Unit

(Cont’d)

Valid for: 3503676-0100 (OK Straw Quality Improvement 3503674-0100)

a) Measure the straw length.
b) Loosen the screw (1), and adjust the height of the upper roller (2) according to
distance A.
c) Tighten the screw (1) firmly.

1
A

A = Straw length + 25 mm
1 Screw
2 Roller
.

390 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.5 Ladder Band Guide

3.5-2 Ladder Band Guide - Change End Section and Pipe

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2987398-0200
3503676-0100

Valid for: 2987398-0200

a) Remove the .
b) Remove the .
c) Change the with the two .
d) Repeat items a) to c) on the other .

4
1

3
5

1 Grub screw 4 End section

2 Shaft 5 Pipe
3 Pipe
.

(Cont’d)

®
Doc. No. MM-3541840-0101 391 (728)
3.5 Ladder Band Guide 3 Applicator Unit

(Cont’d)

Valid for: 3503676-0100 (OK Straw Quality Improvement 3503674-0100)

a) Remove the screw (1).
b) Remove the shaft (2).
c) Change the pipe (3) with the two end sections (4).
d) Check the ball bearings (5) for wear or damage. Change if necessary.
e) Repeat items a) to c) on the other pipe (6).

6
4
5

1 Screw 4 End section

2 Shaft 5 Ball bearing
3 Pipe 6 Pipe
.

392 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.6 Guide Console

3.6 Guide Console

3.6-1 Guide Console - Change Guide Arms
SPC Reference 2829435-0100
3503691-0100 (Valid for: OK Straw Quality
Improvement 3503674-0100)

WARNING
Burn hazard.
The hotmelt guns can be very hot. Use caution when working near the hotmelt guns.

CAUTION
Risk of damage to equipment.
The nozzles are easily damaged. Handle the nozzles with care when removing the
gun holders.
a) Loosen the screw (1).
Note! Remember the positions of the gun holder (2). See the scale (4).
b) Slide the gun holder (2) through the hole (3).

3
2
1
4

1 Screw
2 Gun holder
3 Hole
4 Scale
.

(Cont’d)

®
Doc. No. MM-3541840-0101 393 (728)
3.6 Guide Console 3 Applicator Unit

(Cont’d)

c) Loosen the screw (5).

Note! Remember the positions of the spring holder (6) and the gun holder (8).
See the scale (4).
d) Slide the spring holder (6) through the hole (3).
e) Loosen the screw (7).
f) Slide the gun holder (8) through the hole (3).

4
6
5
7 8

3 Hole
4 Scale
5 Screw
6 Spring holder
7 Screw
8 Gun holder
.

(Cont’d)

394 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.6 Guide Console

(Cont’d)

g) Remove the screw (9) and change the guide arm (10).
h) Remove the screw (11) and change the guide arm (12).
i) Assemble in the reverse order.

10

11

12

9 Screw
10 Guide arm
11 Screw
12 Guide arm
.

3.6-2 Guide Console - Set Gun Holder

Machine Status Electrical supply disconnecting device in position I (ON)
Main air valve ON
SPC Reference 2829435-0100

To set the position of the gun holders, see 5.2.1-3 Hotmelt Gun - Set Gun Holder on
page 467.

Remove Insulating Plate

WARNING
Burn hazard.
Avoid touching the gun holders when they are hot.
Removing the insulation plate will provide an opportunity to increase override limits
on the pressure arm. To set the override, see procedure 3.3.3-7 Pressure Arm - Set
Override.
Note! An increased override may be desirable when using packages with irregular
surfaces.

(Cont’d)

®
Doc. No. MM-3541840-0101 395 (728)
3.6 Guide Console 3 Applicator Unit

(Cont’d)

a) Remove the screws (1) and the washers (2).

b) Remove the screw (3) and the insulating plate (4).

1 2 4
3

1 Screw 3 Screw
2 Washer 4 Insulating plate
.

(Cont’d)

396 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.6 Guide Console

(Cont’d)

c) Attach the hotmelt gun (5) to the gun holder (6) with the screw (3).
Note! Make sure that there are no gap between the hotmelt gun (5) and the
gun holder (6).
d) Attach the screws (1) and the washers (2).
e) Repeat the procedure on the upper gun holder.

6 5

1 2
3

1 Screw
2 Washer
3 Screw
5 Hotmelt gun
6 Gun holder
.

®
Doc. No. MM-3541840-0101 397 (728)
3.7 Spring Holder 3 Applicator Unit

3.7 Spring Holder

3.7-1 Spring Holder - Check Parts
SPC Reference 2923353-0200

a) Check that there is no residue on the leaf spring (1) or in between the surfaces
of the spring holder (2) and the spring bracket (3). Clean, if necessary.
b) Check that the compression springs (4) move in an elastic way by pressing the
leaf spring (1). Change, if necessary. See Procedure 3.7-2 Spring Holder -
Change Compression Springs on page 398.

1 Leaf spring
2 Spring holder
3 Spring bracket
4 Compression spring
(2 pieces)
.

3.7-2 Spring Holder - Change Compression Springs

SPC Reference 2923353-0200

WARNING
Burn hazard.
The hotmelt guns can be very hot. Use caution when working near the hotmelt guns.
(Cont’d)

398 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.7 Spring Holder

(Cont’d)

a) CAUTION
Risk of damage to equipment.
The nozzles are easily damaged. Handle the nozzles with care when removing
the gun holders.
Loosen the screw (1), slide the gun holder (2) upwards, and pull the screw out of
the hole (3).
Note! Remember the positions of the gun holder (2) and the spring holder (6).
See the scale (4).
b) Loosen the screw (5), slide the spring holder (6) upwards, and pull the screw out
of the hole (3).

3
2
1
4
6
5

1 Screw 4 Scale
2 Gun holder 5 Screw
3 Hole 6 Spring holder
.

(Cont’d)

®
Doc. No. MM-3541840-0101 399 (728)
3.7 Spring Holder 3 Applicator Unit

(Cont’d)

c) Remove the screws (7) and the guide arms (8) and (9) from the spring
holder (6).

6 8

7
9
6 Spring holder
7 Screw
8 Guide arm
9 Guide arm
.

d) Loosen the set screw (10). Use a mandrel to release the parallel pin (11) from
the spring bracket (12).

11

10 12
10 Set screw
11 Parallel pin
12 Spring bracket
.

(Cont’d)

400 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.7 Spring Holder

(Cont’d)

e) Change the compression springs (13).

• For TB/TBA, use compression springs 90600-7711.
• For TPA with SD Integrated, use compression springs 3210360-0000.
• For TPA without SD Integrated and for TT, use compression springs
536204-0000.

13
13 Compression spring
.

f)
.
Assemble in the reverse order.

3.7-3 Spring Holder - Change Leaf Spring

SPC Reference 2923353-0200

WARNING
Burn hazard.
The hotmelt guns can be very hot. Use caution when working near the hotmelt guns.
(Cont’d)

®
Doc. No. MM-3541840-0101 401 (728)
3.7 Spring Holder 3 Applicator Unit

(Cont’d)

a) CAUTION
Risk of damage to equipment.
The nozzles are easily damaged. Handle the nozzles with care when removing
the gun holders.
Loosen the screw (1), slide the gun holder (2) upwards, and pull the screw out
of the hole (3).
Note! Remember the positions of the gun holder gun holder (2) and the spring
holder (6). See the scale (4).
b) Loosen the screw (5), slide the spring holder (6) upwards, and pull the screw
out of the hole (3).

3
2
1
4
6
5

1 Screw 4 Scale
2 Gun holder 5 Screw
3 Hole 6 Spring holder
.

c) Remove the screw (7) and the washer (8), and change the leaf spring (9).
d) Assemble in the reverse order.

7 8
7 Screw
8 Washer
9 Leaf spring
.

402 (728) Doc. No. MM-3541840-0101

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3 Applicator Unit 3.7 Spring Holder

3.7-4 Spring Holder - Set Leaf Spring

Machine Status
SPC Reference 2923353-0200

Note! The illustrations show how to set the TB/TBA variant. The procedure is the
same for TPA/TT.
a) Loosen the screw (1).
b) Move the spring holder (2) to set the height of the leaf spring (3). Set the height
on the scale (4) according to the table below. The leaf spring (3) should be
positioned between the arms (5).

Straw direction
Straw type Top right Top left Vertical
U-1654 (TB/TBA) 65 mm 65 mm
U-1455 (TB/TBA) 57 mm 47 mm
125Sq (TPA/TT) 65 mm

Note! When running with U straws (7), the leaf spring should hold the U straw
bend.
c) Tighten the screw (1).

4
2
1 7

3 5

1 Screw 5 Arm
2 Spring holder 6 Straight straw
3 Leaf spring 7 U straw
4 Scale
.

®
Doc. No. MM-3541840-0101 403 (728)
3.8 Crank Shaft 3 Applicator Unit

3.8 Crank Shaft

3.8-1 Crank Shaft - Check Parts
Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
Special Equipment Hook spanner TP No. 90243-0164
Template TP No. 3166869-0000
SPC Reference 2829436-0300

Note! First check the cutting unit. See Procedure 3.2-1 Cutting Unit - Check Parts
on page 344.
Note! The illustrations show the TB/TBA variant. The procedure is the same for the
other variants.
a) Turn the stellar knob (1) until the knife (2) is in position outside the feed wheel.
b) Assemble the template (3).
c) Remove the screw (4).

1
1 Stellar knob
2 Knife
3 Template
4 Screw
.

(Cont’d)

404 (728) Doc. No. MM-3541840-0101

®
3 Applicator Unit 3.8 Crank Shaft

(Cont’d)

d) Remove the template (3) and remove the screw (5).

e) CAUTION
Risk of personal injury.
The knife (2) is very sharp. Be careful when working near the knife.
Remove the knife holder (6).
f) Remove the screw (7) and the knife (2).

6
5

2 Knife
3 Template
5 Screw
6 Knife holder
7 Screw
.

(Cont’d)

®
Doc. No. MM-3541840-0101 405 (728)
3.8 Crank Shaft 3 Applicator Unit

(Cont’d)

g) Remove the screws (8) and the inductive switch (9).

h) Remove the screw (10) and the switch bracket (11).

8 9

10

11

8 Screw
9 Inductive switch
10 Screw
11 Switch bracket
.

i) Loosen the screw (12) and rotate the applicator unit approximately 45° to the
left. Cut the ladder band before turning.
Note! Remember the angle position. See the scale (13).

12 13
5

12 Screw
13 Scale
.

(Cont’d)

406 (728) Doc. No. MM-3541840-0101

®
3 Applicator Unit 3.8 Crank Shaft

(Cont’d)

j) Loosen the screw (14) on the belt tensioner (15).

k) Turn the belt tensioner ¾ of a revolution to the right to release the belt tension.
Use a hook spanner (16).
l) Tighten the screw (14).
m) Lift the timing belt (17) off the pulley (18).

16
17
18

14

15

14 Screw
15 Belt tensioner
16 Hook spanner
17 Timing belt
18 Pulley
.

n) Loosen the screw (19) and the eccentric (20).

20

19

19 Screw
20 Eccentric
.

(Cont’d)

®
Doc. No. MM-3541840-0101 407 (728)
3.8 Crank Shaft 3 Applicator Unit

(Cont’d)

o) Carefully remove the seal ring (21). Change, if necessary.

p) Remove the retaining ring (22).
q) Knock out the shaft (23). Use a nylon hammer or similar tool to avoid damaging
the shaft.

21

23

22

21 Seal ring
22 Retaining ring
23 Shaft
.

r) Check the ball bearings (24) and (25). Change, if necessary.

24

25

24 Ball bearing
25 Ball bearing
.

(Cont’d)

408 (728) Doc. No. MM-3541840-0101

®
3 Applicator Unit 3.8 Crank Shaft

(Cont’d)

s) Assemble in the reverse order, but perform as follows when assembling the
timing belt (17):
• Put the timing belt (17) over the pulley (18) and check that it is properly
positioned over all the pulleys.
• Loosen the screw (14) to let the belt tensioner (15) tighten the timing belt.
• Turn the stellar knob (1) approximately five revolutions to even out the
tension of the belt.
• Tighten the screw (14).

17
18

14

1 15

1 Stellar knob
14 Screw
15 Belt tensioner
17 Timing belt
18 Pulley
.

®
Doc. No. MM-3541840-0101 409 (728)
3.8 Crank Shaft 3 Applicator Unit

3.8-2 Crank Shaft - Change Parts

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2829436-0300

a) Perform item a) to q) in Procedure 3.8-1 Crank Shaft - Check Parts on page

404.
b) Remove the screws (1).
c) Lift out the bearing sleeve (2).
d) Remove the retaining rings (3) andretaining ring (5).
e) CAUTION
Risk of damage to equipment.
Use a puller to remove the ball bearings.
Change the ball bearings (4) and ball bearing (6).

1 3

4
5

2
1

6
1 Screw
2 Bearing sleeve
3 Retaining ring
4 Ball bearing
5 Retaining ring
6 Ball bearing
.

(Cont’d)

410 (728) Doc. No. MM-3541840-0101

®
3 Applicator Unit 3.8 Crank Shaft

(Cont’d)

f) Remove the cap nut (7) and the stellar knob (8).
g) Loosen the screw (9) and remove the pulley (10).
h) Change the key (11) and the key (12), if necessary.
i) Replace the pulley (10), if necessary.

11

12
10

7
7 Cap nut
8 Stellar knob
9 Screw
10 Pulley
11 Key
12 Key
.

(Cont’d)

®
Doc. No. MM-3541840-0101 411 (728)
3.8 Crank Shaft 3 Applicator Unit

(Cont’d)

j) CAUTION
Risk of damage to equipment.
The ball bearings must be pressed onto the shafts. Use appropriate equipment.
Assemble in the reverse order, but perform as follows when assembling the
timing belt (13):
• Put the timing belt (13) over the pulley (10) and check that it is properly
positioned over all the pulleys.
• Loosen the screw (14) to let the belt tensioner (15) tighten the timing belt.
• Tighten the screw (14).
• Turn the stellar knob (8) approximately five revolutions to even out the
tension of the belt.

13
10

14

8 15

8 Stellar knob
10 Pulley
13 Timing belt
14 Screw
15 Belt tensioner
.

412 (728) Doc. No. MM-3541840-0101

®
3 Applicator Unit 3.9 Guide Arm

3.9 Guide Arm

3.9-1 Guide Arm - No Procedure Described (TPA without
SD Integrated and TB/TBA/TT)
Machine Status
SPC Reference 2829442-0100

®
Doc. No. MM-3541840-0101 413 (728)
3.9 Guide Arm 3 Applicator Unit

3.9-2 Guide Arm - Set (TPA with SD Integrated)

SPC Reference 3181104-0100

The straws should be parallel to the guide roller (1).

1 Guide roller
.

414 (728) Doc. No. MM-3541840-0101

®
4 Straw Detector Integrated

®
Doc. No. MM-3541840-0101 415 (728)
 4 Straw Detector Integrated

Description
SPC Reference 663315-0500

3 3

TB, TBA

1
3

3 3

TPA
1 Detector
2 Guide holder
3 Rejecting unit

416 (728) Doc. No. MM-3541840-0101

®
4 Straw Detector Integrated Table of Contents

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416

4.1 Detector .......................................................... 419

4.1-1 Detector - Install IVC Manager . . . . . . . . . . . . . . . . . . . 419
4.1-2 Detector - Install or Restore Straw Detector
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .423

4.1.1 Detector - Vision System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427

4.1-3 Detector - Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
4.1-4 Detector - Set Vision System. . . . . . . . . . . . . . . . . . . . . 429
4.1-5 Detector - Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432

4.2 Guide Holder .................................................... 433

4.2-1 Guide Holder- No Procedure Described . . . . . . . . . . . 433

4.3 Ejector ............................................................ 434

4.3.1 Ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
4.3.1-1 Air Nozzle - Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434

4.3.2 Basket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436

4.3.2-1 Basket - No Procedure Described . . . . . . . . . . . . . . . . 436

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4 Straw Detector Integrated 4.1 Detector

4.1 Detector
4.1-1 Detector - Install IVC Manager
Special Equipment PC with network connection
SPC Reference 3404781-0100

Note! The IVC Manager is delivered as a zip file. To install the software, follow the
procedure below.
a) Unzip the IVC Manager zip file to a folder on the PC.
b) To begin the installation, go to the selected folder and double-click the IVC_
Manager.exe file.
c) The IVC Manager window (1) is launched and automatically begins to search
for any detectors that are connected to the network.
Note! The list can be updated by pressing the Refresh button (2).

2
Example only
1 IVC Manager window
2 Refresh button
.

(Cont’d)

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4.1 Detector 4 Straw Detector Integrated

(Cont’d)

d) Double-click the row with the camera to update.

e) Set sensor properties:

• ID: 224
• Name (NetBIOS): 3D_MINI_21
• IP address: 192.168.1.224
• Subnet mask: 255.255.255.0
f) Press the Apply button (3) and the OK button (4).

4 3
3 Apply button
4 OK button
.

(Cont’d)

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4 Straw Detector Integrated 4.1 Detector

(Cont’d)

g) Press the Yes button (5).

5
5 Yes button
.

h) The update will start.

(Cont’d)

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4.1 Detector 4 Straw Detector Integrated

(Cont’d)

i) Press the Refresh button (2).

2
2 Refresh button
.

j) New search will start.

k) The camera will be visible when search has finished.

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4 Straw Detector Integrated 4.1 Detector

4.1-2 Detector - Install or Restore Straw Detector Software

Machine Status Electrical supply disconnecting device in position I (ON)
Special Equipment PC with network connection
SPC Reference 3404781-0100

Note! Do not disconnect the detector during the install or restore operation.
Disconnection could cause the detector to malfunction.
Note! After a successful install or restore of the software, the detector restarts. After
restart, the detector automatically reconnects to the network using the IP address
specified in the backup file.
Note! If internal error occurs, power cycle the camera. Refresh IVC MANAGER and
double-click Device. Change to a static IP. See Section 10.6 IP Addresses.
a) Make sure the PC and the detector (1) are on the same subnet.
b) To update a detector (1), select it from the list in the IVC Manager window (2). If
the requested detector (1) cannot be found in the list: Make sure that the
detector (1) is connected to the network and turned on, and then press the
Refresh button (3).
c) Press the Restore button (4) to continue.

3 4
Example only
1 Detector
2 IVC Manager window
3 Refresh button
4 Restore button
.

(Cont’d)

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4.1 Detector 4 Straw Detector Integrated

(Cont’d)

d) An Open File window (5) opens up and enables navigation to, and selection
of, the requested backup file (6) (*.ivb file).
e) Press the Open button (7).

7
5 Open File window
6 Backup file
7 Open button
.

(Cont’d)

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4 Straw Detector Integrated 4.1 Detector

(Cont’d)

f) Select Use network settings from the backup file (Recommended) (8)
in the Confirm Restore window (9).
g) Press the Restore button (10).

10
8 Network settings
selection
9 Confirm Restore
window
10 Restore button
.

(Cont’d)

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4.1 Detector 4 Straw Detector Integrated

(Cont’d)

h) Wait while the restore completes. The restore procedure could take several
minutes. The progress is shown in the Restore IVC window (11).
Note! Do not disconnect or turn off the power to the detector (1) during the
restore.

11

1 Detector
11 Restore IVC window
.

i) When the restore procedure is complete, the message The IVC was
successfully restored. is shown and the detector restarts.
Note! When restarting, the detector is set to RUN with the installed or restored
software and configuration settings.
j) Press the OK button (12).

12
12 OK button
.

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4 Straw Detector Integrated 4.1 Detector

4.1.1 Detector - Vision System

In addition to the image, the vision system provides information regarding the straw
position on the package and straw detector rejection criteria.
Note! The image orientation shows the package laying on the right-hand side and
the top is to the right in the image.
Note! If the reject criteria show green numbers, it means that the straw is positioned
within the specified recipe parameters. If a reject criterion is shown with red
numbers, it means that one of the recipe parameters are not OK and the package is
rejected.
• Straw (1), If the displayed value is 1, it means that a straw is detected on the
package. If the value is 0, a straw is not detected on the package.
• Angle (2), The angle, in %, shows in which angle the straw has been applied on
the package. Package is rejected if the value deviates more than ±12 ° from the
recipe.
• Score (3), A value showing how well the found straw is matching the straw recipe
settings. Maximum value is 75.
• Left protrusion (4), Shows the straw position on the left-hand side of the package.
If the straw protrusion exceeds 3.5 mm, the package is rejected.
• Right protrusion (5), Shows the straw position on the right-hand side of the
package. If the straw protrusion exceeds 3.5 mm, the package is rejected.
• Top protrusion (6), Shows the straw position at the top of the package. If the straw
protrusion exceeds 3.5 mm, the package is rejected.
• Bottom protrusion (7), Shows the straw position at the bottom of the package. If
the straw protrusion exceeds 3.5 mm, the package is rejected.

1
2
3
4
5

6
7

1 Straw 4 Left protrusion

2 Angle 5 Right protrusion
3 Score 6 Top protrusion
7 Bottom protrusion
.

(Cont’d)

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4.1 Detector 4 Straw Detector Integrated

(Cont’d)

• The red frame shows what the straw detector interprets as the package
border (8).
• The pink line shows what the straw detector interprets as the straw (9).
• The straw angle (10) shows the measured straw position. The reject criterion is
set to the recipe value ±12 °.
• If any of the values are presented with red numbers (11), it means that the straw
detector has detected a value that is not OK according to the recipe. The
package is then rejected.

11
9

10
8 Package border
interpretation
9 Straw interpretation
10 Straw angle
11 Red numbers
.

4.1-3 Detector - Set

Machine Status Electrical supply disconnecting device in position I
(ON)
SPC Reference 3404781-0100

Set the straw detector settings, for instructions, see Section 2.8 Settings Menu in
the OM.

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4 Straw Detector Integrated 4.1 Detector

4.1-4 Detector - Set Vision System

Machine Status Electrical supply disconnecting device in position I (ON)
SPC Reference 3404781-0100

Note! If the ambient temperature exceeds about 40 °C (104 °F), the detector goes
off to protect the laser from overheating.
Note! When the function SAVE IMAGE TO FTP SERVER is active, it is not possible to
analyse all packages. Therefore there is a risk of packages not getting rejected
correctly.
a) Make sure the PC and the detector are on the same subnet.
b) Open a Microsoft Internet Explorer window and type http://xxx.xxx.xxx.
xxx/status.html in the address field, where xxx.xxx.xxx.xxx corresponds to the IP
address assigned to the detector. The detector IP address can be seen (and
.
changed) in the IVC Manager.
Set Photocell Position
Note! The accuracy of this adjustment is vitally important.
c) Let one or several packages pass through the detector, and press Refresh
Image (alternatively keyboard key F5). The last package that passed the
detector is shown in the centre of the image, otherwise the photocell position
needs adjustment.
Note! Use both the image showing the package position and the package
position values that are shown on the TPOP for this adjustment.

Photocell positioned too far to the right

Photocell positioned too far to the left

.

(Cont’d)

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4.1 Detector 4 Straw Detector Integrated

(Cont’d)

d) The values for package position image left side (1) and package position image
right side (2) must be as equal as possible.

2
1 Package position
image left side
2 Package position
image right side
.

e) Loosen the screws (3) and (4).

3 4
Front view is shown to the left and back view to the right.
3 Screw
4 Screw
.

(Cont’d)

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4 Straw Detector Integrated 4.1 Detector

(Cont’d)

f) Adjust the position of photocell (5) and (6) until the package is in the centre of
the image. Make only small adjustments. To see the result of your adjustments,
repeat item c).
Note! Make sure that both photocell (5) and (6) is positioned perpendicular to
the conveyor and in front of each other.
g) Tighten the screws (3) and (4).

3 5 6 4
Front view is shown to the left and back view to the right.
5 Photocell
6 Photocell
.

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4.1 Detector 4 Straw Detector Integrated

4.1-5 Detector - Clean

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 3404781-0100

CAUTION
Laser Radiation.
Do not stare into beam or view directly with optical instruments.
Note! The illustration shows the TPA variant. The procedure is the same for the
TBA variant.
a) Lift up the cover (1).
b) Gently clean the two lenses (3) on the detector (2) with a piece of cloth.

3
Detector TPA variant
1 Cover
2 Detector
3 Lens
.

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4 Straw Detector Integrated 4.2 Guide Holder

4.2 Guide Holder

4.2-1 Guide Holder- No Procedure Described
SPC Reference 3234412-0200

TB, TBA

TPA

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4.3 Ejector 4 Straw Detector Integrated

4.3 Ejector
4.3.1 Ejector
4.3.1-1 Air Nozzle - Set
Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
Main air valve ON
SPC Reference 3187926-0200

a) Set distance A between the air nozzles on the ejector (1) and the photocell (2).
Any other distance affects the TPOP settings.

1 2

A
A = 420 ±2 mm for
parallel camera
A = 305 ±2 mm for
angled camera
1 Ejector
2 Photocell P50B5136
.

(Cont’d)

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4 Straw Detector Integrated 4.3 Ejector

(Cont’d)

b) Adjust the height of the air nozzles (3) with the screws (4), so that the upper
nozzle is below the top of the package at distance B.
c) Make sure that the clearance between the air nozzles (3) and the nearest
railing (5) maintain at least distance C.

5
3
4

B
5
C

B ≥10 mm
C ≥10 mm
3 Air nozzle
4 Screw
5 Railing
.

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4.3 Ejector 4 Straw Detector Integrated

4.3.2 Basket
4.3.2-1 Basket - No Procedure Described
SPC Reference 3171473-0300

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 5 Hotmelt Equipment

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 5 Hotmelt Equipment

Description
SPC Reference 663303-0500

1 Hotmelt Equipment
Miscellaneous
2 Hotmelt Equipment
Nordson

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5 Hotmelt Equipment Table of Contents

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438

5.1 Hotmelt Equipment Miscellaneous ........................ 441

5.1-1 Hotmelt Equipment Miscellaneous - No
Procedure Described . . . . . . . . . . . . . . . . . . . . . . . . . . . .441

5.2 Hotmelt Equipment Nordson................................ 442

5.2-1 Hotmelt Equipment Nordson - Set Hotmelt
Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .442
5.2-2 Hotmelt Equipment Nordson - Change
Hotmelt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .448
5.2-3 Hotmelt Equipment Nordson - Bleed System . . . . . . 449
5.2-4 Hotmelt Equipment Nordson - Hotmelt Unit,
F2 Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .455
5.2-5 Hotmelt Equipment Nordson - Check Hose . . . . . . . . 456
5.2-6 Hotmelt Equipment Nordson - Clean Nozzle . . . . . . . 457
5.2-7 Hotmelt Equipment Nordson - Change
Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .458
5.2-8 Hotmelt Equipment Nordson - Change Filter. . . . . . . 458
5.2-9 Hotmelt Equipment Nordson - Check Hotmelt
Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .460
5.2-10 Hotmelt Equipment Nordson - Clean Hotmelt
Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .460
5.2-11 Hotmelt Equipment Nordson - Change Hotmelt
Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .463

5.2.1 Hotmelt Gun. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466

5.2.1-1 Hotmelt Gun - Change Gun Module. . . . . . . . . . . . . . . 466
5.2.1-2 Hotmelt Gun - Change Solenoid Valve . . . . . . . . . . . . 467
5.2.1-3 Hotmelt Gun - Set Gun Holder . . . . . . . . . . . . . . . . . . . 467

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5 Hotmelt Equipment 5.1 Hotmelt Equipment Miscellaneous

5.1 Hotmelt Equipment Miscellaneous

5.1-1 Hotmelt Equipment Miscellaneous - No Procedure
Described
SPC Reference 2864776-0300

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5.2 Hotmelt Equipment Nordson 5 Hotmelt Equipment

5.2 Hotmelt Equipment Nordson

5.2-1 Hotmelt Equipment Nordson - Set Hotmelt Unit
Machine Status Electrical supply disconnecting device in position I
(ON)
Main air valve ON
Consumables Hotmelt
SPC Reference 2892717-0200
2863510-0200

WARNING
Burn hazard.
During heating and production, the hotmelt unit gets hot. Do not touch the hotmelt
unit and beware of the trapped heat inside the unit.
Wear safety glasses, protective gloves, and other protective clothing.
a) Make sure that there is hotmelt in the tank (1) and use the electrical supply
switch (2) to switch ON the hotmelt unit. For recommended type of hotmelt, see
Section 10.4.1 Hotmelt on page 601.
Note! The colour of the hotmelt should be light yellow. If the hotmelt has
become brown, change it. To obtain a prolonged lifetime of the hotmelt, the
temperature can be decreased during longer production stops.
b) When connecting hoses, always use port 1 (3). The port position is stamped on
the face of the manifold.

2
1 Tank
2 Electrical supply
switch
3 Port 1
.

(Cont’d)

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5 Hotmelt Equipment 5.2 Hotmelt Equipment Nordson

(Cont’d)

Operator Panel Overview

For further information read the Nordson ProBlue Adhesive Melters Manual. The
manual, in English, is included with the delivery from Tetra Pak. The Hotmelt
Equipment chapter in this manual only deals with what is specific for this machine.

1 2 3 4

20
19
18
17 5
16 6
7
8
15
9

14 13 12 11 10
1 Fault LED 8 CLEAR/RESET button 16 UP button for selector
2 Ready LED 9 ENTER button display
3 HOSE button 10 SETUP button 17 Selector display
4 GUN button 11 SEVEN DAY CLOCK 18 Low level LED
5 Multipurpose display button 19 Service LED
6 UP button for 12 HEATER button 20 TANK button
multipurpose display 13 PUMP button
7 DOWN button for 14 STANDBY button
multipurpose display 15 Keypad
.

(Cont’d)

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5.2 Hotmelt Equipment Nordson 5 Hotmelt Equipment

(Cont’d)

Parameter Settings

Parame-
ter Function Description Setting
4 System- Allows you to set the amount of additional 0
ready time time for hotmelt to melt after all zones minutes
delay have reached their setpoint temperatures.
20 Celsius Allows you to display temperature Celsius
/Fahrenheit measurements in Celsius or Fahrenheit.
0 = Celsius
1 = Fahrenheit
21 Over Allows you to specify the maximum 15 °C
temperature temperature. The features 1 to 3 can
set-point reach before the system initiates a fault
condition.
22 Under The number of degrees that the 5 °C
temperature temperature of any component can
delta decrease from its set-point temperature
before an under temperature fault (F2)
occurs.
40 Standard Ready and Pump is on 2
output 1
41 Standard Low level 4
output 2

(Cont’d)

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5 Hotmelt Equipment 5.2 Hotmelt Equipment Nordson

(Cont’d)

Set the parameters as follows:

a) Press the SETUP button (1) and the selector display (2) flashes. Use the UP
button (3) or the keypad (8) to select parameter and confirm with the ENTER
button (4).
b) Then the multipurpose display (5) starts flashing. Use the UP button (6), the
DOWN button (7), or the keypad (8) to select required value and confirm with
the ENTER button (4).
Note! If the setting is unadjustable, the display is password protected! For
further information read Nordson Pro Blue Adhesive Melters Manual.
c) When the selector display shows next parameter and setting, either continue
with next parameter or exit by pressing the SETUP button (1) twice.

2 5
3 6
7
1
8

4
1 SETUP button 6 UP button for
2 Selector display multipurpose display
3 UP button for selector 7 DOWN button for
display multipurpose display
4 ENTER button 8 Keypad
5 Multipurpose display
.

(Cont’d)

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5.2 Hotmelt Equipment Nordson 5 Hotmelt Equipment

(Cont’d)

Tank, Hoses, and Guns Temperature

Set the temperature of the tank as follows:

Note! Too high temperature will make the adhesive deteriorate quicker, resulting in
reduced quality. A lower temperature results in shorter cooling-off time, but also
increases the risk of threading of the adhesive.
a) Press the TANK button (1) for three seconds.
b) The digit “1” appears flashing in the selector display (2). If the digit “0” appears,
press the UP button (3), or use the keypad (8) for the selector display until digit
“1” appears. Confirm the choice by pressing the ENTER button (4).
c) The multipurpose display (5) starts flashing. Press the multipurpose display
DOWN button (7), the UP button (6), or the keypad (8) to enter the required
value. There are different settings for different types of adhesive and ambient
temperature. See Section 10.4.1 Hotmelt on page 601.
d) Confirm the setting by pressing the ENTER button (4).
e) Exit by pressing the SETUP button twice.

2 5
3 6

4
1 TANK button 6 UP button for
2 Selector display multipurpose display
3 UP button for selector 7 DOWN button for
display multipurpose display
4 ENTER button 8 Keypad
5 Multipurpose display
.

(Cont’d)

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5 Hotmelt Equipment 5.2 Hotmelt Equipment Nordson

(Cont’d)

Set the temperature of the hoses and guns as follows:

Note! Remember to set all hoses and guns.

f) Press the HOSE button (9) to specify the hose set point temperature or the GUN
button (10) to specify the gun set point temperature. Press the key for three
seconds.
g) The digit “1” appears flashing in the selector display (2). Press the UP button (3)
or use the keypad (8) for selector display until the digit “0” appears. Confirm the
choice by pressing the ENTER button (4).
h) The multipurpose display (5) starts flashing. Press the multipurpose display
DOWN button (7), the UP button (6), or the keypad (8) to enter the required
value. There are different settings for different types of adhesive and ambient
temperature. See Section 10.4.1 Hotmelt on page 601.
i) Confirm the setting by pressing the ENTER button (4).
j) Exit by pressing the SETUP button twice.
k) Press the HEATER button (11) to heat up the hotmelt unit.

10 11

2 5
3 6

8 12

4
2 Selector display 7 DOWN button for
3 UP button for selector multipurpose display
display 8 Keypad
4 ENTER button 9 HOSE button
5 Multipurpose display 10 GUN button
6 UP button for 11 HEATER button
multipurpose display
.

Air Pressure
Note! The values are also stated in the OM.
(Cont’d)

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5.2 Hotmelt Equipment Nordson 5 Hotmelt Equipment

(Cont’d)

Set the air pressure values according to the table above.

a) Set the pressure on the hotmelt unit by turning the pressure adjustment
screw (1) on the hotmelt unit. The pressure is stated on the manometer (2).
b) To set the hotmelt gun pressure, see Procedure 8.1-2 Air Supply - Set Air
Pressure on page 506.

2 1
1 Pressure adjustment
screw
2 Manometer
.

5.2-2 Hotmelt Equipment Nordson - Change Hotmelt

Machine Status Electrical supply disconnecting device in position I
(ON)
Main air valve ON
Consumables Hotmelt
SPC Reference 2892717-0200

WARNING
Burn hazard
Hot hotmelt. Do not touch the drain shut during tank drainage.
Wear safety glasses, protective gloves, and other protective clothing to avoid
injuries from adhesive pouring out. A splash guard is needed in front of the drain
shut when the tank is almost empty because the last adhesive can splash.
Note! The machine must be preheated before the work can start.
a)
.
Step the machine up to step 2; AIR ON.

(Cont’d)

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5 Hotmelt Equipment 5.2 Hotmelt Equipment Nordson

(Cont’d)

b) Lower the pressure to 0 bar (0 MPa) by turning the screw (3).

c) Put a container under the drain chute (1).
d) Pull down the drain chute (1).
e) Open the drain valve (4) by slowly turning it to the left until the hotmelt begins to
flow.
f) Empty the tank by gently raising the pressure by turning the screw (3) until the
remaining hotmelt flows out.
g) Close the drain valve (4), clean, and pull up the drain chute (1).
h) Fill the tank (2) with hotmelt. For recommended type of hotmelt, see Section
10.4.1 Hotmelt on page 601.
i) Set the pressure to a value according to Section Air Pressure on page 447.
j) Bleed the system.

1 2

3
1

1 Drain chute
2 Tank
3 Screw
4 Drain valve
.

5.2-3 Hotmelt Equipment Nordson - Bleed System

Machine Status Electrical supply disconnecting device in position I (ON)
Main air valve ON
Special Equipment Waste pipe TP no. 3046523-0100
SPC Reference 2892717-0200

Note! The machine must be preheated, and the guns have reached operating
temperature.

WARNING
Burn hazard.
Hot hotmelt. Wear safety glasses, protective gloves, and other protective clothing to
avoid injuries from hotmelt pouring out through the nozzles.
(Cont’d)

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5.2 Hotmelt Equipment Nordson 5 Hotmelt Equipment

(Cont’d)

a) Turn the bearing housing (1) to move the arms (2) to a position outside the feed
wheel slots.
b) Turn the stellar knob (3) until the knife (4) is in position outside the feed wheel.
c) Turn the stellar knob (5) to the left until the feed wheel (6) is released from the
shaft.
d) Press the leaf spring (7) outwards from the feed wheel and pull up the feed
wheel.

5
6
4

3
7
2
1 Bearing housing 5 Stellar knob
2 Arm 6 Feed wheel
3 Stellar knob 7 Leaf spring
4 Knife
.

(Cont’d)

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5 Hotmelt Equipment 5.2 Hotmelt Equipment Nordson

(Cont’d)

e) Loosen the screw (8) and rotate the applicator unit to 0°.
Note! Remember the angle position. See the scale (9).
f) Tighten the screw (8) again.

8 9
5

8 Screw
9 Scale
.

(Cont’d)

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5.2 Hotmelt Equipment Nordson 5 Hotmelt Equipment

(Cont’d)

Note! Remember the positions of the hotmelt guns, and the spring holder.
g) Loosen the screw (10) and remove the upper hotmelt gun (11) from the guide
console (12).
h) Loosen the screw (13) and remove the spring holder (14) from the guide
console (12).
i) Put the upper hotmelt gun (11) back. It should be positioned as far up as
possible on the guide console (12).
j) Tighten the screw (10).
k) Loosen the screw (15) and move the lower hotmelt gun (16) as tight to the
upper hotmelt gun as possible.
l) Tighten the screw (15).

11

12 10
13

14 15

16

10 Screw
11 Hotmelt gun
12 Guide console
13 Screw
14 Spring holder
15 Screw
16 Hotmelt gun
.

(Cont’d)

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5 Hotmelt Equipment 5.2 Hotmelt Equipment Nordson

(Cont’d)

m) Move the arms (2) out of the way and press down the waste pipe (17). Hang the
waste pipe on the shaft (18).
n) Check that the opening in the waste pipe is directed towards the nozzles (19) so
that the hotmelt is shot into the waste pipe.
o) Put a disposable container under the machine for the hotmelt to run into.
p) Close the doors to the machine.

18

19

17 2
2 Arm
17 Waste pipe
18 Shaft
19 Nozzle
.

(Cont’d)

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5.2 Hotmelt Equipment Nordson 5 Hotmelt Equipment

(Cont’d)

q) Log on as a technician or higher. See Procedure 1.2.2.1-2 User Management -

Log On as a User on page 174.
r) Press the Maintenance button (20) on the TPOP.
s) In the Apply unit maintenance window, press the Hotmelt bleed
icon (21).
t) Press the Select button (22).
u) Press the STEP UP button (23).
v) Press the Confirmation button (24).
w) The machine will empty the hotmelt hoses for one minute. Press the Deselect
button (25) to abort earlier.

22 25 24 20

21

23
20 Maintenance button
21 Hotmelt bleed icon
22 Select button
23 STEP UP button
24 Confirmation
button
25 Deselect button
.

(Cont’d)

454 (728) Doc. No. MM-3541840-0101

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5 Hotmelt Equipment 5.2 Hotmelt Equipment Nordson

(Cont’d)

x) WARNING
Burn hazard.
Be very careful when removing the containers. The hotmelt core may still be in
liquid form even if there is a skin on the hotmelt in the container. Wear safety
glasses, protective gloves, and other protective clothing.
Open the doors and remove the disposable container.
y) Remove the waste pipe from the shaft.
z) Assemble in the reverse order.
aa) Wait until the hotmelt in the waste pipe has cooled down and solidified, then
.
bend the waste pipe to loosen the remaining hotmelt and pull it out.

5.2-4 Hotmelt Equipment Nordson - Hotmelt Unit, F2 Alarm

Machine Status Electrical supply disconnecting device in position I (ON)
Main air valve ON
SPC Reference 2892717-0200

If the guns are cooled down an alarm called “F2” locks the hotmelt unit. The hotmelt
unit needs to be reset and reheated.
a) Press the CLEAR/RESET button (1).
b) Press the HEATER button (2).
c) The hotmelt unit starts to heat up.

1 CLEAR/RESET button
2 HEATER button
.

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5.2 Hotmelt Equipment Nordson 5 Hotmelt Equipment

5.2-5 Hotmelt Equipment Nordson - Check Hose

SPC Reference 2892717-0200

WARNING
Burn hazard.
Risk of personal injury. Wear safety glasses, protective gloves, and other protective
clothing to avoid injuries from hotmelt pouring out.
a) Check the hoses (arrows) for wear and the connections for leakage.
b) If required, replace or tighten the hose connections.

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5 Hotmelt Equipment 5.2 Hotmelt Equipment Nordson

5.2-6 Hotmelt Equipment Nordson - Clean Nozzle

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
Main air valve LOCKED in OFF position
SPC Reference 2892717-0200

WARNING
Burn hazard.
Hot hotmelt and hot equipment. Wear safety glasses and protective gloves to avoid
injuries from hotmelt pouring out. Let the hotmelt gun cool off before performing any
work on it.
a) Reduce the air pressure to zero. See Procedure 8.1-2 Air Supply - Set Air
Pressure on page 506.
b) Position the hotmelt guns on the brackets (1).
c) Clean the nozzle (arrow) from hotmelt remains.
To clean the nozzles (arrows), see instructions in the Nordson ProBlue Adhesive
Melters Manual.

1 Bracket
.

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5.2 Hotmelt Equipment Nordson 5 Hotmelt Equipment

5.2-7 Hotmelt Equipment Nordson - Change Nozzle

Machine Status
SPC Reference 2892717-0200

To change the nozzles (arrows), see instructions in the Nordson ProBlue Adhesive
Melters Manual.

Note! When reducing the pump air pressure to zero (0), follow the instruction 8.1-2
.
Air Supply - Set Air Pressure on page 506.

5.2-8 Hotmelt Equipment Nordson - Change Filter

Machine Status Electrical supply disconnecting device in position I
(ON)
Main air valve ON
SPC Reference 2892717-0200

WARNING
Burn hazard.
Risk of personal injury. Wear safety glasses, protective gloves, and other protective
clothing to avoid injuries from hotmelt pouring out.
a) Press the PUMP button (1) to stop the pump.

1 PUMP button
.

(Cont’d)

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5 Hotmelt Equipment 5.2 Hotmelt Equipment Nordson

(Cont’d)

b) Use an 8 mm allen key, wrench to the left, to loosen the nut (2) and then
properly dispose the old filter.
c) Before fitting the new filter, check that the O-ring (3) is in good condition. Tighten
the nut (2) to 4.5 Nm.

2 Nut
3 O-ring
.

d) On the hoses; loosen the nut (4) and remove the filter (5).
e) Change and insert the filter (5). Tighten the nut (4).
f) Press the PUMP button (1) to start the pump.

4
5

1 PUMP button
4 Nut
5 Filter
.

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5.2 Hotmelt Equipment Nordson 5 Hotmelt Equipment

5.2-9 Hotmelt Equipment Nordson - Check Hotmelt Tank

Machine Status Electrical supply disconnecting device in position I
(ON)
Main air valve ON
SPC Reference 2892717-0200

WARNING
Burn hazard.
During heating and production the hotmelt unit gets hot. Do not touch the hotmelt
unit and beware of the trapped heat inside the unit.
Wear safety glasses, protective gloves, and other protective clothing.
Check for excessive char inside the hotmelt tank. Clean, if necessary. See
Procedure 5.2-10 Hotmelt Equipment Nordson - Clean Hotmelt Tank on page 460.

5.2-10 Hotmelt Equipment Nordson - Clean Hotmelt Tank

Machine Status Electrical supply disconnecting device in position I
(ON)
Main air valve ON
SPC Reference 2892717-0200

WARNING
Burn hazard.
Risk of personal injury. A splash guard is needed in front of the drain chute when the
tank is almost empty because the last hotmelt can splash. During tank drainage
never touch the drain chute!
Wear safety goggles, protective gloves, and other protective clothing to avoid
injuries from hotmelt pouring out.
Note! The procedures provided in this section requires appropriate hot melt
cleaning fluid supplied with a data sheet providing a description of the cleaning
procedure.
(Cont’d)

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5 Hotmelt Equipment 5.2 Hotmelt Equipment Nordson

(Cont’d)

To Clean the Tank When Changing Hotmelt

a) Empty the tank as described in Procedure 5.2-2 Hotmelt Equipment Nordson -
Change Hotmelt, item a) to g).
b) Allow the melter to heat or cool to the temperature recommended by the
manufacturer of the hot melt cleaning fluid.
c) Press the PUMP button (1) to stop the pump.
d) Wipe off any residual hot melt from inside the tank.
e) Add the appropriate type and quantity of hot melt cleaning fluid to the tank.
f) Press the PUMP button (1) to start the pump.
g) Following the instructions provided with the cleaning fluid, pump all of the
cleaning fluid from the tank.

1 PUMP button
.

(Cont’d)

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5.2 Hotmelt Equipment Nordson 5 Hotmelt Equipment

(Cont’d)

To Clean the Tank of Excessive Char

a) Empty the tank as described in Procedure 5.2-2 Hotmelt Equipment Nordson -
Change Hotmelt, item a) to g).
b) Allow the melter to heat or cool to the temperature recommended by the
manufacturer of the hot melt cleaning fluid.
c) Press the PUMP button (1) to stop the pump.
d) Wipe off any residual hot melt and loose char from inside the tank.

1 PUMP button
.

(Cont’d)

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5 Hotmelt Equipment 5.2 Hotmelt Equipment Nordson

(Cont’d)

e) Add cleaning fluid to the tank and clean the tank according to instructions
provided with the cleaning fluid.
f) Step up the machine to step 2; AIR ON.
g) Lower the pressure to 0 bar (0 MPa) by turning the screw (3).
h) Put a container under the drain chute (2) and pull the chute down.
i) Open the drain valve (4) by slowly turning it to the left.
j) Raise the pressure gently by turning the screw (3) until the remaining cleaning
fluid pours out.
k) Empty the tank.
l) Close the drain valve (4) by turning it to the right. Clean and pull up the drain
chute (2).
m) Change the filter as described in Procedure 5.2-8 Hotmelt Equipment Nordson -
Change Filter on page 458.

2 3
2 Drain chute
3 Screw
4 Drain valve
.

5.2-11 Hotmelt Equipment Nordson - Change Hotmelt Unit

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2892717-0200

WARNING
Burn hazard.
Risk of personal injury. Wear safety glasses, protective gloves, and other protective
clothing to avoid injuries from hot surfaces or hotmelt pouring out.
a) Empty the hotmelt container as described in 5.2-2 Hotmelt Equipment Nordson -
.
Change Hotmelt on page 448.

(Cont’d)

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5.2 Hotmelt Equipment Nordson 5 Hotmelt Equipment

(Cont’d)

b) Switch off the hotmelt unit with the power switch (1) and let it cool off.
c) Relieve the air pressure and disconnect the hoses (2).
d) Open the electrical enclosure door (3). Disconnect the electrical supply cable
connector (4) from the receptacle (5) on the main board.
e) Disconnect the ground lead (6) from the ground lug (7) on the sub-base.
f) Disconnect the ground jumper (8) from the ground post (9) on the sub-base.

5
4
9 1
8
7 6
1 Power switch 5 Receptacle
2 Air hose 6 Ground lead
3 Door 7 Ground lug
4 Electrical supply cable 8 Ground jumper
connector 9 Ground post
.

(Cont’d)

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5 Hotmelt Equipment 5.2 Hotmelt Equipment Nordson

(Cont’d)

g) Turn the locking screws (10) to the left approximately 10 turns.

h) Slide the hotmelt unit forward and then lift it clear of the sub-base.
i) Assemble in the reverse order.

10

10 Screw

For further information, read the Nordson ProBlue Adhesive Melters Manual,
included in the delivery from Tetra Pak.

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5.2 Hotmelt Equipment Nordson 5 Hotmelt Equipment

5.2.1 Hotmelt Gun

5.2.1-1 Hotmelt Gun - Change Gun Module
Machine Status Electrical supply disconnecting device in position I
(ON)
Main air valve LOCKED in OFF position
Program step PREHEATED
SPC Reference 90600-2959

Note! The guns must have reached operating temperature. Set the pump air
pressure to zero.

a) WARNING
Burn hazard.
Risk of personal injury.
Wear safety glasses, protective gloves, and other protective clothing to avoid
injuries from hotmelt pouring out.
Press the PUMP button (1) to stop the pump.

1 PUMP button
.

(Cont’d)

466 (728) Doc. No. MM-3541840-0101

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5 Hotmelt Equipment 5.2 Hotmelt Equipment Nordson

(Cont’d)

b) Remove module (2) and/or (3). Use an allen key 5/32”.

c) Carefully wipe the contact surface with a dry cloth to remove any hotmelt waste.
d) Change the module.
e) Press the PUMP button (1) to start the pump.

1 PUMP button
2 Module
3 Module
.

5.2.1-2 Hotmelt Gun - Change Solenoid Valve

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
Main air valve LOCKED in OFF position
SPC Reference 90600-2959

WARNING
Burn hazard.
Risk of personal injury. Wear safety glasses, protective gloves, and other protective
clothing to avoid injuries from hotmelt pouring out.
Change the solenoid valves (arrows).
.

5.2.1-3 Hotmelt Gun - Set Gun Holder

Machine Status Electrical supply disconnecting device in position I (ON)
Main air valve ON
SPC Reference 90600-2959

WARNING
Burn hazard.
Risk of personal injury. The guns are hot. Be careful when handling the gun holder.
(Cont’d)

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5.2 Hotmelt Equipment Nordson 5 Hotmelt Equipment

(Cont’d)

Lower Dot Position

a) Loosen the screw (1).
b) Move the lower gun holder (3). Set the value at the scale mark (2) according to
the table below.

Straw type Top right Top left

U-1654 (TB/TBA) 21 mm 15 mm
U-1455 (TB/TBA) 10 mm 8 mm

1 Screw
2 Scale mark
3 Gun holder
.

(Cont’d)

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5 Hotmelt Equipment 5.2 Hotmelt Equipment Nordson

(Cont’d)

c) Check that the nozzle (5) does not shoot hotmelt on the guide arm (4).
d) Set the nozzle (5) at the angle A. If the angle is zero, hotmelt will splash back on
the nozzle and the guide arm.
• Loosen the nozzle with a wrench.
• Adjust the nozzle with a screwdriver.
• Keep the nozzle in position with the screwdriver and tighten the inner part of
the nozzle with the wrench.

A ≈ 10°
4 Guide arm
5 Nozzle
.

(Cont’d)

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5.2 Hotmelt Equipment Nordson 5 Hotmelt Equipment

(Cont’d)

Upper Dot Position

a) Loosen the screw (1).
b) Move the upper gun holder (3) upwards/downwards. Set the value at the scale
mark (2) according to the table below.

Straw type Top right Top left

U-1654 (TB/TBA) 105 mm 105 mm
U-1455 (TB/TBA) 90 mm 75 mm

c) Check that the nozzle (5) does not shoot hotmelt on the guide arm (4). Adjust
the nozzle, if necessary. See section Lower Dot Position, item d) on page 469.

1 Screw
2 Scale mark
3 Gun holder
4 Guide arm
5 Nozzle
.

(Cont’d)

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5 Hotmelt Equipment 5.2 Hotmelt Equipment Nordson

(Cont’d)

Final Check
a) Operate the machine. Check that the hotmelt dots are deposited on the straw,
and the straw deposited on the package according to the illustrations below.
Note! If the package is bulging, adjust the settings so the hotmelt dot will be
placed on the ridge.
Note! Horizontal adjustments of the straw position can be made in the TPOP.
See Procedure 1.2.2.6-1 Maintenance - Set Apply Unit on page 247.

S/T Straw Check the A measure. The hotmelt dots (1) should be equally
(TB/TBA) positioned from the package edges.
S/T Straw The upper hotmelt dot should be positioned as close to the top of
(TPA/TT) the straw as possible. The lower hotmelt dot should be positioned
as low as possible above the cutting, as shown in the illustration.
U Straw The hotmelt dots (2) should be positioned with the upper dot on
(TB/TBA) the straw bend (although this dot can be lowered to enhance
contact), and with the lower dot behind the straw, as shown in the
illustration.

1 2 2

3 4

1 Hotmelt dot S/T straw 2 Hotmelt dot U straw 3 Hotmelt dot (TPA)
(TB/TBA) (TB/TBA) 4 Hotmelt dot (TT)
.

(Cont’d)

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5.2 Hotmelt Equipment Nordson 5 Hotmelt Equipment

(Cont’d)

b) Make sure that the nozzles (5) and (6) do not apply hotmelt where the arms (7)
pick the straw.

5 Nozzle
6 Nozzle
7 Arm
.

472 (728) Doc. No. MM-3541840-0101

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 6 Machine Body

®
Doc. No. MM-3541840-0101 473 (728)
 6 Machine Body

Description
SPC Reference 663304-0500

4
3

8
5
1
1 Cable duct
2 Machine body
3 Indicating tower
4 Light fixture
5 Vibration damper
6 Cable (not in
illustration)
7 Connection block
8 Connector

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6 Machine Body Table of Contents

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474

6.1 Cable Duct ....................................................... 477

6.1-1 Cable Duct - No Procedure Described . . . . . . . . . . . . 477

6.2 Machine Body................................................... 478

6.2-1 Machine Body - No Procedure Described . . . . . . . . . 478

6.3 Vibration Damper .............................................. 479

6.3-1 Vibration Damper - No Procedure Described
(TBA/TPA with SD Integrated) . . . . . . . . . . . . . . . . . . . .479

6.4 Indicating Tower................................................ 480

6.4-1 Indicating Tower - No Procedure Described . . . . . . . 480

6.5 Light Fixture..................................................... 481

6.5-1 Light Fixture - No Procedure Described . . . . . . . . . . . 481

6.6 Connection Block .............................................. 482

6.6-1 Connection Block - No Procedure Described . . . . . . 482

6.7 Connector........................................................ 483

6.7-1 Connector - No Procedure Described . . . . . . . . . . . . . 483

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 6 Machine Body

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476 (728) Doc. No. MM-3541840-0101

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6 Machine Body 6.1 Cable Duct

6.1 Cable Duct

6.1-1 Cable Duct - No Procedure Described
SPC Reference 2843700-0200

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Doc. No. MM-3541840-0101 477 (728)
6.2 Machine Body 6 Machine Body

6.2 Machine Body

6.2-1 Machine Body - No Procedure Described
SPC Reference 2788657-0500

478 (728) Doc. No. MM-3541840-0101

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6 Machine Body 6.3 Vibration Damper

6.3 Vibration Damper

6.3-1 Vibration Damper - No Procedure Described (TBA/TPA
with SD Integrated)
SPC Reference 2946861-0400

Note! Disconnect the vibration damper when using package type TBA 500B.

®
Doc. No. MM-3541840-0101 479 (728)
6.4 Indicating Tower 6 Machine Body

6.4 Indicating Tower

6.4-1 Indicating Tower - No Procedure Described
SPC Reference 3245337-0200

480 (728) Doc. No. MM-3541840-0101

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6 Machine Body 6.5 Light Fixture

6.5 Light Fixture

6.5-1 Light Fixture - No Procedure Described
SPC Reference 2901717-0200

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Doc. No. MM-3541840-0101 481 (728)
6.6 Connection Block 6 Machine Body

6.6 Connection Block

6.6-1 Connection Block - No Procedure Described
SPC Reference 90604-0093

482 (728) Doc. No. MM-3541840-0101

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6 Machine Body 6.7 Connector

6.7 Connector
6.7-1 Connector - No Procedure Described
SPC Reference 2913340-0100

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6.7 Connector 6 Machine Body

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484 (728) Doc. No. MM-3541840-0101

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 7 Machine Covering

®
Doc. No. MM-3541840-0101 485 (728)
 7 Machine Covering

Description
SPC Reference 663305-0500

5
7
9 6
8

1
4
1 Glass door
2 Covering panel
3 Covering panel
4 Covering panel
5 Covering panel
6 Covering panel
7 Covering plate
8 Tunnel
9 Tunnel

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7 Machine Covering Table of Contents

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486

7.1 Glass Door ....................................................... 489

7.1-1 Glass Door - No Procedure Described . . . . . . . . . . . . 489

7.2 Covering Panel ................................................. 490

7.2-1 Covering Panel - No Procedure Described . . . . . . . . 490

7.3 Covering Panel ................................................. 491

7.3-1 Covering Panel - No Procedure Described . . . . . . . . 491

7.4 Covering Panel ................................................. 492

7.4-1 Covering Panel - No Procedure Described . . . . . . . . 492

7.5 Covering Panel ................................................. 493

7.5-1 Covering Panel - No Procedure Described . . . . . . . . 493

7.6 Tunnel............................................................. 494

7.6-1 Tunnel - No Procedure Described . . . . . . . . . . . . . . . . 494

7.7 Discharge Tunnel .............................................. 495

7.7-1 Discharge Tunnel - No Procedure Described . . . . . . 495

7.8 Tunnel............................................................. 496

7.8-1 Tunnel - No Procedure Described . . . . . . . . . . . . . . . . 496

7.9 Tunnel............................................................. 497

7.9-1 Tunnel - No Procedure Described . . . . . . . . . . . . . . . . 497

7.10 Covering Panel ................................................. 498

7.10-1 Covering Panel - No Procedure Described . . . . . . . . 498

7.11 Covering Plate .................................................. 499

7.11-1 Covering Plate - No Procedure Described . . . . . . . . . 499

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 7 Machine Covering

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7 Machine Covering 7.1 Glass Door

7.1 Glass Door

7.1-1 Glass Door - No Procedure Described
SPC Reference 2839815-0400

®
Doc. No. MM-3541840-0101 489 (728)
7.2 Covering Panel 7 Machine Covering

7.2 Covering Panel

7.2-1 Covering Panel - No Procedure Described
SPC Reference 2839820-0200
3174051-0100

490 (728) Doc. No. MM-3541840-0101

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7 Machine Covering 7.3 Covering Panel

7.3 Covering Panel

7.3-1 Covering Panel - No Procedure Described
SPC Reference 3210341-0100

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Doc. No. MM-3541840-0101 491 (728)
7.4 Covering Panel 7 Machine Covering

7.4 Covering Panel

7.4-1 Covering Panel - No Procedure Described
SPC Reference 2840890-0300

492 (728) Doc. No. MM-3541840-0101

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7 Machine Covering 7.5 Covering Panel

7.5 Covering Panel

7.5-1 Covering Panel - No Procedure Described
SPC Reference 2840892-0200

®
Doc. No. MM-3541840-0101 493 (728)
7.6 Tunnel 7 Machine Covering

7.6 Tunnel
7.6-1 Tunnel - No Procedure Described
SPC Reference 3073180-0100

494 (728) Doc. No. MM-3541840-0101

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7 Machine Covering 7.7 Discharge Tunnel

7.7 Discharge Tunnel

7.7-1 Discharge Tunnel - No Procedure Described
SPC Reference 3321347-0100

®
Doc. No. MM-3541840-0101 495 (728)
7.8 Tunnel 7 Machine Covering

7.8 Tunnel
7.8-1 Tunnel - No Procedure Described
SPC Reference 3321348-0100

496 (728) Doc. No. MM-3541840-0101

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7 Machine Covering 7.9 Tunnel

7.9 Tunnel
7.9-1 Tunnel - No Procedure Described
SPC Reference 2885383-0100

®
Doc. No. MM-3541840-0101 497 (728)
7.10 Covering Panel 7 Machine Covering

7.10 Covering Panel

7.10-1 Covering Panel - No Procedure Described
SPC Reference 2941199-0100

Note! Valid for straight infeed/discharge.

498 (728) Doc. No. MM-3541840-0101

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7 Machine Covering 7.11 Covering Plate

7.11 Covering Plate

7.11-1 Covering Plate - No Procedure Described
SPC Reference 3168952-0200
3234441-0200

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7.11 Covering Plate 7 Machine Covering

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 8 Air Equipment

®
Doc. No. MM-3541840-0101 501 (728)
 8 Air Equipment

Description
SPC Reference 663306-0500

1 Air supply
2 Main pipe

502 (728) Doc. No. MM-3541840-0101

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8 Air Equipment Table of Contents

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502

8.1 Air Supply........................................................ 505

8.1-1 Air Supply - Shut Off Air Pressure . . . . . . . . . . . . . . . . 505
8.1-2 Air Supply - Set Air Pressure . . . . . . . . . . . . . . . . . . . . . 506
8.1-3 Air Supply - Clean Filter Regulator. . . . . . . . . . . . . . . . 507

8.1.1 Air Supply - Set Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508

8.1-4 Air Supply - Set Pressure Sensor . . . . . . . . . . . . . . . . . 509

8.2 Main Pipe......................................................... 514

8.2-1 Main Pipe - No Procedure Described . . . . . . . . . . . . . 514

8.3 Pneumatic diagrams .......................................... 515

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 8 Air Equipment

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8 Air Equipment 8.1 Air Supply

8.1 Air Supply

8.1-1 Air Supply - Shut Off Air Pressure
Machine Status Electrical supply disconnecting device in position I (ON)
SPC Reference 2839813-0400

a) The direction of the knob (1) on the shut off valve is the same as the flow
direction and can be set in two positions:
• Closed (OFF) (5)
Shut off the air supply by turning the knob (1) to the right. The shut off valve
can be locked in this position.
• Open (ON) (4)
Turn on the air supply by turning the knob (1) to the left.

b) Check that the air pressure is zero on the manometer (2) on the regulator (3).

3
2
1
5

1 Knob, shut off valve

A01Q3010
2 Manometer
3 Filter regulator,
A01K3020
4 Open (ON)
5 Closed (OFF)
.

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8.1 Air Supply 8 Air Equipment

8.1-2 Air Supply - Set Air Pressure

Machine Status Electrical supply disconnecting device in position I
(ON)
Main air valve ON
SPC Reference 2839813-0400

a) Turn on the air supply by turning the shut off valve’s knob (1) to the left. The
direction of the knob is the same as the flow direction.
Note! In the illustration the valve is closed.
b) Set the working pressure according to the table. Use the knob (2) on the
regulator (3). The pressure is displayed on the manometer (4).
c) Set the hotmelt gun pressure according to the table. Use the knob (5) on the
regulator (6). The pressure is displayed on the manometer (7).
Note! The pressure sensor (8) is related to the hotmelt gun pressure. See
Procedure 8.1-4 Air Supply - Set Pressure Sensor on page 509.

Working pressure 0.55 MPa (5.5 bar)

Hotmelt gun pressure 0.4 to 0.45 MPa (4 to 4.5 bar)

Note! The values are also stated in the OM.

5
6
1
7

2
8
3

1 Knob, shut off valve 4 Manometer 6 Regulator A01K3030

A01Q3010 5 Knob 7 Manometer
2 Knob 8 Pressure sensor
3 Filter regulator A01B2010
A01K3020
.

506 (728) Doc. No. MM-3541840-0101

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8 Air Equipment 8.1 Air Supply

8.1-3 Air Supply - Clean Filter Regulator

Machine Status Main air valve LOCKED in OFF position
Program step IDLE
SPC Reference 2839813-0400

WARNING
Risk of injuries.
The system must be depressurized before cleaning. For more information, see
Chapter ii Safety Precautions.
a) Shut off the air supply. See Procedure 8.1-1 Air Supply - Shut Off Air Pressure
on page 505.
b) Turn the filter bowl (1) to the left. Jerk it and pull gently downwards.

1 Filter bowl
.

(Cont’d)

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8.1 Air Supply 8 Air Equipment

(Cont’d)

c) Turn the separating plate (2) to the left.

d) Remove the separating plate (2) and the filter element (3).
e) Change the filter element (3) or clean it with water (maximum temperature 60 °
C/140 °F), soup suds, or petroleum ether (free of compounds).
Note! A cleaned filter gets clogged much quicker than a new filter. It is
recommended to change the filter instead of cleaning it.
Note! Hold the clean filter in the lower end only.
f) Reinstall the separating plate (2).

g) WARNING
Risk of personal injury.
The filter bowl must be turned fully to the right into the body before pressurizing
the unit.
Reinstall the filter bowl (1). Make sure that the locking pin (4) points towards the
large recess (5) in the housing.
h) Turn the filter bowl (1) to the right until a clicking sound is heard. To get it in
place, it might be necessary to jerk it a bit.

4
3

6
5
2
1 Filter bowl
2 Separating plate
3 Filter element
4 Locking pin
5 Large recess
.

8.1.1 Air Supply - Set Safety Valve

See Section 11.15-3 Safety Valve - Set.

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8 Air Equipment 8.1 Air Supply

8.1-4 Air Supply - Set Pressure Sensor

Machine Status Electrical supply disconnecting device in position I (ON)
Main air valve ON
SPC Reference 2839813-0400

Set the pressure sensor (1) according to the table.

Switching output Out A Out A

Comparator Window comparator

SP min (Lower switching 0.4 MPa / 4 bar / 58 PSI

pressure)
SP max (Upper switching 0.6 MPa / 6 bar / 87 PSI
pressure)
HY (Hysteresis) 0.02 MPa / 0.2 bar / 2.9 PSI
Contact NO (Normally open)
[NO]
Note! In the illustration the main air valve is closed.

1 Pressure sensor,
F09B2032

Check Values
Press the UP button (1) repeatedly to check the set values. Compare with the values
in the table above. If the settings are correct, nothing more needs to be done.

Factory Reset
To perform a factory reset, follow these steps:

(Cont’d)

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8.1 Air Supply 8 Air Equipment

(Cont’d)

a) Turn off the electrical supply by disconnecting the electrical supply cable from
the pressure sensor.
b) Press the UP button (1), DOWN button (2), and EDIT button (3) at the same
time. Use a pointed object to press the EDIT button (3).
c) Turn on the electrical supply again by connecting the electrical supply cable to
the pressure sensor.

1 2

Edit

A B

3
1 UP button
2 DOWN button
3 EDIT button
.

(Cont’d)

510 (728) Doc. No. MM-3541840-0101

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8 Air Equipment 8.1 Air Supply

(Cont’d)

Edit Values
a) Press the EDIT button (3) with a pointed object.
b) Switching output A, Out A (4), will flash. Check that the unit is set to bar in the
lower part of the display.
c) Confirm with the EDIT button (3).
d) Press the UP button (1) until Window comparator (6) is selected. The flashing
symbol shows what is selected.
e) Confirm with the EDIT button (3).
f) Lower switching pressure, SP min (7), will flash.
g) Press the UP button (1) or the DOWN button (2) to change the value.
h) Confirm with the EDIT button (3).
i) Upper switching pressure, SP max (8), will flash.
j) Press the UP button (1) or the DOWN button (2) to change the value.
k) Confirm with the EDIT button (3).

Out A 4

3 6

1 2
Edit 7
[SP] [min]
A B 8
[SP] [max]
1 UP button 5 Threshold comparator
2 DOWN button 6 Window comparator
3 EDIT button 7 SP min
4 Out A 8 SP max
.

(Cont’d)

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8.1 Air Supply 8 Air Equipment

(Cont’d)

l) Hysteresis, HY (9), will flash.

m) Press the UP button (1) or the DOWN button (2) to change the value.
n) Confirm with the EDIT button (3).
o) Normally open contact, NO (10), or normally closed contact, NC (11) will flash.
p) Select NO (10). Press the UP button (1) to change.
q) Confirm with the EDIT button (3). The pressure sensor will return to the main
menu.

9
[HY]
10
[NO]
11
3 [NC]
1 2
Edit

A B

1 UP button
2 DOWN button
3 EDIT button
9 HY
10 NO
11 NC
.

Password Definition
a) Press the UP button (1) or DOWN button (2) to find the password definition and
confirm the choice by pressing the EDIT button (3).
b) Select either:
• 0 = No password
• 1 = Password

Note! The default value is 0.

c) Confirm the setting by pressing the EDIT button (3).
d) If password protection is chosen, choose the password with the UP button (1)
or /and DOWN button (2) and confirm the setting with the EDIT button (3).
e)
.
Press the EDIT button (3) once more to return to the main menu.

(Cont’d)

512 (728) Doc. No. MM-3541840-0101

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8 Air Equipment 8.1 Air Supply

(Cont’d)

Remove a Password
a) Turn off the power supply disconnector.
b) Press the EDIT button (3), UP button (1) and DOWN button (2), simultaneously,
while turning on the power supply disconnector.

1 2

1 UP button
2 DOWN button
3 EDIT button
.

®
Doc. No. MM-3541840-0101 513 (728)
8.2 Main Pipe 8 Air Equipment

8.2 Main Pipe

8.2-1 Main Pipe - No Procedure Described
SPC Reference 2941716-0200

514 (728) Doc. No. MM-3541840-0101

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8 Air Equipment 8.3 Pneumatic diagrams

8.3 Pneumatic diagrams

®
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8.3 Pneumatic diagrams 8 Air Equipment

(Cont’d)

516 (728) Doc. No. MM-3541840-0101

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 9 Regular Accessories

®
Doc. No. MM-3541840-0101 517 (728)
 9 Regular Accessories

Description
SPC Reference 663310-0500

1 2

3
4

1 Photocell unit
2 Straw magazine
3 Tools and Templates
4 Waste pipe

(Cont’d)

518 (728) Doc. No. MM-3541840-0101

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9 Regular Accessories

(Cont’d)

1 2

3
4

Valid for: OK Straw Quality Improvement 3503674-0100

1 Photocell unit
2 Straw magazine
3 Tools and Templates
4 Waste pipe

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Table of Contents 9 Regular Accessories

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518

9.1 Photocell Unit ................................................... 523

9.1-1 Photocell Unit - No Procedure Described . . . . . . . . . . 523

9.2 Straw Magazine................................................. 524

9.2-1 Straw Magazine - No Procedure Described. . . . . . . . 524

9.3 Tools and Templates .......................................... 525

9.3.1 Template. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
9.3.1-1 Template - No Procedure Described
(TPA/TT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .525
9.3.2 Template. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
9.3.2-1 Template - No Procedure Described
(TB/TBA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .525

9.3.3 Template. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526

9.3.3-1 Template - No Procedure Described
(TPA/TT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .526

9.3.4 Template. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526

9.3.4-1 Template - No Procedure Described
(TB/TBA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .526

9.3.5 Position Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526

9.3.5-1 Position Template - No Procedure Described . . . . . . 526

9.3.6 Tools and Templates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527

9.3.6.1 Hook Spanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
9.3.6.1-1 Hook Spanner - No Procedure Described . . . . . . . . . 527
9.3.6.2 Setting Template. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
9.3.6.2-1 Setting Template- No Procedure Described. . . . . . . . 527

9.4 Quick Change ................................................... 528

9.4.1 Feed Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528
9.4.1-1 Feed Wheel - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . 528
9.4.2 Cutting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528
9.4.2-1 Cutting Unit - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . 528

9.4.3 Pressure Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530

9.4.3-1 Pressure Arm - Assemble. . . . . . . . . . . . . . . . . . . . . . . . 530

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9 Regular Accessories Table of Contents

9.5 Bent Foil Treater................................................ 531

9.5.1 Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531
9.5.1-1 Heater - Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531
9.5.1.1 Roller Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
9.5.1.1-1 Roller Unit - Check Bushings. . . . . . . . . . . . . . . . . . . . . 533
9.5.1.1-2 Roller Unit - Change Bushings . . . . . . . . . . . . . . . . . . . 534
9.5.1.1-3 Roller Unit - Change Roller Chain . . . . . . . . . . . . . . . . 538
9.5.1.1-4 Roller Unit - Check Wheel . . . . . . . . . . . . . . . . . . . . . . . 540
9.5.1.1-5 Roller Unit - Change Wheel . . . . . . . . . . . . . . . . . . . . . . 541
9.5.1.1-6 Roller Unit - Check Hand Wheel . . . . . . . . . . . . . . . . . . 542
9.5.1.1-7 Roller Unit - Change Hand Wheel . . . . . . . . . . . . . . . . 543
9.5.1.2 Bending Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
9.5.1.2-1 Bending Roller - Check Bushings/Ball
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .544
9.5.1.2-2 Bending Roller - Check Rollers . . . . . . . . . . . . . . . . . . . 546

9.5.2 Electrical Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548

9.5.2-1 Electrical Cabinet - Change Thermocouple . . . . . . . . 548
9.5.2-2 Electrical Cabinet - Change Heating Element . . . . . . 549
9.5.2-3 Electrical Cabinet - Set Relays . . . . . . . . . . . . . . . . . . . 550
9.5.2.1 Temperature Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551
9.5.2.1-1 Temperature Controller - Check Error
Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .554
9.5.2.1-2 Temperature Controller - Change . . . . . . . . . . . . . . . . . 557
9.5.2.1-3 Temperature Controller - Set Switches . . . . . . . . . . . . 558
9.5.2.1-4 Temperature Controller - Set Parameters
Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .560
9.5.2.1-5 Temperature Controller - Install BlueLoader . . . . . . . 565
9.5.2.1-6 Temperature Controller - Set Parameters with
BlueLoader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .567

9.5.3 Motor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572

9.5.3-1 Motor Unit - Change Fan . . . . . . . . . . . . . . . . . . . . . . . . 572
9.5.4 Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573
9.5.4-1 Warning Lamp - Error Handling. . . . . . . . . . . . . . . . . . . 573

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Table of Contents 9 Regular Accessories

This page intentionally left blank

522 (728) Doc. No. MM-3541840-0101

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9 Regular Accessories 9.1 Photocell Unit

9.1 Photocell Unit

9.1-1 Photocell Unit - No Procedure Described
SPC Reference 2909952-0200

®
Doc. No. MM-3541840-0101 523 (728)
9.2 Straw Magazine 9 Regular Accessories

9.2 Straw Magazine

9.2-1 Straw Magazine - No Procedure Described
SPC Reference 3405670-0100
3503681-0100

Valid for: 3405670-0100

Valid for: 3503681-0100 (OK Straw Quality Improvement 3503674-0100)

524 (728) Doc. No. MM-3541840-0101

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9 Regular Accessories 9.3 Tools and Templates

9.3 Tools and Templates

SPC Reference 2957779-0300

9.3.1 Template
9.3.1-1 Template - No Procedure Described (TPA/TT)
SPC Reference 3013619-0100

9.3.2 Template
9.3.2-1 Template - No Procedure Described (TB/TBA)
SPC Reference 3013391-0100

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9.3 Tools and Templates 9 Regular Accessories

9.3.3 Template
9.3.3-1 Template - No Procedure Described (TPA/TT)
SPC Reference 3013902-0100

9.3.4 Template
9.3.4-1 Template - No Procedure Described (TB/TBA)
SPC Reference 3013617-0100

9.3.5 Position Template

9.3.5-1 Position Template - No Procedure Described
SPC Reference 3057744-0100

526 (728) Doc. No. MM-3541840-0101

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9 Regular Accessories 9.3 Tools and Templates

9.3.6 Tools and Templates

9.3.6.1 Hook Spanner
.

9.3.6.1-1 Hook Spanner - No Procedure Described

SPC Reference 90243-0164

9.3.6.2 Setting Template

.

9.3.6.2-1 Setting Template- No Procedure Described

SPC Reference 3166869-0000

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Doc. No. MM-3541840-0101 527 (728)
9.4 Quick Change 9 Regular Accessories

9.4 Quick Change

SPC Reference 3025775-0400

9.4.1 Feed Wheel

9.4.1-1 Feed Wheel - Assemble
SPC Reference 2960584-0100

Prepare the feed wheel quick change kit by assembling the variant feed wheel to the
quick change parts by the screws (1).

1 Screw (3 pieces)

9.4.2 Cutting Unit

9.4.2-1 Cutting Unit - Assemble
Machine Status
Consumables Mist lubrication oil
SPC Reference 3234510-0100

CAUTION
Risk of personal injury.
The knife is very sharp.
Be careful when working near the knife.
(Cont’d)

528 (728) Doc. No. MM-3541840-0101

®
9 Regular Accessories 9.4 Quick Change

(Cont’d)

Prepare the cutting unit quick change kit:

a) Assemble the bearing bushings (5) and (7) on the shaft (6). Apply a drop of oil
between each bearing bushing and the shaft. Use the lubricant described in
Section 10.4.2 Lubricants on page 601.
b) Assemble the knife (2) to the shaft (6) with the screw (1).
c) Assemble the bracket (4) with the screws (3).

2 4

5
1 6

1 Screw 5 Bearing bushing

2 Knife 6 Shaft
3 Screw 7 Bearing bushing
4 Bracket
.

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9.4 Quick Change 9 Regular Accessories

9.4.3 Pressure Arm

9.4.3-1 Pressure Arm - Assemble
Machine Status
SPC Reference 3234511-0100

Prepare the quick change pressure arm kit:

Assemble the variant pressure arms to the quick change parts with the screws (1).

1
1 Screw
.

530 (728) Doc. No. MM-3541840-0101

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9 Regular Accessories 9.5 Bent Foil Treater

9.5 Bent Foil Treater

SPC Reference 2643050-0400

9.5.1 Heater
9.5.1-1 Heater - Clean
Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2643060-0300

a) Loosen the screws (1).

b) Remove the reel holder (2) and the rollers (3).
c) Loosen the screw (4).
d) Remove the angle (5) and the rollers (6).

2 1 6
4 5
3

1 Screw 4 Screw
2 Reel holder 5 Angle
3 Roller 6 Roller
.

(Cont’d)

®
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9.5 Bent Foil Treater 9 Regular Accessories

(Cont’d)

e) Remove any loose straws.

f) Remove the screws (7).
g) Remove the plate (8) from the heater and rinse the plate thoroughly with water.
h) Clean the heater with a cloth to remove dust and soil.
i) Assemble the in reverse order.

7 Screw (4 pieces)
8 Plate
.

532 (728) Doc. No. MM-3541840-0101

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9 Regular Accessories 9.5 Bent Foil Treater

9.5.1.1 Roller Unit

.

9.5.1.1-1 Roller Unit - Check Bushings

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2960755-0100

Check the bushings by cranking the hand wheel (1). Change, if necessary. See
Procedure 9.5.1.1-2 Roller Unit - Change Bushings on page 534.

1 Hand wheel
.

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Doc. No. MM-3541840-0101 533 (728)
9.5 Bent Foil Treater 9 Regular Accessories

9.5.1.1-2 Roller Unit - Change Bushings

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2960755-0100

a) Loosen the screws (1).

b) Remove the reel holder (2).

2 1

1 Screw
2 Reel holder
.

(Cont’d)

534 (728) Doc. No. MM-3541840-0101

®
9 Regular Accessories 9.5 Bent Foil Treater

(Cont’d)

c) Loosen the screws (3).

d) Remove the screw (4) and the bracket (5).
e) Change the bushings (6).
f) Assemble the bracket (5) and the screw (4).

5
4
3

3 Screw
4 Screw
5 Bracket
6 Bushing
.

(Cont’d)

®
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9.5 Bent Foil Treater 9 Regular Accessories

(Cont’d)

g) Loosen the screw (7).

h) Remove the sprocket (8) and the roller chain (9).
i) Remove the screws (10) and disassemble the hand wheel unit.
j) Remove the hand wheel (11) and remove the plastic cover (12).
k) Remove the retaining ring (13).
l) Change the flange bushings (14).

8 9
7

10

13
12
11

14
14

7 Screw 11 Hand wheel

8 Sprocket 12 Plastic cover
9 Roller chain 13 Retaining ring
10 Screw (4 pieces) 14 Flange bushing
.

(Cont’d)

536 (728) Doc. No. MM-3541840-0101

®
9 Regular Accessories 9.5 Bent Foil Treater

(Cont’d)

m) Remove the sprocket (15).

n) Change the flange bushing (16).
o) Assemble in the reverse order.

16

15

15 Sprocket
16 Flange bushing
.

®
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9.5 Bent Foil Treater 9 Regular Accessories

9.5.1.1-3 Roller Unit - Change Roller Chain

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2960755-0100

a) Loosen the screws (1).

b) Remove the reel holder (2).

2 1

1 Screw
2 Reel holder
.

(Cont’d)

538 (728) Doc. No. MM-3541840-0101

®
9 Regular Accessories 9.5 Bent Foil Treater

(Cont’d)

c) Loosen the screws (3).

d) Loosen the screw (4) and remove the sprocket (5).
e) Change the roller chain (6).
f) Assemble in the reverse order.

6
5 3
4

3 Screw (2 pieces)
4 Screw
5 Sprocket
6 Roller chain
.

®
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9.5 Bent Foil Treater 9 Regular Accessories

9.5.1.1-4 Roller Unit - Check Wheel

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2960755-0100

a) Check the wheel (1) for wear and damage. Change, if necessary.
b) Clean the heater. See Procedure 9.5.1-1 Heater - Clean on page 531.

1 Wheel
.

540 (728) Doc. No. MM-3541840-0101

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9 Regular Accessories 9.5 Bent Foil Treater

9.5.1.1-5 Roller Unit - Change Wheel

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2960755-0100

a) Loosen the screws (1).

b) Remove the reel holder (2).
c) Remove the screw (3) and change the wheel (4).
d) Assemble in the reverse order.

2 1

3
4

1 Screw
2 Reel holder
3 Screw
4 Wheel
.

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Doc. No. MM-3541840-0101 541 (728)
9.5 Bent Foil Treater 9 Regular Accessories

9.5.1.1-6 Roller Unit - Check Hand Wheel

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2960755-0100

Check the hand wheel (1) for wear or damage. Change, if necessary. See
Procedure 9.5.1.1-7 Roller Unit - Change Hand Wheel on page 543.

1 Hand wheel

542 (728) Doc. No. MM-3541840-0101

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9 Regular Accessories 9.5 Bent Foil Treater

9.5.1.1-7 Roller Unit - Change Hand Wheel

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2960755-0100

a) Remove the lid (1) and remove the retaining ring (2) inside.
b) Change the hand wheel (3).
c) Assemble in the reverse order.

3
1

1 Lid
2 Retaining ring
3 Hand wheel
.

®
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9.5 Bent Foil Treater 9 Regular Accessories

9.5.1.2 Bending Roller

.

9.5.1.2-1 Bending Roller - Check Bushings/Ball Bearings

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2789703-0200
3503678-0100

Valid for: 2789703-0200

a) Check the bushings (1) on the bending rollers (2) for wear and damage.
Change, if necessary.
b) Clean the heater. See Procedure 9.5.1-1 Heater - Clean on page 531.

1
1 Bushing (14 pieces)
2 Bending roller
(7 pieces)
.

(Cont’d)

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(Cont’d)

Valid for: 3503678-0100 (OK Straw Quality Improvement)

a) Check the bushings (1) on the bending rollers (2) for wear and damage.
Change, if necessary.
b) Clean the heater. See Procedure 9.5.1-1 Heater - Clean on page 531.

1 Ball bearing (14

pieces)
2 Bending roller
(7 pieces)
.

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9.5.1.2-2 Bending Roller - Check Rollers

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2789703-0200
3503678-0100

a) Check the bending rollers (1) for wear and damage. Change, if necessary.
b) Clean the heater. See Procedure 9.5.1-1 Heater - Clean on page 531.

Valid for: 2789703-0200

1 Bending roller
(7 pieces)

(Cont’d)

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(Cont’d)

Valid for: 3503678-0100 (OK Straw Quality Improvement 3503674-0100)

1 Bending roller
(7 pieces)

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9.5.2 Electrical Cabinet

9.5.2-1 Electrical Cabinet - Change Thermocouple
Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2727159-0400

Change the thermocouple (1).

1 Thermocouple,
V50B2010
.

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9.5.2-2 Electrical Cabinet - Change Heating Element

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2727159-0400

Change the heating elements (1).

1 Heating element
.

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9.5.2-3 Electrical Cabinet - Set Relays

Machine Status Electrical supply disconnecting device in position I
(ON)
SPC Reference 2727159-0400

a) Set the switches on the time relay (1) according to the illustration below. The
settings should be 10 seconds and mode on-delay.
b) Set the time adjuster (2) to two seconds.
c) Set the current control relay (3) to UNDER CURRENT and WITH MEMORY,
according to the illustration below.
d) Set the screw (4) to 30%, and the other screws (5) to zero.
Note! If the yellow warning lamp lights and only one of the LEDs (6) lights -
check the heating elements. Change heating element, if necessary. See
Procedure 9.5.2-2 Electrical Cabinet - Change Heating Element on page 549.
Press STEP DOWN and then press STEP UP to restart the heating process.

4 5

5
3

1 Time relay, A50K2042

2 Time adjuster
3 Current control relay,
V50K1030
4 Screw
5 Screw
6 LED
.

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9.5.2.1 Temperature Controller

Front view of Controller KS 50-1

LED colours
LED 1, 2 and 3 yellow
LED OK green
Other LEDs red

3 1

9 2
5
10
6
11 7
4 8
16 12
14 13
15
1 For function states 8 Error LED 12 Enter Calls up
(Out1, Out2 and 9 Set-point SP.2 or SP.E extended operating
Out3). Lit when status is effective level/error list
ON. 10 Set-point gradient 13 Decrease/In-
2 Lit with limit value 1 effective crease Changing the
(PArA/LiM) not 11 Manual/automatic set-point or the
exceeded switch-over: Off = controller output value
3 Process value (current Automatic; Lit = 14 Manual mode/special
temperature) Manual, changing function (ConF / LOGI)
4 Set-point value, possible; Flashes = 15 PC connection for
controller output Manual, changing not BlueControl®
5 Signals ConF and possible (engineering tool)
PArA level (→ConF/Cntr/MAn) 16 Freely programmable
6 Programmer running function button F
7 Self-tuning active
.

(Cont’d)

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(Cont’d)

Operation
After supply voltage switch-on, the unit starts in OPERATING MODE. The unit is in
the condition which was active before power-off. If the temperature controller was in
MANUAL OPERATING MODE before power-off, the controller starts with the last
correcting value after switching on again.

Automatic Manual

OPERATING
Time out Time out
MODE

Time out
Error list (if errors exists)

EXTENDED
OPERATING
MODE

(Cont’d)

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(Cont’d)

In the upper display line, the process value (3) is always displayed. In parameter,
configuration, calibration as well as extended operating mode, the bottom display
line changes cyclically between parameter name and parameter value.

3 Process value (current

temperature)
.

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9.5.2.1-1 Temperature Controller - Check Error Indicators

Machine Status Electrical supply disconnecting device in position I
(ON)
SPC Reference 2727159-0400

With one or several errors, the extended operating level always starts with the error
list. Signalling an actual entry in the error list (alarm, error) is done by the Err
LED (1) in the display. This is applicable only if at least one limit value function, the
loop alarm, or the heating current alarm is activated. The error signal is displayed
until the error is acknowledged, or until its cause has been eliminated.

For display of the error list, press the ENTER button (2) twice.

1 Err LED
2 ENTER button

Error Indication

Err LED status Description Proceed as Follows

flashes Alarm due to existing error • Determine the error type in the error list via the
(Status 2) error number
• The device changes to status 1 after error removal
lit Error removed, alarm not • Acknowledge the alarm in the error list pressing
(Status 1) acknowledged the ARROW UP button or the ARROW DOWN
button
• The alarm entry was deleted (Status 0)
off No error - all alarm entries deleted Not visible except when acknowledging
(Status 0)

(Cont’d)

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(Cont’d)

Error list

Name Description Cause Possible remedial action

• Contact manufacturer service
Internal error - cannot be for example defective
E.1 removed EEPROM • Return unit to our factory
E.2 Internal error - can be reset for example EMC trouble • Keep measurement and electrical supply
cables in separate runs
• Ensure that interference suppression of
contactors is provided
E.4 Hardware error Code number and • Replace part
hardware are not • Claim part
identical
FBF.1 Sensor break INP1 • Sensor defective • Replace INP1 sensor
• Faulty cabling • Check INP1 connection
SHT.1 Short circuit INP1 • Sensor defective • Replace INP1 sensor
• Faulty cabling • Check INP1 connection
POL.1 INP1 polarity error Faulty cabling Reverse INP1 polarity
ADA.H Self-tuning heating alarm See Self-tuning heating See Self-tuning heating error status
(ADAH) error status

(Cont’d)

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(Cont’d)

Saved alarms (Err LED (1) is lit) can be acknowledged and deleted with the digital
input di1/2/3, the function button F (3) or the MANUAL MODE/SPECIAL
FUNCTION button (4).

If an alarm is still valid, indicating that the cause of the alarm is not removed so far
(Err LED (1) flashes), then other saved alarms cannot be acknowledged and
deleted.

1 Err LED
3 Freely programmable
function button F
4 MANUAL
MODE/SPECIAL
FUNCTION (ConF /
LOGI) button

In case of problems with the temperature controller, check all connections. Change
the temperature regulator, if required. See procedure 9.5.2.1-2 Temperature
Controller - Change on page 557.

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9.5.2.1-2 Temperature Controller - Change

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2727159-0400

Note! When changing the temperature controller, also change the housing.
a) Remove the screws (1) and the holder (2) from the electrical cabinet.
b) Remove the fixing clamps (3) from the housing (4).
c) Remove all electrical connections from the housing (4).
d) Change the temperature controller (5) and housing (4).
e) Assemble in the reverse order. Connect the electrical connections as described
in the Electrical Manual.
f) Set the temperature controller. See Procedure 9.5.2.1-4 Temperature Controller
- Set Parameters Manually on page 560 or 9.5.2.1-6 Temperature Controller -
Set Parameters with BlueLoader on page 567.

2
3

4 3 5
1 Screw 4 Temperature controller
2 Holder housing
3 Fixing clamp 5 Temperature controller
.

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9.5.2.1-3 Temperature Controller - Set Switches

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2727159-0400

Note! The unit contains ESD sensitive components.

a) For access to the switches, the controller must be withdrawn from the housing.
Squeeze the top and bottom of the front panel (1) between thumb and
forefinger and pull the controller firmly from the housing (2).

2
1 Front panel
2 Temperature controller
housing
.

(Cont’d)

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(Cont’d)

b) CAUTION
Risk of damaged equipment.
Leaving Switch (4) open may lead to faulty functions.
This switch must always be set in LH or RH position.
Check that the switches are set correctly. See illustration.
• Switch (3) in closed position
• Switch (4) in position RH (mA/Pt)
• Switch (5) in position RH (I)
c) Put the temperature controller back into the housing and push it firmly until it is
in place.

5
U I

3 4
Loc 10V mA/Pt
3 Switch (Loc)
4 Switch
5 Switch
.

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9.5.2.1-4 Temperature Controller - Set Parameters Manually

Machine Status Electrical supply disconnecting device in position I
(ON)
SPC Reference 2727159-0400

Note! If a factory reset has been made, the parameters need to be configured with
Blue Loader. See Procedure 9.5.2.1-6 Temperature Controller - Set Parameters
with BlueLoader on page 567.
When the electrical supply is switched on, the controller starts in OPERATING
MODE.

The display shows the process value (1), and the set-point value (2).

1
2

1 Process value (current

temperature)
2 Set-point value,
controller output

(Cont’d)

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(Cont’d)

a) Set the switches as described in Procedure 9.5.2.1-3 Temperature Controller -

Set Switches on page 558.
b) Press the MENU button (3) for three seconds to step to PARAMETER MODE.
c) Set the parameters according to the parameter table below. Proceed as follows:
• Adjust up/down with the INCREASE button (4) and the DECREASE
button (5).
• Transit to the next parameter by pressing the MENU button (3).
• After the last configuration of a group, done is displayed and followed by an
automatic change to the next group.
• Return to the beginning of a group by pressing the MENU button (3) for
three seconds.
• If no key is pressed for 30 seconds, the controller returns to the process
value and set-point display (time out = 30 seconds).

5 4
3 MENU button
4 INCREASE button
5 DECREASE button
.

(Cont’d)

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(Cont’d)

d) Parameter table:

Name Description Value

Cntr
Pb1 Proportional band 1/2 (heating) in physical 8
dimensions (e.g. °C)
ti1 Integral action time 1 (heating) [s] 50
t1 Minimal cycle duration 1/2 (heating/cooling) [s]. 10
The minimum impulse is 1/4 x t1/t2
SEtP
SP.Lo 1) Set-point limit low for Weff 0
SP.Hi 1) Set-point limit high for Weff 100
SP.2 Set-point 2 5
Lim
L.1 Lower limit 1 -5
H.1 Upper limit 1 5
L.2 Lower limit 2 OFF
H.2 Upper limit 2 50

1) The set-point value can also be set when the safety switch is in open position by pressing the INCREASE and

DECREASE buttons. However, the temperature can never exceed the set-point value set in the parameter level

(with safety switch in closed position).

.

(Cont’d)

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(Cont’d)

e) Press the DECREASE button (5) once for transition to the CONFIGURATION
MODE.
f) Set the configurations according to the configuration table below. Proceed as
follows:
• Adjust up/down with the INCREASE button (4) and the DECREASE
button (5).
• Transit to the next parameter by pressing the MENU button (3).
• After the last configuration of a group, donE is displayed and followed by an
automatic change to the next group.
• Return to the beginning of a group by pressing the MENU button (3) for
3 seconds.

5 4
3 MENU button
4 INCREASE button
5 DECREASE button
.

g) Configuration table:

Name Description Value

Cntr
C.Fnc Control behaviour 1
InP.1
S.tYP Sensor type selection 2
Lim
Src. 1 Source of limit 1 1
Src. 2 Source of limit 2 0
.

(Cont’d)

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(Cont’d)

h) When all settings are correct, wait for 30 seconds and the temperature
controller returns to OPERATING MODE automatically.
i) Turn the electrical supply off and pull out the controller from the housing.
j) Set the safety switch (Loc) (6) in open position. See illustration below. This
means that the configuration and parameter settings are locked and not
accessible for changes.
k) Put back the temperature controller into the housing and push it firmly in place.
l) Turn the electrical supply on. Before stepping up the Bent Foil Treater, check
the set-point value (2) on the display. The set-point value can be adjusted by
pressing the INCREASE button (4) and the DECREASE button (5), even if the
safety switch (Loc) (6) is open.
Note! The set-point value can never exceed the value set in the parameter list.

2
5 4

2 Set-point value,
controller output
4 INCREASE button
5 DECREASE button
6 Safety switch (Loc)
.

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9.5.2.1-5 Temperature Controller - Install BlueLoader

Machine Status Electrical supply disconnecting device in position I (ON)
Special Equipment PC
Software media
SPC Reference 2727159-0400

a) Insert the software media into the PC. Browse to the software media. Open the
folder BlueLoader.
b) Choose the file BlueLoader.exe. If a warning message occurs, click Yes.
c) Choose language for the installation. Click OK.

d) Click Next.

(Cont’d)

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(Cont’d)

e) Choose installation path. Click Next.

f) Click Next.

(Cont’d)

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(Cont’d)

g) Wait for installation to finish, then click Finish.

9.5.2.1-6 Temperature Controller - Set Parameters with

BlueLoader
Machine Status Electrical supply disconnecting device in position I (ON)
Special Equipment PC with CD-ROM drive and Proficy software
Communication cable TP No. 90603-0388 with CD
SPC Reference 2727159-0400

Note! The unit contains ESD sensitive components.

(Cont’d)

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(Cont’d)

a) Set the switches as described in Procedure 9.5.2.1-3 Temperature Controller -

Set Switches on page 558.
b) Connect the communication cable between the communication port (1) on the
controller and the USB port on the PC.
Note! Before the first time the cable is connected, install the device driver from
the CD delivered with the cable.

1 Communication port
.

c) Start the BlueLoader program and select File/Open or F4.

(Cont’d)

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(Cont’d)

d) In the next pop-up window, locate the correct *.bct file and click Open.

e) In the next pop-up window, choose Device/Save data to device or click F8.

(Cont’d)

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(Cont’d)

f) In the next pop-up window, make the following settings and click OK.

g) In the next pop-up window, check the uploading process in the window Store
data to device and click OK when finished.

(Cont’d)

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(Cont’d)

h) When the upload is complete, click File/Exit or F2. The parameters are now
uploaded and the temperature controller is ready for use.

i) Disconnect the communication cable between the controller and the PC.
j) Turn the electrical supply disconnecting device off. Pull out the controller from
the housing and set the safety switch (Loc) (2) in open position. See illustration.
k) Put back the temperature controller into the housing and push it firmly in place.

2 Safety switch (Loc)

.

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9.5.3 Motor Unit

9.5.3-1 Motor Unit - Change Fan
Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 2751400-0300

a) Remove the screws (1) and the cover (2).

b) Remove the screws (3) and the motor unit (4).
c) Change the fan (5).
d) Assemble in the reverse order.
Note! The fan rotates to the left, as indicated by the arrows in the illustration
below.

2 5
4
1 3
1 Screw
2 Cover
3 Screw (4 pieces)
4 Motor unit
5 Fan
.

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9.5.4 Warning Lamp

9.5.4-1 Warning Lamp - Error Handling
Machine Status Electrical supply disconnecting device in position I (ON)
SPC Reference 2998253-0100

Warning lamp status Possible cause(s) Action

Yellow light The temperature within the machine has Wait. It takes approximately 30 minutes
not reached the running temperature. for the BFT to reach its running
The machine is not ready to run. temperature.
The overload protection (1) in the Switch the overload protection (1) to
electrical cabinet has tripped. position I (on)
The current control relay (2) in the Step down the machine to reset the
electrical cabinet has tripped. Possible alarm.
reason may be that one of the heating If the alarm still does not go out, replace
elements is not working. the heating element. See Procedure
9.5.2-2 Electrical Cabinet - Change
Heating Element on page 549.
Green light The temperature within the machine has
reached the running temperature. This
means that the machine is ready to run.

1 Overload protection,
Q50F1020
2 Current control relay,
V50K1030
.

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 10 General

Description
This chapter includes general guidelines settings.

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10 General Table of Contents

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576

10.1 Straw Angle Settings.......................................... 579

10.1.1 S/T Straws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579
10.1.2 U Straws With Top to the Left. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580
10.1.3 U Straws With Top to the Right . . . . . . . . . . . . . . . . . . . . . . . . . . . 581

10.2 Conversion ...................................................... 582

10.2-1 Change Straw Length/Diameter . . . . . . . . . . . . . . . . . . 582
10.2-2 Change Straw Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584
10.2-3 Change Package Type . . . . . . . . . . . . . . . . . . . . . . . . . . 593

10.3 Setting Sequence .............................................. 600

10.4 Consumables ................................................... 601
10.4.1 Hotmelt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
10.4.2 Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601

10.5 Troubleshooting................................................ 602

10.5.1 Machine Material Interaction - Straw. . . . . . . . . . . . . . . . . . . . . 602
10.5.1.1 Ladder Band Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
10.5.1.1.1 Troubleshoot Ladder Band Failure . . . . . . . . . . . . . 604
10.5.1.2 More Than One Straw on Package . . . . . . . . . . . . . . . . . . . . . 606
10.5.1.2.1 Troubleshoot More Than One Straw on
Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .607
10.5.1.3 Packages Glued Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
10.5.1.3.1 Troubleshoot Packages Glued Together . . . . . . . . 609
10.5.1.4 Damaged Straw on Package . . . . . . . . . . . . . . . . . . . . . . . . . . 612
10.5.1.4.1 Troubleshoot Damaged Straw on
Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .613
10.5.1.5 Straw Missing or Misplaced . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
10.5.1.5.1 Troubleshoot Straw Missing or Misplaced . . . . . . 617
10.5.1.6 Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
10.5.1.6.1 Splice Ladder Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
10.5.1.6.2 Replace Faulty Part of the Ladder Band . . . . . . . . 621
10.5.1.6.3 Thread Ladder Band in Bent Foil Treater. . . . . . . . 622
10.5.1.6.4 Daily Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623

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Table of Contents 10 General

10.5.1.6.5 Conveyor Chain Link . . . . . . . . . . . . . . . . . . . . . . . . . . 624

10.5.1.6.5-1 Conveyor Chain Link - Centre Conveyor
Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .624
10.5.1.6.6 Encoder Synchronisation Conveyer Chain
Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .625
10.5.1.6.6-1 Encoder Synchronisation Conveyor Chain Link -
Set Conveyor Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .625
10.5.1.7 Supporting Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 626
10.5.1.7.1 Straw Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 626
10.5.1.7.2 Straw Position Top. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 626
10.5.1.7.3 Film Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627
10.5.1.7.4 Film Sealing Strength . . . . . . . . . . . . . . . . . . . . . . . . . . 627
10.5.1.7.5 Sealing Distance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 628
10.5.1.7.6 Straw Pocket Length. . . . . . . . . . . . . . . . . . . . . . . . . . . 629
10.5.1.7.7 Ladder Band Folding Inside the Straw
Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .629
10.5.1.7.8 Bent Straw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630
10.5.1.7.9 Bent Foil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630
10.5.1.7.10 Film Splice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631

10.5.2 Electric Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631

10.5.3 Applicator Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631
10.5.4 Conveyor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631
10.5.5 Straw Detector Integrated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632
10.5.5.1 IVC Flash Memory Corrupt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632

10.5.6 Hotmelt Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632

10.5.7 Machine Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632
10.5.8 Machine Covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632
10.5.9 Air Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632
10.5.10 Regular Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633

10.6 IP Addresses .................................................... 634

10.7 Lockout Procedures........................................... 635
10.7-1 Electrical Supply - Lockout Procedure . . . . . . . . . . . . 635
10.7-2 Air Supply - Lockout Procedure . . . . . . . . . . . . . . . . . . 638

578 (728) Doc. No. MM-3541840-0101

®
10 General 10.1 Straw Angle Settings

10.1 Straw Angle Settings

Basic settings for applicator unit angle used when setting recipe.

In the tables below, the upper row corresponds to package length and the column to
the left corresponds to package height. All measures are in millimetre.

10.1.1 S/T Straws

L
H 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98
68 30 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 47 48 49 50 50 51 52 52 53 54 54 55 55
70 30 31 32 33 34 36 37 38 39 40 41 42 42 43 44 45 46 47 47 48 49 50 50 51 51 52 53 53 54 54
72 29 30 31 33 34 35 36 37 38 39 40 41 42 43 43 44 45 46 47 47 48 49 49 50 51 51 52 53 53 54
74 28 30 31 32 33 34 35 36 37 38 39 40 41 42 43 43 44 45 46 47 47 48 49 49 50 51 51 52 52 53
76 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 43 44 45 46 46 47 48 49 49 50 50 51 52 52
78 27 28 29 31 32 33 34 35 36 37 38 38 39 40 41 42 43 43 44 45 46 46 47 48 48 49 50 50 51 51
80 27 28 29 30 31 32 33 34 35 36 37 38 39 40 40 41 42 43 44 44 45 46 46 47 48 48 49 50 50 51
82 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 40 41 42 43 44 44 45 46 46 47 48 48 49 49 50
84 25 27 28 29 30 31 32 33 34 35 36 36 37 38 39 40 41 41 42 43 44 44 45 46 46 47 48 48 49 49
86 25 26 27 28 29 30 31 32 33 34 35 36 37 38 38 39 40 41 41 42 43 44 44 45 46 46 47 48 48 49
88 24 26 27 28 29 30 31 32 32 33 34 35 36 37 38 39 39 40 41 42 42 43 44 44 45 46 46 47 47 48
90 24 25 26 27 28 29 30 31 32 33 34 35 35 36 37 38 39 39 40 41 42 42 43 44 44 45 46 46 47 47
92 23 25 26 27 28 29 29 30 31 32 33 34 35 36 36 37 38 39 40 40 41 42 42 43 44 44 45 46 46 47
94 23 24 25 26 27 28 29 30 31 32 33 33 34 35 36 37 37 38 39 40 40 41 42 42 43 44 44 45 46 46
96 23 24 25 26 27 28 28 29 30 31 32 33 34 35 35 36 37 38 38 39 40 41 41 42 43 43 44 44 45 46
98 22 23 24 25 26 27 28 29 30 31 31 32 33 34 35 36 36 37 38 39 39 40 41 41 42 43 43 44 44 45
100 22 23 24 25 26 27 27 28 29 30 31 32 33 33 34 35 36 37 37 38 39 39 40 41 41 42 43 43 44 44
102 21 22 23 24 25 26 27 28 29 30 30 31 32 33 34 34 35 36 37 37 38 39 39 40 41 41 42 43 43 44
104 21 22 23 24 25 26 27 27 28 29 30 31 32 32 33 34 35 35 36 37 38 38 39 40 40 41 41 42 43 43
106 21 22 23 23 24 25 26 27 28 29 30 30 31 32 33 33 34 35 36 36 37 38 38 39 40 40 41 42 42 43
108 20 21 22 23 24 25 26 27 27 28 29 30 31 31 32 33 34 34 35 36 37 37 38 39 39 40 40 41 42 42
110 20 21 22 23 24 24 25 26 27 28 29 29 30 31 32 32 33 34 35 35 36 37 37 38 39 39 40 41 41 42
112 20 21 21 22 23 24 25 26 27 27 28 29 30 31 31 32 33 33 34 35 36 36 37 38 38 39 39 40 41 41
114 19 20 21 22 23 24 25 25 26 27 28 29 29 30 31 32 32 33 34 34 35 36 36 37 38 38 39 40 40 41
116 19 20 21 22 22 23 24 25 26 27 27 28 29 30 30 31 32 33 33 34 35 35 36 37 37 38 38 39 40 40
118 19 20 20 21 22 23 24 25 25 26 27 28 28 29 30 31 31 32 33 33 34 35 35 36 37 37 38 39 39 40
120 18 19 20 21 22 23 23 24 25 26 27 27 28 29 30 30 31 32 32 33 34 34 35 36 36 37 37 38 39 39
122 18 19 20 21 21 22 23 24 25 25 26 27 28 28 29 30 31 31 32 33 33 34 35 35 36 36 37 38 38 39
124 18 19 20 20 21 22 23 24 24 25 26 27 27 28 29 29 30 31 32 32 33 33 34 35 35 36 37 37 38 38
126 18 18 19 20 21 22 22 23 24 25 25 26 27 28 28 29 30 30 31 32 32 33 34 34 35 36 36 37 37 38
128 17 18 19 20 21 21 22 23 24 24 25 26 27 27 28 29 29 30 31 31 32 33 33 34 35 35 36 36 37 37
130 17 18 19 19 20 21 22 23 23 24 25 25 26 27 28 28 29 30 30 31 32 32 33 33 34 35 35 36 36 37
132 17 18 18 19 20 21 22 22 23 24 24 25 26 27 27 28 29 29 30 31 31 32 32 33 34 34 35 35 36 37
134 17 17 18 19 20 20 21 22 23 23 24 25 26 26 27 28 28 29 30 30 31 31 32 33 33 34 34 35 36 36
136 16 17 18 19 19 20 21 22 22 23 24 25 25 26 27 27 28 29 29 30 30 31 32 32 33 33 34 35 35 36
138 16 17 18 18 19 20 21 21 22 23 23 24 25 26 26 27 28 28 29 29 30 31 31 32 33 33 34 34 35 35
140 16 17 17 18 19 20 20 21 22 23 23 24 25 25 26 27 27 28 28 29 30 30 31 32 32 33 33 34 34 35
142 16 16 17 18 19 19 20 21 22 22 23 24 24 25 26 26 27 28 28 29 29 30 31 31 32 32 33 34 34 35
144 16 16 17 18 18 19 20 21 21 22 23 23 24 25 25 26 27 27 28 28 29 30 30 31 31 32 33 33 34 34
146 15 16 17 17 18 19 20 20 21 22 22 23 24 24 25 26 26 27 27 28 29 29 30 30 31 32 32 33 33 34
148 15 16 17 17 18 19 19 20 21 21 22 23 23 24 25 25 26 27 27 28 28 29 30 30 31 31 32 32 33 34
150 15 16 16 17 18 18 19 20 20 21 22 22 23 24 24 25 26 26 27 27 28 29 29 30 30 31 32 32 33 33

®
Doc. No. MM-3541840-0101 579 (728)
10.1 Straw Angle Settings 10 General

10.1.2 U Straws With Top to the Left

L
H 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98
68 19 21 22 24 25 27 28 29 30 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 47 48 49 50 50
70 19 20 22 23 25 26 27 28 30 31 32 33 34 36 37 38 39 40 41 42 42 43 44 45 46 47 47 48 49 50
72 18 20 21 23 24 25 27 28 29 30 31 33 34 35 36 37 38 39 40 41 42 43 43 44 45 46 47 47 48 49
74 18 19 21 22 23 25 26 27 28 30 31 32 33 34 35 36 37 38 39 40 41 42 43 43 44 45 46 47 47 48
76 18 19 20 22 23 24 25 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 43 44 45 46 46 47
78 17 18 20 21 22 24 25 26 27 28 29 31 32 33 34 35 36 37 38 38 39 40 41 42 43 43 44 45 46 46
80 17 18 19 21 22 23 24 25 27 28 29 30 31 32 33 34 35 36 37 38 39 40 40 41 42 43 44 44 45 46
82 16 18 19 20 21 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 40 41 42 43 44 44 45
84 16 17 18 20 21 22 23 24 25 27 28 29 30 31 32 33 34 35 36 36 37 38 39 40 41 41 42 43 44 44
86 16 17 18 19 20 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 38 39 40 41 41 42 43 44
88 15 16 18 19 20 21 22 23 24 26 27 28 29 30 31 32 32 33 34 35 36 37 38 39 39 40 41 42 42 43
90 15 16 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 35 36 37 38 39 39 40 41 42 42
92 15 16 17 18 19 20 21 22 23 25 26 27 28 29 29 30 31 32 33 34 35 36 36 37 38 39 40 40 41 42
94 14 15 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 33 34 35 36 37 37 38 39 40 40 41
96 14 15 16 17 18 20 21 22 23 24 25 26 27 28 28 29 30 31 32 33 34 35 35 36 37 38 38 39 40 41
98 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 31 32 33 34 35 36 36 37 38 39 39 40
100 13 15 16 17 18 19 20 21 22 23 24 25 26 27 27 28 29 30 31 32 33 33 34 35 36 37 37 38 39 39
102 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 30 31 32 33 34 34 35 36 37 37 38 39
104 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 27 28 29 30 31 32 32 33 34 35 35 36 37 38 38
106 13 14 15 16 17 18 19 20 21 22 23 23 24 25 26 27 28 29 30 30 31 32 33 33 34 35 36 36 37 38
108 13 14 15 16 17 17 18 19 20 21 22 23 24 25 26 27 27 28 29 30 31 31 32 33 34 34 35 36 37 37
110 12 13 14 15 16 17 18 19 20 21 22 23 24 24 25 26 27 28 29 29 30 31 32 32 33 34 35 35 36 37
112 12 13 14 15 16 17 18 19 20 21 21 22 23 24 25 26 27 27 28 29 30 31 31 32 33 33 34 35 36 36
114 12 13 14 15 16 17 18 18 19 20 21 22 23 24 25 25 26 27 28 29 29 30 31 32 32 33 34 34 35 36
116 12 13 14 15 15 16 17 18 19 20 21 22 22 23 24 25 26 27 27 28 29 30 30 31 32 33 33 34 35 35
118 11 12 13 14 15 16 17 18 19 20 20 21 22 23 24 25 25 26 27 28 28 29 30 31 31 32 33 33 34 35
120 11 12 13 14 15 16 17 18 18 19 20 21 22 23 23 24 25 26 27 27 28 29 30 30 31 32 32 33 34 34
122 11 12 13 14 15 16 16 17 18 19 20 21 21 22 23 24 25 25 26 27 28 28 29 30 31 31 32 33 33 34
124 11 12 13 14 14 15 16 17 18 19 20 20 21 22 23 24 24 25 26 27 27 28 29 29 30 31 32 32 33 33
126 11 12 13 13 14 15 16 17 18 18 19 20 21 22 22 23 24 25 25 26 27 28 28 29 30 30 31 32 32 33
128 11 11 12 13 14 15 16 17 17 18 19 20 21 21 22 23 24 24 25 26 27 27 28 29 29 30 31 31 32 33
130 10 11 12 13 14 15 15 16 17 18 19 19 20 21 22 23 23 24 25 25 26 27 28 28 29 30 30 31 32 32
132 10 11 12 13 14 14 15 16 17 18 18 19 20 21 22 22 23 24 24 25 26 27 27 28 29 29 30 31 31 32
134 10 11 12 13 13 14 15 16 17 17 18 19 20 20 21 22 23 23 24 25 26 26 27 28 28 29 30 30 31 31
136 10 11 12 12 13 14 15 16 16 17 18 19 19 20 21 22 22 23 24 25 25 26 27 27 28 29 29 30 30 31
138 10 11 11 12 13 14 15 15 16 17 18 18 19 20 21 21 22 23 23 24 25 26 26 27 28 28 29 29 30 31
140 10 11 11 12 13 14 14 15 16 17 17 18 19 20 20 21 22 23 23 24 25 25 26 27 27 28 28 29 30 30
142 10 10 11 12 13 13 14 15 16 16 17 18 19 19 20 21 22 22 23 24 24 25 26 26 27 28 28 29 29 30
144 9 10 11 12 13 13 14 15 16 16 17 18 18 19 20 21 21 22 23 23 24 25 25 26 27 27 28 28 29 30
146 9 10 11 12 12 13 14 15 15 16 17 17 18 19 20 20 21 22 22 23 24 24 25 26 26 27 27 28 29 29
148 9 10 11 11 12 13 14 14 15 16 17 17 18 19 19 20 21 21 22 23 23 24 25 25 26 27 27 28 28 29
150 9 10 11 11 12 13 13 14 15 16 16 17 18 18 19 20 20 21 22 22 23 24 24 25 26 26 27 27 28 29

580 (728) Doc. No. MM-3541840-0101

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10 General 10.1 Straw Angle Settings

10.1.3 U Straws With Top to the Right

L
H 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98
68 30 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 47 48 49 50 50 51 52 52 53 54 54 55 55
70 30 31 32 33 34 36 37 38 39 40 41 42 42 43 44 45 46 47 47 48 49 50 50 51 51 52 53 53 54 54
72 29 30 31 33 34 35 36 37 38 39 40 41 42 43 43 44 45 46 47 47 48 49 49 50 51 51 52 53 53 54
74 28 30 31 32 33 34 35 36 37 38 39 40 41 42 43 43 44 45 46 47 47 48 49 49 50 51 51 28 30 31
76 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 43 44 45 46 46 47 48 49 49 50 50 28 29 30
78 27 28 29 31 32 33 34 35 36 37 38 38 39 40 41 42 43 43 44 45 46 46 47 48 48 49 50 27 28 29
80 27 28 29 30 31 32 33 34 35 36 37 38 39 40 40 41 42 43 44 44 45 46 46 47 48 48 49 27 28 29
82 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 40 41 42 43 44 44 45 46 46 47 48 48 26 27 28
84 25 27 28 29 30 31 32 33 34 35 36 36 37 38 39 40 41 41 42 43 44 44 45 46 46 47 48 25 27 28
86 25 26 27 28 29 30 31 32 33 34 35 36 37 38 38 39 40 41 41 42 43 44 44 45 46 46 47 25 26 27
88 24 26 27 28 29 30 31 32 32 33 34 35 36 37 38 39 39 40 41 42 42 43 44 44 45 46 46 24 26 27
90 24 25 26 27 28 29 30 31 32 33 34 35 35 36 37 38 39 39 40 41 42 42 43 44 44 45 46 24 25 26
92 23 25 26 27 28 29 29 30 31 32 33 34 35 36 36 37 38 39 40 40 41 42 42 43 44 44 45 23 25 26
94 23 24 25 26 27 28 29 30 31 32 33 33 34 35 36 37 37 38 39 40 40 41 42 42 43 44 44 23 24 25
96 23 24 25 26 27 28 28 29 30 31 32 33 34 35 35 36 37 38 38 39 40 41 41 42 43 43 44 23 24 25
98 22 23 24 25 26 27 28 29 30 31 31 32 33 34 35 36 36 37 38 39 39 40 41 41 42 43 43 22 23 24
100 22 23 24 25 26 27 27 28 29 30 31 32 33 33 34 35 36 37 37 38 39 39 40 41 41 42 43 22 23 24
102 21 22 23 24 25 26 27 28 29 30 30 31 32 33 34 34 35 36 37 37 38 39 39 40 41 41 42 21 22 23
104 21 22 23 24 25 26 27 27 28 29 30 31 32 32 33 34 35 35 36 37 38 38 39 40 40 41 41 21 22 23
106 21 22 23 23 24 25 26 27 28 29 30 30 31 32 33 33 34 35 36 36 37 38 38 39 40 40 41 21 22 23
108 20 21 22 23 24 25 26 27 27 28 29 30 31 31 32 33 34 34 35 36 37 37 38 39 39 40 40 20 21 22
110 20 21 22 23 24 24 25 26 27 28 29 29 30 31 32 32 33 34 35 35 36 37 37 38 39 39 40 20 21 22
112 20 21 21 22 23 24 25 26 27 27 28 29 30 31 31 32 33 33 34 35 36 36 37 38 38 39 39 20 21 21
114 19 20 21 22 23 24 25 25 26 27 28 29 29 30 31 32 32 33 34 34 35 36 36 37 38 38 39 19 20 21
116 19 20 21 22 22 23 24 25 26 27 27 28 29 30 30 31 32 33 33 34 35 35 36 37 37 38 38 19 20 21
118 19 20 20 21 22 23 24 25 25 26 27 28 28 29 30 31 31 32 33 33 34 35 35 36 37 37 38 19 20 20
120 18 19 20 21 22 23 23 24 25 26 27 27 28 29 30 30 31 32 32 33 34 34 35 36 36 37 37 18 19 20
122 18 19 20 21 21 22 23 24 25 25 26 27 28 28 29 30 31 31 32 33 33 34 35 35 36 36 37 18 19 20
124 18 19 20 20 21 22 23 24 24 25 26 27 27 28 29 29 30 31 32 32 33 33 34 35 35 36 37 18 19 20
126 18 18 19 20 21 22 22 23 24 25 25 26 27 28 28 29 30 30 31 32 32 33 34 34 35 36 36 18 18 19
128 17 18 19 20 21 21 22 23 24 24 25 26 27 27 28 29 29 30 31 31 32 33 33 34 35 35 36 17 18 19
130 17 18 19 19 20 21 22 23 23 24 25 25 26 27 28 28 29 30 30 31 32 32 33 33 34 35 35 17 18 19
132 17 18 18 19 20 21 22 22 23 24 24 25 26 27 27 28 29 29 30 31 31 32 32 33 34 34 35 17 18 18
134 17 17 18 19 20 20 21 22 23 23 24 25 26 26 27 28 28 29 30 30 31 31 32 33 33 34 34 17 17 18
136 16 17 18 19 19 20 21 22 22 23 24 25 25 26 27 27 28 29 29 30 30 31 32 32 33 33 34 16 17 18
138 16 17 18 18 19 20 21 21 22 23 23 24 25 26 26 27 28 28 29 29 30 31 31 32 33 33 34 16 17 18
140 16 17 17 18 19 20 20 21 22 23 23 24 25 25 26 27 27 28 28 29 30 30 31 32 32 33 33 16 17 17
142 16 16 17 18 19 19 20 21 22 22 23 24 24 25 26 26 27 28 28 29 29 30 31 31 32 32 33 16 16 17
144 16 16 17 18 18 19 20 21 21 22 23 23 24 25 25 26 27 27 28 28 29 30 30 31 31 32 33 16 16 17
146 15 16 17 17 18 19 20 20 21 22 22 23 24 24 25 26 26 27 27 28 29 29 30 30 31 32 32 15 16 17
148 15 16 17 17 18 19 19 20 21 21 22 23 23 24 25 25 26 27 27 28 28 29 30 30 31 31 32 15 16 17

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Doc. No. MM-3541840-0101 581 (728)
10.2 Conversion 10 General

10.2 Conversion
Note! If nothing else stated, the illustrations show the TBA with SD Integrated
variant and the procedure is also valid for the other variants.

10.2-1 Change Straw Length/Diameter

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
Special Equipment Template TP No. 3166869-0000
SPC Reference 663301-0500

a) Turn the bearing housing (6) to move the arms (8) to a position outside the feed
wheel slots.
b) Remove the screws (7) and the pressure arm (5).
c) Turn the stellar knob (10) until the knife (2) is in position outside the feed wheel.
d) Fit the template (1).
e) Turn the stellar knob (3) to the left until the feed wheel (4) is released from the
shaft.
f) Press the leaf spring (9) outwards from the wheel and pull up the feed wheel.

3
2 4 5

1
6

10 9
8 7
1 Template 6 Bearing housing
2 Knife 7 Screw
3 Stellar knob 8 Arm
4 Feed wheel 9 Leaf spring
5 Pressure arm 10 Stellar knob
.

(Cont’d)

582 (728) Doc. No. MM-3541840-0101

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10 General 10.2 Conversion

(Cont’d)

g) Press the leaf spring (9) outwards and lift in the new feed wheel (4).
h) When the feed wheel is in its correct position, tighten the stellar knob (3).
i) Put back the pressure arm (5) and tighten the screws (7).
j) Adjust the pressure arm, if necessary. See Procedure 3.3.3-3 Pressure Arm -
Set Height (TB/TBA) on page 364 or 3.3.3-6 Pressure Arm - Set
Height (TPA/TT) on page 367.
k) Remove the template (1).
l) Set the feed wheel, if necessary. See Procedure 3.1-3 Feed Wheel Unit - Set on
page 338.
m) Set the ladder band guide. See Procedure 3.5-1 Ladder Band Guide - Set on
page 389
n) Set the pick position, if necessary. See Procedure 1.2.2.6-2 Maintenance - Set
Pick Position on page 249.

3
4 5

9
7
1 Template 5 Pressure arm
3 Stellar knob 7 Screw
4 Feed wheel 9 Leaf spring
.

®
Doc. No. MM-3541840-0101 583 (728)
10.2 Conversion 10 General

10.2-2 Change Straw Type

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
Special Equipment Template TP No. 3166869
Dynamometric wrench
SPC Reference 663301-0500

Remove Pressure Arm and Feed Wheel

a) Turn the bearing housing (5) to move the arms (7) to a position outside the feed
wheel slots.
b) Remove the screws (6) and the pressure arm (4).
c) Turn the stellar knob (9) until the knife (1) is in position outside the feed wheel.
d) Turn the stellar knob (2) to the left until the feed wheel (3) is released from the
shaft.
e) Press the leaf spring (8) outwards from the wheel and pull up the feed wheel.

2
3 4
1
5

9 8
7 6
1 Knife 4 Pressure arm 7 Arm
2 Stellar knob 5 Bearing housing 8 Leaf spring
3 Feed wheel 6 Screw 9 Stellar knob

Change Knife Holder Unit

CAUTION
Risk of personal injury.
The knife is very sharp. Be careful when working near the knife.
(Cont’d)

584 (728) Doc. No. MM-3541840-0101

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10 General 10.2 Conversion

(Cont’d)

a) Remove the screws (1) and (8), and remove the guide (9).
b) Fit the template (6) and remove the screw (3).
c) Remove the template (6). Remove the screw (7).
d) Lift up the axle pin (4) from the eccentric (5).
e) Remove the knife holder unit (2).
f) Install the new knife holder unit. Use the hole marked S/T for S and T type
straws and use the hole marked with a U for U type straws in the eccentric (5).
g) Tighten the screw (7).
h) Make sure that the knife is in position outside the feed wheel and fit the
template (6).
i) Tighten the screw (3).
j) Assemble the guide (9) with the screws (1) and (8).

2
3
4
9
5

8
6
7

1 Screw 4 Axle pin 7 Screw

2 Knife holder unit 5 Eccentric 8 Screw
3 Screw 6 Template 9 Guide
.

Change Pulley

WARNING
Burn Hazard.
The hotmelt unit can be very hot and there is risk of severe burns. Use caution when
working near the hotmelt unit.
(Cont’d)

®
Doc. No. MM-3541840-0101 585 (728)
10.2 Conversion 10 General

(Cont’d)

a) To improve access, rotate the applicator unit approximately 45° to the left. See
Procedure 3-2 Applicator Unit - Set Angle on page 330. Reset the scale value
afterwards.
b) Loosen the screw (4) on the belt tensioner (6).
c) Turn the belt tensioner ¾ of a revolution to the right to release the belt tension.
Use a hook spanner (1).
Note! Turning the belt tensioner more than ¾ of a revolution will destroy the
torsion spring.
d) Tighten the screw (4).
e) Remove the screws (2) and the axle support (3).
f) Remove the timing belt (5).

4
5
5
1 Hook spanner
2 Screw (3 pieces)
3 Axle support
4 Screw
5 Timing belt
6 Belt tensioner
.

(Cont’d)

586 (728) Doc. No. MM-3541840-0101

®
10 General 10.2 Conversion

(Cont’d)

g) Loosen the screw (10) and the screws (9) and remove the pulley (8) from the
shaft (7).
h) Put the new pulley on the shaft and push it to the bottom.
• For S and T type straws, use pulley 3272813-0000.
• For U type straws, use pulley 3272809-0000.
i) Turn the pulley (8) until the flat surfaces on the shaft (arrows) are facing the
screws (9).
j) Tighten the screws (9) alternately to a torque of 10 to 12 Nm; using a
dynamometric wrench. Do not overtighten the screw.
k) Tighten the screw (10) to a torque of 10 to 12 Nm; using a dynamometric
wrench. Do not overtighten the screw.

9
10
9

7 Shaft
8 Pulley
9 Screw
10 Screw
.

(Cont’d)

®
Doc. No. MM-3541840-0101 587 (728)
10.2 Conversion 10 General

(Cont’d)

Move Belt Tensioner

a) Loosen the screw (3) entirely and pull it out together with the belt tensioner (4)
and the turn spring (5).
b) Move the loosened assembly to the hole (1) stamped with S/T-15 for S or T type
straws, or to the hole (2) stamped with U-22 for U type straws. Do not tighten
the screw (3) yet.

1 Hole S/T-15
2 Hole U-22
3 Screw
4 Belt tensioner
5 Turn spring
.

(Cont’d)

588 (728) Doc. No. MM-3541840-0101

®
10 General 10.2 Conversion

(Cont’d)

c) Turn the belt tensioner (4) ¾ of a revolution to the right. Use a hook spanner (6).
Note! Turning the belt tensioner more than ¾ of a revolution will destroy the
torsion spring.
d) Tighten the screw (3).

3 Screw
4 Belt tensioner
6 Hook spanner
.

(Cont’d)

®
Doc. No. MM-3541840-0101 589 (728)
10.2 Conversion 10 General

(Cont’d)

Install Timing Belt

a) Put the timing belt (1) over the pulleys and check that it is properly positioned
over all the pulleys.
b) Attach the axle support (2) with the screws (3).
c) Loosen the screw (5) to let the belt tensioner (4) tighten the timing belt.
d) Turn the stellar knob (6) approximately five revolutions to even out the tension
of the timing belt.
e) Tighten the screw (5).

6 5 4
1 Timing belt
2 Axle support
3 Screw (3 pieces)
4 Belt tensioner
5 Screw
6 Stellar knob
.

(Cont’d)

590 (728) Doc. No. MM-3541840-0101

®
10 General 10.2 Conversion

(Cont’d)

Install Feed Wheel and Pressure Arm

a) Turn the stellar knob (7) until the knife (1) is in position outside the feed wheel.
b) Press the leaf spring (6) outwards and lift in the new feed wheel (3).
c) When the feed wheel is in correct position, tighten the stellar knob (2).
d) Put on the correct pressure arm (4) and tighten the screws (5).

2
3 4
1

7 6
1 Knife
2 Stellar knob
3 Feed wheel
4 Pressure arm
5 Screw
6 Leaf spring
7 Stellar knob
.

Set
Carry out the following settings:

(Cont’d)

®
Doc. No. MM-3541840-0101 591 (728)
10.2 Conversion 10 General

(Cont’d)

a) 3.1-3 Feed Wheel Unit - Set on page 338.

b) 3.3.3-3 Pressure Arm - Set Height (TB/TBA) on page 364 or 3.3.3-6 Pressure
Arm - Set Height (TPA/TT) on page 367.
c) 1.2.2.6-2 Maintenance - Set Pick Position on page 249.
d) 2.1.1-1 Support Rail - Set on page 288.
e) 2.2-4 Belt Brake - Set on page 294.
f) 2.4-1 Top Support - Set Horizontal Position on page 300.
g) 2.4-2 Top Support - Set Lateral Position on page 301.
h) 2.5-1 Height Adjustment - Set Height on page 308.
i) 3-2 Applicator Unit - Set Angle on page 330.
j) 3-3 Applicator Unit - Set Height and Straw Position on page 331.
k) 3.3.3-7 Pressure Arm - Set Override on page 368.
l) 3.5-1 Ladder Band Guide - Set on page 389.
m) 3.7-4 Spring Holder - Set Leaf Spring on page 403.
n) 5.2.1-3 Hotmelt Gun - Set Gun Holder on page 467.
o) Change the recipe according to the Operation Manual, or create a new recipe.
.
See Procedure 1.2.2.5-1 Recipes - Set Recipe on page 241.

592 (728) Doc. No. MM-3541840-0101

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10 General 10.2 Conversion

10.2-3 Change Package Type

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
Consumables Cable ties
SPC Reference 663301-0500

Remove
a) Disconnect the cables from the squeezer’s servo motor (1).
b) Disconnect the cables from the inductive sensors (2), (3), and (4).

4
1 Servo motor
2 Inductive sensor
3 Inductive sensor
4 Inductive sensor
.

(Cont’d)

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10.2 Conversion 10 General

(Cont’d)

c) CAUTION
Risk of personal injury.
Be careful as the vibration damper will contract when disconnected.
(Speed machines only) Disconnect the vibration damper (5) to make it possible
to rotate the applicator unit. Take action not to break its screws.

5 Vibration damper
.

(Cont’d)

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10 General 10.2 Conversion

(Cont’d)

d) Memorize the angle position on the scale (6) and rotate the applicator unit
approximately 45° to the right. See Procedure 3-2 Applicator Unit - Set Angle on
page 330.

You may need to cut some cable ties in order to give a free rotation of the
applicator unit table.
To extend access, rotate the applicator unit approximately 45° further to the
right. To be able to do this, execute item e). Otherwise, continue at item f).
e) Remove the hotmelt guns (7) and the spring holder (8). You can use the holders
for the bleeding hose to hang the guns.

6 Scale
7 Hotmelt gun
8 Spring holder
.

(Cont’d)

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10.2 Conversion 10 General

(Cont’d)

f) Remove the screws (10) and the squeezer (9).

10
10

9 Squeezer
10 Screw
.

Install
a) Install the new squeezer (1) with the screws (2).
b) Rotate the applicator to the left until the scale reaches the same angle position
as before.

2
2

1 Squeezer
2 Screw
.

(Cont’d)

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10 General 10.2 Conversion

(Cont’d)

c) (Speed machines only) Connect the vibration damper (3).

Note! When using package type TBA 500B, keep the vibration damper
disconnected.

3 Vibration damper
.

(Cont’d)

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10.2 Conversion 10 General

(Cont’d)

d) Install the hotmelt guns (4) and the spring holder (5).

4 Hotmelt gun
5 Spring holder
.

(Cont’d)

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10 General 10.2 Conversion

(Cont’d)

e) Connect the cables to the squeezer’s servo motor (6) and to the inductive
sensors (7), (8), and (9).
f) Attach new cable ties where needed.

9
6 Servo motor
7 Inductive sensor
8 Inductive sensor
9 Inductive sensor
.

Set
Carry out the following settings:
a) 2.1.1-1 Support Rail - Set on page 288.
b) 2.2-4 Belt Brake - Set on page 294.
c) 2.4-1 Top Support - Set Horizontal Position on page 300.
d) 2.4-2 Top Support - Set Lateral Position on page 301.
e) 2.5-1 Height Adjustment - Set Height on page 308.
f) 3-2 Applicator Unit - Set Angle on page 330.
g) 3-3 Applicator Unit - Set Height and Straw Position on page 331.
h) 3.3.3-7 Pressure Arm - Set Override on page 368.
i) 3.5-1 Ladder Band Guide - Set on page 389.
j) 3.7-4 Spring Holder - Set Leaf Spring on page 403.
k) 5.2.1-3 Hotmelt Gun - Set Gun Holder on page 467.
l) Change the recipe according to the Operation Manual, or create a new recipe.
.
See Procedure 1.2.2.5-1 Recipes - Set Recipe on page 241.

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10.3 Setting Sequence 10 General

10.3 Setting Sequence

a) Synchronize the top support versus the conveyor chain speed:
1.2.2.6-5 Maintenance - Set Conveyor Unit Parameters on page 256.
b) Set the feed wheel:
3.1-3 Feed Wheel Unit - Set on page 338.
c) Set the ladder band guide:
3.5-1 Ladder Band Guide - Set on page 389.
d) Set the pressure arms:
3.3.3-3 Pressure Arm - Set Height (TB/TBA) on page 364
or
3.3.3-6 Pressure Arm - Set Height (TPA/TT) on page 367.
e) Set the pick position:
1.2.2.6-2 Maintenance - Set Pick Position on page .
f) Set the height of the top support:
2.5-1 Height Adjustment - Set Height on page 308.
g) Set the tension of the timing belt:
2.4.1-3 Support Belt - Set Timing Belt Tension on page 304.
h) Set the belt brakes:
2.2-4 Belt Brake - Set on page 294
or
2.2-5 Belt Brake - Set Height (TPA with SD Integrated) on page 297.
i) Set the override:
3.3.3-7 Pressure Arm - Set Override on page 368.
j) Set the height of the hotmelt guns:
5.2.1-3 Hotmelt Gun - Set Gun Holder on page 467.
k) Set the leaf spring:
3.7-4 Spring Holder - Set Leaf Spring on page 403.
l) Set height and angle of the applicator unit:
3-3 Applicator Unit - Set Height and Straw Position on page 331.

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10 General 10.4 Consumables

10.4 Consumables
10.4.1 Hotmelt
Required hotmelt Ambient Tank Hose Gun
type temperature temperature temperature temperature
Tetra Pak StrawFix 5 ºC to 50 ºC ~160 ºC ~165 ºC ~170 ºC
100 (41 ºF to (~320 ºF) (~329 ºF) (~338 ºF)
TP No. 1606010- 122 ºF)
8000

Note! Any other adhesive affects the functionality.

10.4.2 Lubricants
WARNING
Risk of personal injury.
Certain lubricants can cause injury if they come into contact with the eyes, skin,
mucous membranes, or clothing. Always follow the instructions of the manufacturer
for handling chemical products.
The table lists only a selection of lubricants with their respective designations.
Lubricant specifications can be ordered from

Tetra Pak Technical Service - Parts Supply Chain, Ruben Rausings gata, SE-221 86
LUND, Sweden

Example
Part No.(used
when ordering Product
Lubricant from Tetra Pak) Supplier Designation
Mist lubrication oil 90606-3606 Shell Shell Spirax S2
ATF AX

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10.5 Troubleshooting 10 General

10.5 Troubleshooting
10.5.1 Machine Material Interaction - Straw
The intended use of this troubleshooting guide is to identify and solve problems with
the machine connected to straw interaction.
This troubleshooting guide covers these failures:

Failure Section
Ladder band failure See Section 10.5.1.1 Ladder Band Failureon page 603.
More than one straw on package See Section 10.5.1.2 More Than One Straw on
Packageon page 606.
Packages glued together See Section 10.5.1.3 Packages Glued Togetheron page
609.
Damaged straw on package See Section 10.5.1.4 Damaged Straw on Packageon
page 612.
Straw missing or misplaced See Section 10.5.1.5 Straw Missing or Misplacedon
page 616.

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10 General 10.5 Troubleshooting

10.5.1.1 Ladder Band Failure

A broken ladder band or a broken sensor in the ladder band guide causes a ladder
band failure (1) alarm.

To troubleshoot this alarm, see Section 10.5.1.1.1 Troubleshoot Ladder Band Failure
on page 604.

1 Ladder band failure

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10.5 Troubleshooting 10 General

10.5.1.1.1 Troubleshoot Ladder Band Failure

Follow the tables from Check 1 to Action by answering yes or no to get a
recommended solution.

Check 1 Check 2 Check 3 Check 4 Action

Is the LB broken? Y Is the LB broken Y See Section
E due to a faulty E 10.5.1.6.2
splice? See Replace Faulty
S S
Section Part of the Ladder
10.5.1.7.10 Film Band.
Splice. Verify that the
splice is made
according to
Section 10.5.1.6.1
Splice Ladder
Band.
N Go to the next
O Check 2 and
continue TS.

Is the LB moving Y Is the position of Y Are there cuts or YSee Section

freely from straw E the straw in the E damage on the E10.5.1.6.2
box and BFT? feed wheel slot LB foil? See Replace Faulty
S S S
correct? Section 10.5.1.7.3 Part of the Ladder
Film Cut. Band.
NNo more checks,
Ocall a Tetra Pak
technician.
N Is the LB correctly N See Section
O sealed so that the O 10.5.1.6.2
straw pockets are Replace Faulty
strong enough? Part of the Ladder
See Section Band.
10.5.1.7.4 Film Y Go to the next
Sealing Strength.
E Check 4 and
continue TS.
S

Is the LB broken? Y Is the LB moving Y Is the position of N Are the straw Y No more checks,
E freely from straw E the straw in the O pitch, the sealing E call a Tetra Pak
box and BFT? feed wheel slot distance, the technician.
S S S
correct? straw position top
and the straw N See Section
pocket length
correct? See O 10.5.1.6.2
Replace Faulty
Section 10.5.1.7.1 Part of the Ladder
Straw Band.
Pitch,10.5.1.7.5
Sealing Distance
,10.5.1.7.2 Straw
Position Top and
10.5.1.7.6 Straw
Pocket Length.

(Cont’d)

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10 General 10.5 Troubleshooting

(Cont’d)

Check 1 Check 2 Check 3 Check 4 Action

N Is the LB correctly Y Is the LB stuck in Y See Section
O threaded? E the straw box? E 10.5.1.6.2
Note! Also check S Replace Faulty
S
Part of the Ladder
inside the BFT.
Band.
Verify storage of
straw box. See
Section 6.1
Supply of
materials in the
OM.
N Go to the next
O Check 4 and
continue TS.

Does the LB lay Y No more checks,

correctly in the E call a Tetra Pak
straw box? See technician.
S
Section 10.5.1.7.7
Ladder Band N See Section
Folding Inside the O 10.5.1.6.2
Straw Box. Replace Faulty
Part of the Ladder
Band.
N See Section
O 10.5.1.6.2
Replace Faulty
Part of the Ladder
Band.
See Section
10.5.1.6.3 Thread
Ladder Band in
Bent Foil Treater.
Is the LB broken? N Is the sensor in Y No more checks,
O the LB guide E call a Tetra Pak
functioning? technician.
S
N Verify that the
O sensor in the LB
guide (V30B2080)
is functioning by
checking PLC
input.

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10.5 Troubleshooting 10 General

10.5.1.2 More Than One Straw on Package

The applicator unit puts more than one straw on the package.

To troubleshoot this failure, see Section 10.5.1.2.1 Troubleshoot More Than One
Straw on Package on page 607.

More than one straw on the package

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10 General 10.5 Troubleshooting

10.5.1.2.1 Troubleshoot More Than One Straw on Package

Follow the tables from Check 1 to Action by answering yes or no to get a
recommended solution.

Check 1 Check 2 Check 3 Check 4 Action

Is the problem Y Is the problem Y Verify that the
solved after E caused by a E splice is made
running 1-3 manual splice? according to
packages? S See Section S
Section 10.5.1.6.1
10.5.1.7.10 Film Splice Ladder
Splice. Band.
N Is the problem Y See Section
O caused by a E 10.5.1.6.2
factory splice? Replace Faulty
S
See Section Part of the Ladder
10.5.1.7.10 Film Band.
Splice. N Is the straw pitch Y See Section
O on the LB E 10.5.1.6.2
inconsistent? See Replace Faulty
S
Section 10.5.1.7.1 Part of the Ladder
Straw Pitch. Band.
N No more checks,
O call a Tetra Pak
technician.
N Is the straw Y Is the knife getting Y Is the knife blunt Y See Section 3.2-2
O positioned inside E deep enough in to E or damaged? E Cutting Unit -
the feed wheel the feed wheel Change Parts.
slot? S S S
knife slot?
N Go to the next
O Check 4 and
continue TS.

Is the LB located Y See Section 3.5-1

too high in the E Ladder Band
feed wheel? Guide - Set.
S
N No more checks,
O call a Tetra Pak
technician.
N Are the feed Y See Section
O wheel knife slots E 10.5.1.6.4 Daily
clogged? Cleaning.
S
N Go to the next
O Check 4 and
continue TS.

(Cont’d)

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10.5 Troubleshooting 10 General

(Cont’d)

Check 1 Check 2 Check 3 Check 4 Action

Is the problem N Is the straw Y Is the knife getting N Is the straw type Y Verify that correct
solved after O positioned inside E deep enough in to O changed E parts (knife holder
running 1-3 the feed wheel the feed wheel recently? unit and position
S S
packages? slot? knife slot? in eccentric) is
used for the
configuration (U
vers. S/T straws).
See Section 10.2
Conversion.
Is the straw type N Go to the next
changed O Check 4 and
recently? continue TS.

Is the feed wheel Y Verify that the

squeezer slots too E latest version of
big (should be 15 the feed wheel is
S
mm ±0,2 mm)? used. See Section
Feed Wheel Unit
in the SPC.
N No more checks,
O call a Tetra Pak
technician.
N Are the straw Y No more checks,
O pitch, the sealing E call a Tetra Pak
distance, the technician.
S
straw position top
and the straw N See Section
pocket length O 10.5.1.6.2
correct? See Replace Faulty
Section 10.5.1.7.1 Part of the Ladder
Straw Band.
Pitch,10.5.1.7.5
Sealing Distance
,10.5.1.7.2 Straw
Position Top and
10.5.1.7.6 Straw
Pocket Length.

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10 General 10.5 Troubleshooting

10.5.1.3 Packages Glued Together

Packages are glued together.

To troubleshoot this failure, see Section 10.5.1.3.1 Troubleshoot Packages Glued

Together on page 609.

Packages glued together

10.5.1.3.1 Troubleshoot Packages Glued Together

Follow the tables from Check 1 to Action by answering yes or no to get a
recommended solution.
(Cont’d)

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10.5 Troubleshooting 10 General

(Cont’d)

Check 1 Check 2 Check 3 Check 4 Action

Is the straw Y Are the conveyor N Is the conveyor Y Are the chain Y See Section
applied outside E and the top O unit calibrated? E expansion E 10.5.1.6.6-1
the package support running at sensors Encoder
borders? S the same speed S (W40B2180 and S
Synchronisation
and not creating W40B2182) Conveyor Chain
tilted packages? reading more than Link - Set
the encoder Conveyor Shaft.
synchronisation
See Section
conveyor chain
10.5.1.6.5-1
link?
Conveyor Chain
Link - Centre
Conveyor Shaft.
N No more checks,
O call a Tetra Pak
technician.
N See Section
O 1.2.2.6-5
Maintenance - Set
Conveyor Unit
Parameters.
Y Go to the next
E Check 2 and
continue TS.
S

Does the Y Do the pressure Y Is override set Y No more checks,

pressure arm pick E arm and the leaf E correctly? E call a Tetra Pak
up the straw spring hold the technician.
S S S
properly? straw properly?
N See Section
O 3.3.3-7 Pressure
Arm - Set
Override.
N Is the leaf spring Y See Section 3.7-3
O worn out? E Spring Holder -
Change Leaf
S
Spring.
N Go to the next
O Check 4 and
continue TS.

Is the straw Y Does the Y Do the pressure N Is the leaf spring N See Section
applied outside E pressure arm pick E arm and the leaf O moving freely and O 10.5.1.6.4 Daily
the package up the straw spring hold the is it clean from Cleaning.
S S
borders? properly? straw properly? glue residues?
See Section 3.7-1
Spring Holder -
Check Parts.

(Cont’d)

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10 General 10.5 Troubleshooting

(Cont’d)

Check 1 Check 2 Check 3 Check 4 Action

Y Go to the next
E Check 4 and
continue TS.
S

Are the pressure Y See Section

arms worn out? E 3.3.3-2 Pressure
Arm - Change
S
Parts (TB/TBA).
N See Section
O 10.5.1.6.4 Daily
Cleaning.
N Is the pick position Y Are the pressure Y See Section
O set correctly? E arms worn out? E 3.3.3-2 Pressure
Arm - Change
S S
Parts (TB/TBA).
N No more checks,
O call a Tetra Pak
technician.
N See Section
O 1.2.2.6-2
Maintenance - Set
Pick Position .
N Is there glue Y Clean the outfeed
O residue on the E support rail.
outfeed support
S See Section
rail?
2.1.1-1 Support
Rail - Set.
N Are the support Y No more checks,
O rail and the rail E call a Tetra Pak
holders on the technician.
S
conveyor aligned?
N See Section
O 2.1.1-1 Support
Rail - Set.

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10.5 Troubleshooting 10 General

10.5.1.4 Damaged Straw on Package

The straw on the package is damaged.

To troubleshoot this failure, see Section 10.5.1.4.1 Troubleshoot Damaged Straw on

Package on page 613.

Damaged straw on package

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10 General 10.5 Troubleshooting

10.5.1.4.1 Troubleshoot Damaged Straw on Package

Follow the tables from Check 1 to Action by answering yes or no to get a
recommended solution.

Check 1 Check 2 Check 3 Check 4 Action

Is a splice made Y Verify that the
recently? See E splice is made
Section according to
10.5.1.7.10 Film S
Section 10.5.1.6.1
Splice. Splice Ladder
Band.
See Section
10.5.1.6.2
Replace Faulty
Part of the Ladder
Band.
N Go to the next
O Check 1 and
continue TS.

Is the position of Y Is the LB correctly Y No more checks,

the straw in the E sealed so that the E call a Tetra Pak
feed wheel slot straw pockets are technician.
S S
correct? strong enough?
See Section N See Section
10.5.1.7.4 Film O 10.5.1.6.2
Sealing Strength. Replace Faulty
Part of the Ladder
Band.
N Is the LB moving Y Is the LB guide Y Are the straw N See Section
O freely from the E moving freely and E pitch, the sealing O 10.5.1.6.2
straw box and the are the LB guide distance, the Replace Faulty
S S
BFT? height settings straw position top, Part of the Ladder
Note! Also check correct? and the straw Band.
pocket length Y Go to the next
inside the BFT.
correct? See Check 4 and
Section 10.5.1.7.1 E continue TS.
Straw S
Pitch,10.5.1.7.5
Sealing Distance ,
10.5.1.7.2 Straw
Position Top and
10.5.1.7.6 Straw
Pocket Length.

Is the position of N Is the LB moving Y Is the LB guide Y Is the feed wheel Y No more checks,
the straw in the O freely from the E moving freely and E version correct for E call a Tetra Pak
feed wheel slot straw box and the are the LB guide the configuration technician.
BFT? S height settings S S
correct? and straw size?
correct?
Note! Also check
inside the BFT.

(Cont’d)

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10.5 Troubleshooting 10 General

(Cont’d)

Check 1 Check 2 Check 3 Check 4 Action

N Change the feed
O wheel to the
correct version.
See Section Feed
Wheel Unit in the
SPC.
N Is the height N See Section 3.5-1
O setting correct? O Ladder Band
Guide - Set.
Y Go to the next
E Check 4 and
continue TS.
S

Is the LB guide Y No more checks,

moving freely? E call a Tetra Pak
technician.
S
N Clean the LB
O guide.
N Does the LB lay N See Section
O correctly in the O 10.5.1.6.2
straw box? See Replace Faulty
Section 10.5.1.7.7 Part of the Ladder
Ladder Band Band.
Folding Inside the Verify storage of
Straw Box. straw box. See
Section 6.1
Supply of
materials in the
OM.
Y Are the N Align the machine
E alignments and O according to
distances for the Section 1.1.2.1
S
straw magazine Straight Through
and the BFT (TB/TBA/TPA/TT)
correct? in the IM.
Y Go to the next
E Check 3 and
continue TS.
S

Is the position of N Is the LB moving N Is the LB correctly N See Section

the straw in the O freely from the O threaded? O 10.5.1.6.2
feed wheel slot straw box and the Replace Faulty
correct? BFT? Part of the Ladder
Note! Also check Band.
inside the BFT. Y Is the roller in the N See Section
E BFT moving O 9.5.1.2-2 Bending
freely? Roller - Check
S
Rollers.

(Cont’d)

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10 General 10.5 Troubleshooting

(Cont’d)

Check 1 Check 2 Check 3 Check 4 Action

Y Go to the next
E Check 3 and
continue TS.
S

Are empty straw Y No more checks,

boxes removed? E call a Tetra Pak
technician.
S
N Remove empty
O straw boxes.

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10.5 Troubleshooting 10 General

10.5.1.5 Straw Missing or Misplaced

Straws are missing or misplaced on the packages.

To troubleshoot this failure, see Section 10.5.1.5.1 Troubleshoot Straw Missing or

Misplaced on page 617.

Straw missing or misplaced on the packages

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10 General 10.5 Troubleshooting

10.5.1.5.1 Troubleshoot Straw Missing or Misplaced

Follow the tables from Check 1 to Action by answering yes or no to get a
recommended solution.

Check 1 Check 2 Check 3 Check 4 Action

Is the foil on the Y Is the BFT used? Y Is the correct BFT Y See Section
straw bent or E E temperature E 10.5.1.6.2
folded? See reached Replace Faulty
S S (100 ±10 ºC)? S
Section 10.5.1.7.9 Part of the Ladder
Bent Foil. Band.
N Is the BFT warm Y See Section
O up period E 9.5.2.1-4
finished? Temperature
S
Controller - Set
Parameters
Manually.
N Wait for the BFT
O to warm up.
N Is there glue Y Clean knife and
O residue on the E see Section
knife, leaf spring 10.5.1.6.4 Daily
S
or feed wheel? Cleaning.
N Is the knife blunt Y See Section 3.2-2
O or damaged? E Cutting Unit -
Change Parts.
S
N See Section
O 10.5.1.6.2
Replace Faulty
Part of the Ladder
Band.
Verify storage of
straw box. See
Section 6.1
Supply of
materials in the
OM.
N Is the straw bent? Y See Section
O See Section E 10.5.1.6.2
10.5.1.7.8 Bent Replace Faulty
S
Straw. Part of the Ladder
Band.
Verify storage of
straw box. See
Section 6.1
Supply of
materials in the
OM.
N Is the straw N See Section
O applied with 2 mm O 3.3.3-7 Pressure
(±1 mm) override Arm - Set
pressure? Override.
Is the foil on the N Is the straw bent? N Is the straw Y Is the pick N See Section
straw bent or O See Section O applied with 2 mm E position correct? O 1.2.2.6-2
folded? See 10.5.1.7.8 Bent (±1 mm) override Maintenance - Set
S
Section 10.5.1.7.9 Straw. pressure? Pick Position .
Bent Foil.

(Cont’d)

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10.5 Troubleshooting 10 General

(Cont’d)

Check 1 Check 2 Check 3 Check 4 Action

Y Go to the next
E Check 1 and
continue TS.
S

Is there enough N Are the nozzles or Y Replace/clean

glue on the O filters in the E clogged parts.
straw? hotmelt See Section 5.2-7
S
equipment Hotmelt
clogged? Equipment
Nordson -
Change Nozzle.
Replace/clean
clogged parts.
See Section 5.2-8
Hotmelt
Equipment
Nordson -
Change Filter.
N Are the gun Y Replace/clean
O modules in the E clogged parts.
hotmelt See Section
S
equipment 5.2.1-1 Hotmelt
clogged or Gun - Change
leaking? Gun Module.
N Is the hotmelt N See Section 10.2
O temperature set O Hotmelt in the
correctly? OM.
Y Go to the next
E Check 2 and
continue TS.
S

Are the pressure Y Is the Y Is the nozzle size Y No more checks,

settings for the E recommended E correct? E call a Tetra Pak
hotmelt pump and glue used? technician.
the gun correct? S S S
N Change to
O recommended
nozzle type. See
Section Hotmelt
Equipment in the
SPC.
N See Section 10.2
O Hotmelt in the
OM.
Is there enough N Are the pressure N See Section 10.1
glue on the O settings for the O Pressure
straw? hotmelt pump and Regulators in the
the gun correct? OM.
Y Go to the next
E Check 1 and
continue TS.
S

(Cont’d)

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10 General 10.5 Troubleshooting

(Cont’d)

Check 1 Check 2 Check 3 Check 4 Action

Does the shape Y Is the package Y Is the belt brake Y It the height of the Y Verify package
or dimension of E flow into the E set correctly? E top support E forming from FM.
the packages machine correct?
S S S S
vary? corresponding
with the machine N See Section 2.4-2
capacity? O Top Support - Set
Lateral Position.
N See Section 2.2-4
O Belt Brake - Set.
N See Section
O 1.1.2.1 Straight
Through
(TB/TBA/TPA/TT)
in the IM.
Set up the line
automation
(accumulator
output and
start/stop timers).
N Are the conveyor Y Is the feed wheel Y No more checks,
and the top E stop position E call a Tetra Pak
support running at correct? technician.
S S
the same speed
not creating tilted N Tighten the
packages? O driving belt and
perform new
homing.
N Is the conveyor Y Are the chain Y See Section
O unit calibrated? E expansion E 10.5.1.6.5-1
sensors Conveyor Chain
S S
(W40B2180 and Link - Centre
W40B2182) Conveyor Shaft.
reading more than
See Section
the special
10.5.1.6.6-1
conveyor chain
Encoder
link?
Synchronisation
Conveyor Chain
Link - Set
Conveyor Shaft.
N No more checks,
O call a Tetra Pak
technician.
N See Section
O 1.2.2.6-5
Maintenance - Set
Conveyor Unit
Parameters.

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10.5 Troubleshooting 10 General

10.5.1.6 Solutions
10.5.1.6.1 Splice Ladder Band
Use the splicing table (1) to splice the ladder band. See Section 6.1 Supply of
Materials in the OM.

1 Splicing table
.

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10 General 10.5 Troubleshooting

10.5.1.6.2 Replace Faulty Part of the Ladder Band

Remove the damaged/faulty ladder band and re-thread the machine. See Section
3.1 Preparation in the OM.

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10.5 Troubleshooting 10 General

10.5.1.6.3 Thread Ladder Band in Bent Foil Treater

Remove the damaged ladder band and re-thread the BFT. See Section 3.1
Preparation in the OM.

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10 General 10.5 Troubleshooting

10.5.1.6.4 Daily Cleaning

Clean the feed wheel (1), the pressure arm (2), and the leaf spring (3). See Section
9.1 Daily Care in the OM.

3
1 Feed wheel
2 Pressure arm
3 Leaf Spring
.

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10.5 Troubleshooting 10 General

10.5.1.6.5 Conveyor Chain Link

10.5.1.6.5-1 Conveyor Chain Link - Centre Conveyor Shaft
Note! The sensor (1) and the sensor (2) function are to read on the shaft (3) , not
on the conveyor shaft (4).
a) Centre the conveyor shaft (4) in the conveyor chain link (5). The distance A
between the conveyor shaft (4) and the chain link (5) should be 3 ±0.2 mm.

3 A
2 5
4
1

5
4

A A
A = 3 ±0.2 mm
1 Sensor W40B2180 3 Shaft
2 Sensor W40B2182 4 Conveyor shaft
5 Chain link
.

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10 General 10.5 Troubleshooting

10.5.1.6.6 Encoder Synchronisation Conveyer Chain Link

10.5.1.6.6-1 Encoder Synchronisation Conveyor Chain Link - Set
Conveyor Shaft
a) Set the distance A on the sensor (1) and the sensor (2).

2
1

A
A = 12 mm
1 Sensor W40B2180 3 Bracket
2 Sensor W40B2182 4 Conveyor shaft head
.

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10.5 Troubleshooting 10 General

10.5.1.7 Supporting Documents

10.5.1.7.1 Straw Pitch
The straw pitch is the distance from one straw pocket edge (1) to the next equivalent
straw pocket edge (2). All straw pitches in a ladder band must be equal. See the
specifications for each particular straw type.

A B

1 2
1 Straw pocket edge
2 Straw pocket edge

A=B
.

10.5.1.7.2 Straw Position Top

The straw position top is the distance between the top film sealing surface (1) and
the film (2). The distance A should be maximum 1,4 mm.

1 2
A

Ladder band
1 Top film sealing
surface
2 Film
.

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10 General 10.5 Troubleshooting

10.5.1.7.3 Film Cut

The film cut (2) is the edge of the film closest to the straw angle cut (1). The film cut
should be straight, clean, and not cause an irregular ladder band width.

1 2
1 Straw angle cut
2 Film cut
.

10.5.1.7.4 Film Sealing Strength

The film sealing strength is the strength of the film sealing area (1) around the straw
pockets (2). The sealing should be strong enough to keep the straws within each
straw pocket.

1 2
1 Film sealing area
2 Straw pocket
.

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10.5 Troubleshooting 10 General

10.5.1.7.5 Sealing Distance

The sealing distance is the distance from one straw pocket (1) to the next straw
pocket (2). See the specifications for each particular straw type.

1 2
1 Straw pocket
2 Straw pocket

A = Sealing distance
.

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10 General 10.5 Troubleshooting

10.5.1.7.6 Straw Pocket Length

The straw pocket length is the distance between the edges of one straw pocket (1).
See the specifications for each particular straw type.

1
1 Straw pocket

A = Straw pocket length

.

10.5.1.7.7 Ladder Band Folding Inside the Straw Box

The ladder band should be folded with a Z-shaped spreading inside the straw box.

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10.5 Troubleshooting 10 General

10.5.1.7.8 Bent Straw

A bent straw is a straw with an excess of deformation. The distance between the
package and the straw should be less than 3 mm.

A
A < 3 mm
.

10.5.1.7.9 Bent Foil

A bent foil (1) is a foil with an excess of deformation. It can be present on the edges
of the Z-shaped spreading inside the straw box. Use the BFT to solves this problem.

1
1 Bent foil
.

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10 General 10.5 Troubleshooting

10.5.1.7.10 Film Splice

A film splice (1) is the sealing bond between two ladder bands. It is made with heat
sealing or tape.

1
1 Film splice
.

10.5.2 Electric Equipment

The intended use of this troubleshooting guide is to identify and solve problems with
the machine that is connected to Electric Equipment.
This troubleshooting guide covers these failures:

Failure Section

10.5.3 Applicator Unit

The intended use of this troubleshooting guide is to identify and solve problems with
the machine that is connected to Applicator Unit.

This troubleshooting guide covers these failures:

Failure Section

10.5.4 Conveyor Section

The intended use of this troubleshooting guide is to identify and solve problems with
the machine that is connected to Conveyor Section.

This troubleshooting guide covers these failures:

Failure Section

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10.5 Troubleshooting 10 General

10.5.5 Straw Detector Integrated

The intended use of this troubleshooting guide is to identify and solve problems with
the machine that is connected to Straw Detector Integrated.
This troubleshooting guide covers these failures:

Failure Section
IVC Flash Memory Corrupt See Section 10.5.5.1 IVC Flash Memory Corrupton
page 632.

10.5.5.1 IVC Flash Memory Corrupt

If the function LED blinks cyclically, red-yellow-green, it means that the flash has
become corrupt for some reason and cannot initialise. If a reboot of the camera
does not solve the problem, then claim the camera.

10.5.6 Hotmelt Equipment

The intended use of this troubleshooting guide is to identify and solve problems with
the machine that is connected to Hotmelt Equipment.

This troubleshooting guide covers these failures:

Failure Section

10.5.7 Machine Body

The intended use of this troubleshooting guide is to identify and solve problems with
the machine that is connected to Machine Body.

This troubleshooting guide covers these failures:

Failure Section

10.5.8 Machine Covering

The intended use of this troubleshooting guide is to identify and solve problems with
the machine that is connected to Machine Covering.

This troubleshooting guide covers these failures:

Failure Section

10.5.9 Air Equipment

The intended use of this troubleshooting guide is to identify and solve problems with
the machine that is connected to Air Equipment.
This troubleshooting guide covers these failures:

Failure Section

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10 General 10.5 Troubleshooting

10.5.10 Regular Accessories

The intended use of this troubleshooting guide is to identify and solve problems with
the machine that is connected to Regular Accessories.
This troubleshooting guide covers these failures:

Failure Section

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10.6 IP Addresses 10 General

10.6 IP Addresses
Refdes. Denomination IP Address Note
A01X2114 NAT ROUTER 192.168.1.1
A03K2010 PLC 192.168.1.8
A08A2010 OPERATING PANEL 192.168.1.12
W30T1010 FEED UNIT 192.168.1.64
W30T1020 SQUEEZER UNIT 192.168.1.65
P30B3010 CIP SYNC ENCODER 192.168.1.66 PM motor
A01X2121 SNP GATEWAY 192.168.1.191
W40T1030 INFEED CONVEYOR 192.168.1.192
W40T1010 MAIN CONVEYOR 192.168.1.193 Asynchronous motor
192.168.1.197 PM motor
W40T1020 TOP SUPPORT 192.168.1.194
W40T1030 BELT BRAKE 192.168.1.195
W90T1010 DISCHARGE CONVEYOR 192.168.1.196
W40T1020 VISION CAMERA 192.168.1.224

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10 General 10.7 Lockout Procedures

10.7 Lockout Procedures

10.7-1 Electrical Supply - Lockout Procedure
Machine Status Program step PREHEATING
Special Equipment Padlock
Lockout hasp 90523-1761

DANGERI
DANGER
Hazardous voltage can be present with the electrical supply disconnecting
device in position 0 (ZERO).
Circuits identified by orange-coloured conductors are not disconnected by the main
electrical supply disconnecting device. The location of the electrical supply
disconnecting device of these circuits is described in the procedures that include
work on these types of circuit.
(Cont’d)

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10.7 Lockout Procedures 10 General

(Cont’d)

Main Machine
a) Turn the electrical supply disconnecting device (1) to position 0 (ZERO).
b) Attach the padlock (2). If several technicians are working on the machine,
attach a lockout hasp (3) and then attach your padlock on the lockout hasp.
Note! Each technician working on the equipment must attach their own
padlock and retain the key in their possession until all work is completed.
c) When your work is completed, remove your padlock (2).
d) When all technicians have completed their work, remove the lockout hasp (3).

3
2

1 Electrical supply
disconnecting device
2 Padlock
3 Lockout hasp
.

(Cont’d)

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10 General 10.7 Lockout Procedures

(Cont’d)

BFT

1 3

2
1 Electrical supply
disconnecting device
2 Padlock
3 Lockout hasp

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10.7 Lockout Procedures 10 General

10.7-2 Air Supply - Lockout Procedure

Machine Status Program step PREHEATING
Special Equipment Padlock
Lockout hasp 90523-1761

Main Air Valve

a) Turn the knob on the main air valve (1).
b) Attach the padlock (2). If several technicians are working on the equipment,
attach a lockout hasp (3) and then attach your padlock on the lockout hasp.
Note! Each technician working on the equipment must attach their own
padlock and retain the key in their possession until all work is completed.
c) To verify that all the compressed air has been released, check that the filter
regulator (4) shows the value 0 (zero).
d) When your work is completed, remove your padlock (2).
e) When all technicians have completed their work, remove the lockout hasp (3).

4 3
1

2 2

1 Main air valve 3 Lockout hasp

2 Padlock 4 Filter regulator
.

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11 Safety System Description

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Table of Contents 11 Safety System Description

11.1 General ........................................................... 643

11.1.1 Description of System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643

11.2 List of Safety Components .................................. 644

11.3 Modes of Operation ........................................... 645
11.3.1 Normal Operating Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645

11.4 Safety System Architecture ................................. 646

11.5 Safety Zones in the Machine ................................ 647
11.5.1 Emergency Stop Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 647
11.5.1.1 Location of Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . 647
11.5.1.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 647
11.5.1.3 Parts in the SRP/CS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 648
11.5.1.4 SRP/CS Diagrammatic Presentation . . . . . . . . . . . . . . . . . . . 648

11.5.2 Door Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 649

11.5.2.1 Location of Safeguards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 649
11.5.2.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 649
11.5.2.3 Parts in the SRP/CS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 649
11.5.2.4 SRP/CS Diagrammatic Presentation . . . . . . . . . . . . . . . . . . . 650

11.6 Fault Exclusions ............................................... 651

11.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651
11.6.2 Fault Exclusion Short Circuit Inside Cabinet . . . . . . . . . . . 651

11.7 Emergency Stop................................................ 652

11.7-1 Emergency Stop – Check. . . . . . . . . . . . . . . . . . . . . . . . 652
11.7-2 Emergency Stop - Change . . . . . . . . . . . . . . . . . . . . . . . 652

11.7.1 Emergency Stop - Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . 653

11.8 Safeguard ........................................................ 654

11.8-1 Safeguard – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 654
11.8-2 Safeguard - Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 654
11.8-3 Safeguard - Teach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655
11.8-4 Safeguard Status Codes. . . . . . . . . . . . . . . . . . . . . . . . . 656

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11 Safety System Description Table of Contents

11.9 Safety PLC ...................................................... 657

11.9-1 Safety PLC - Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . 657

11.10 Pluto Manager .................................................. 658

11.10-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 658
11.10-2 Pluto Manager - Install . . . . . . . . . . . . . . . . . . . . . . . . . . 659
11.10-3 Pluto Manager - Set Project . . . . . . . . . . . . . . . . . . . . . . 660
11.10-4 Pluto Manager - Check Firmware and
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .661
11.10-5 Pluto Manager - Set an IDFIX Address . . . . . . . . . . . . 662
11.10-6 Pluto Manager - Install Pluto from PC . . . . . . . . . . . . . 664
11.10-7 Pluto Manager - Reset Alarms . . . . . . . . . . . . . . . . . . . 665
11.10-8 Pluto Manager - Update Firmware . . . . . . . . . . . . . . . . 666
11.10-9 Pluto Manager - Troubleshoot Safety
System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .668

11.11 Safety Relay Expansion Module............................ 673

11.11-1 Safety Relay Expansion Module - Check . . . . . . . . . . 673
11.11-2 Safety Relay Expansion Module - Change. . . . . . . . . 674

11.12 Contactor ........................................................ 675

11.12-1 Contactor - Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675
11.12-2 Contactor - Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 676

11.13 Servo Drive ...................................................... 677

11.13.1 LED Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677
11.13-1 Servo Drive - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 679
11.13-2 Servo Drive - Change . . . . . . . . . . . . . . . . . . . . . . . . . . . 679
11.13-3 Servo Drive - Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 682

11.13.2 Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 684

11.14 Frequency Converter.......................................... 691

11.14-1 Frequency Converter - Change. . . . . . . . . . . . . . . . . . . 691
11.14-2 Frequency Converter PF 525 - Check. . . . . . . . . . . . . 696
11.14-3 Frequency Converter PF 525 - Parameters . . . . . . . . 699
11.14-4 Frequency Converter PF 525 - Error Codes . . . . . . . 701
11.14-5 Frequency Converter PF 527 - Check. . . . . . . . . . . . . 705
11.14-6 Frequency Converter PF 527 - Set IP-
address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .708
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Table of Contents 11 Safety System Description

11.14-7 Frequency Converter PF 527 - Drive Status

Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .710

11.14.1 Frequency Converter PF 527 - Troubleshoot the Safe

Torque-Off Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713
11.14-8 Frequency Converter PF 527 - Error Codes . . . . . . . 714

11.15 Safety Valve ..................................................... 722

11.15.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 722
11.15-1 Safety Valve - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 723
11.15-2 Safety Valve - Change. . . . . . . . . . . . . . . . . . . . . . . . . . . 724
11.15-3 Safety Valve - Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 725

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11 Safety System Description 11.1 General

11.1 General
DANGERI
DANGER
Risk of death or serious injury.
Any modification that changes the different categories or performance levels of the
applied safety functions can lead to a dangerous failure in the safety system. The
machine is equipped with a safety system containing emergency stops and
interlocking door guards. Categories and performance levels of separate functions
are given in the following sections.
To ensure the performance of the safety related parts of the control system, any
modification must be performed in a way that does not change the status and
integrity of the categories or performance levels of the applied safety functions.

11.1.1 Description of System

The safety system of the Straw Applicator 30 - 0500 is managed by the safety PLC
F09K2010 and safety relay expansion module F09K2014.
The machine is divided into two safety zones; one for emergency stops and one for
the door guard. When a door or cover in any safety zone opens, a signal is sent to
the safety PLCs, and the zone is secured.
When any emergency stop button is pressed on the machine, all the safety zones
are secured.

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11.2 List of Safety Components 11 Safety System Description

11.2 List of Safety Components

All components included in the safety system are listed in this section.

DANGERI
DANGER
Risk of death or serious injury.
Replace safety components in the safety system with components that have the
same performance level. Otherwise there may be a dangerous failure in the safety
system.
For the safety system, use only designated safety components listed in the Spare
Parts Catalogue.

Reference designation Description

Sensor
F09S2020 Emergency stop HMI panel
F09S2022 Emergency stop electrical cabinet
F09B2026 Door guard

Reference designation Description

Input
F09X2050 Connection block
F09X2052 Blanking plug
F09X2054 Blanking plug
F09X2056 Blanking plug

Reference designation Description

Logic
F09K2010 Safety PLC

Reference designation Description

Output
F09K2014 Safety relay expansion module

Reference designation Description

Actuator
F09K2040 Safety valve Straw Applicator
F09Q1010 Power contactor emergency stop 1st level
F09Q1020 Power contactor emergency stop 2nd level
W40T1020 STO frequency converter top support
W40T1030 STO frequency converter belt brake
W30T1010 STO servo drive feed unit
W30T1020 STO servo drive squeezer unit

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11 Safety System Description 11.3 Modes of Operation

11.3 Modes of Operation

11.3.1 Normal Operating Mode
The normal mode of operation of the safety system is described in Section 11.5
Safety Zones in the Machine.

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11.4 Safety System Architecture 11 Safety System Description

11.4 Safety System Architecture

These are the safety zones in the machine:

• 11.7 Emergency Stop

• 11.8 Safeguard

The illustration shows the safeguards and how they affect the actuators in the
machine.

Emergency stop Safeguard

Emergency stop Door zone Door zone

Power actuators Safety valve Power actuators

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11 Safety System Description 11.5 Safety Zones in the Machine

11.5 Safety Zones in the Machine

11.5.1 Emergency Stop Zone
11.5.1.1 Location of Emergency Stop

11.5.1.2 Description
The EMERGENCY STOP disconnects the power to all power loads outside the
electrical cabinets and shuts off the air pressure in the machine.
Reset the safety system with the RESET button on the operator panel.

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11.5 Safety Zones in the Machine 11 Safety System Description

11.5.1.3 Parts in the SRP/CS

SRP/CS
Standard Stop Response
No. SRP/CS Architecture / Performance Level Category Time Fault Exclusions
1 Safety related EN ISO 13849-1:2008 0 < 51 ms N/A
stop function of Category 4 / PL e
contactors
2 Safety related EN ISO 13849-1:2008 0 < 101 ms N/A
stop function of Category 1 / PL c
safety valve
3 Safety related EN ISO 13849-1:2008 1 < 537 ms 11.6.2 Fault Exclusion
stop function of Category 3 / PL d Short Circuit Inside
servo drives Cabinet
4 Safety related EN ISO 13849-1:2008 1 < 625 ms 11.6.2 Fault Exclusion
stop function of Category 3 / PL d Short Circuit Inside
frequency drives Cabinet
PF525.
5 Safety related EN ISO 13849-1:2008 1 < 537 ms 11.6.2 Fault Exclusion
stop function of Category 3 / PL e Short Circuit Inside
frequency drives Cabinet
PF527.
.

11.5.1.4 SRP/CS Diagrammatic Presentation

These are the safety functions realised by the SRP/CS.

SRP/CSA → SRP/CSB → SRP/CSC → SRP/CSD → SRP/CSE → SRP/CSF

S I B L O A

No. Sensor (S) Input (I) Bridge (B) Logic (L) Output (O) Actuator (A)
1 Emergency stop Connection N/A Safety PLC with N/A Two contactors
button with block with cross channel wired according
electronic electronic monitoring of to category 4.
pulsating signal. pulsating signal CPU, inputs and
monitoring outputs
2 Emergency stop Connection N/A Safety PLC with N/A Safety valve
button with block with cross channel with single
electronic electronic monitoring of channel and
pulsating signal. pulsating signal CPU, inputs and separate
monitoring outputs pressure sensor
for diagnostics
3 Emergency stop Connection N/A Safety PLC with Safety relay Servo drive with
button with block with cross channel expansion dual channel
electronic electronic monitoring of module with Safe Torque Off
pulsating signal. pulsating signal CPU, inputs and internal two
monitoring outputs channel
disconnection.

(Cont’d)

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11 Safety System Description 11.5 Safety Zones in the Machine

(Cont’d)

No. Sensor (S) Input (I) Bridge (B) Logic (L) Output (O) Actuator (A)
4 Emergency stop Connection N/A Safety PLC with Safety relay Frequency
button with block with cross channel expansion converter
electronic electronic monitoring of module with PF525 with dual
pulsating signal. pulsating signal CPU, inputs and internal two channel Safe
monitoring outputs channel Torque Off
disconnection.
5 Emergency stop Connection N/A Safety PLC with Safety relay Frequency
button with block with cross channel expansion converter
electronic electronic monitoring of module with PF527 with dual
pulsating signal. pulsating signal CPU, inputs and internal two channel Safe
monitoring outputs channel Torque Off
disconnection.

11.5.2 Door Zone

11.5.2.1 Location of Safeguards

11.5.2.2 Description
The safeguards are triggered if a door is opened. When a door is opened all motors
in the machine stop, and air pressure is removed from the hot melt gun.
Reset the safety system with the RESET button on the operator panel.

11.5.2.3 Parts in the SRP/CS

SRP/CS
Standard Stop Response
No. SRP/CS Architecture / Performance Level Category Time Fault Exclusions
1 Safety related EN ISO 13849-1:2008 0 < 131 ms N/A
stop function of Category 1 / PL c
safety valve
2 Safety related EN ISO 13849-1:2008 1 < 537 ms 11.6.2 Fault Exclusion
stop function of Category 3 / PL d Short Circuit Inside
servo drive Cabinet

(Cont’d)

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11.5 Safety Zones in the Machine 11 Safety System Description

(Cont’d)

SRP/CS
Standard Stop Response
No. SRP/CS Architecture / Performance Level Category Time Fault Exclusions
3 Safety related EN ISO 13849-1:2008 1 < 655 ms 11.6.2 Fault Exclusion
stop function of Category 3 / PL d Short Circuit Inside
frequency Cabinet
converters
PF525
4 Safety related EN ISO 13849-1:2008 1 < 567 ms 11.6.2 Fault Exclusion
stop function of Category 3 / PL e Short Circuit Inside
frequency Cabinet
converters
PF527

11.5.2.4 SRP/CS Diagrammatic Presentation

These are the safety functions realised by the SRP/CS.

SRP/CSA → SRP/CSB → SRP/CSC → SRP/CSD → SRP/CSE → SRP/CSF

S I B L O A

No. Sensor (S) Input (I) Bridge (B) Logic (L) Output (O) Actuator (A)
1 Non-contact N/A N/A Safety PLC with N/A Safety valve
safety switch cross channel with single
with electronic monitoring of channel and
pulsating signal CPU, inputs and separate
monitoring. outputs pressure sensor
for diagnostics
2 Non-contact N/A N/A Safety PLC with Safety relay Servo drive with
safety switch cross channel expansion dual channel
with electronic monitoring of module with Safe Torque Off
pulsating signal CPU, inputs and internal two
monitoring. outputs channel
disconnection.
3 Non-contact N/A N/A Safety PLC with Safety relay Frequency
safety switch cross channel expansion converter
with electronic monitoring of module with PF525 with dual
pulsating signal CPU, inputs and internal two channel Safe
monitoring. outputs channel Torque Off
disconnection.
4 Non-contact N/A N/A Safety PLC with Safety relay Frequency
safety switch cross channel expansion converter
with electronic monitoring of module with PF527 with dual
pulsating signal CPU, inputs and internal two channel Safe
monitoring. outputs channel Torque Off
disconnection.
.

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11 Safety System Description 11.6 Fault Exclusions

11.6 Fault Exclusions

11.6.1 General
The integrity of the safety system is based on the fault exclusions given in the
following subsections.

DANGERI
DANGER
Risk of death or serious injury.
Altering the conditions given in the fault conditions will lead to a hazardous situation.
Ensure that all the listed conditions for the fault exclusion are fulfilled.

11.6.2 Fault Exclusion Short Circuit Inside Cabinet

A fault exclusion has been made inside the electrical cabinet for short-circuits
between conductors.
To maintain the justification and the safety performance level, the following
conditions must be fulfilled:

• The electrical cabinet must be kept locked, with access restricted to skilled or
instructed persons.
• The protective bonding circuit must be maintained.
• The degree of protection of the electrical cabinet must not be reduced so that
there is a risk of ingress of water or dust below the prior level of protection.
• The lids of the cable ducts must be restored after maintenance.

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11.7 Emergency Stop 11 Safety System Description

11.7 Emergency Stop

11.7-1 Emergency Stop – Check
Machine Status Electrical supply disconnecting device in position I
(ON)

The locations of the emergency stop buttons can be found in Section 11.5.1.1
Location of Emergency Stop.
a) Identify the emergency stop button(s) to be tested.
b) In the electrical cabinet, check on the safety PLC (1) that the LED I0 (2) is lit.
c) Press the emergency stop button.
d) Check that the button remains in the pushed-in position.
e) Check that the LED I0 (2) is no longer lit.
f) Check that no UE code is displayed on the safety PLC (1).
g) Reset the emergency stop button by turning it slightly to the left.
h) Check that the LED I0 (2) is lit up again.
i) Repeat from step b) for each emergency stop button.

2 1

1 Safety PLC F09K2010

2 LED I0

11.7-2 Emergency Stop - Change

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)

a) Disconnect the cable, and change the EMERGENCY STOP button.

b) Connect the cable.
c) Perform a test for the replaced EMERGENCY STOP button. See Procedure
11.7-1 Emergency Stop – Check on page 652.
Note! Dispose of the electrical components and batteries in special waste
management systems. Follow local regulations.
.

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11 Safety System Description 11.7 Emergency Stop

11.7.1 Emergency Stop - Status Codes

The EMERGENCY STOP buttons in an emergency stop circuit are connected in a
series. As long as no EMERGENCY STOP button is activated, a dynamic signal is
sent trough the chain of sensors. For details, see the Electrical manual for the
machine.
The LED (1) indicates the status of an EMERGENCY STOP button:

LED Description
Fixed green light Safety circuit closed;
EMERGENCY STOP button
OK.
Fixed red light Safety circuit open;
EMERGENCY STOP button
pressed.
Alternating green/red light Safety circuit is broken;
another EMERGENCY STOP
button in the circuit is pressed.

1
1 LED

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11.8 Safeguard 11 Safety System Description

11.8 Safeguard
11.8-1 Safeguard – Check
Machine Status Electrical supply disconnecting device in position I
(ON)

Note! See Section 11.5.2.1 Location of Safeguards for the locations of the
safeguards on the machine.
Check one safeguard at a time:

a) With the door closed, check that the LED (1) on the sensor (2) is lit with a
steady green light.
b) Open the door and check that the LED (1) is lit with a steady red light.
c) Check that the input LED I1 (3) on the safety PLC (4) is not lit.
d) Close the door and check that the input LED I1 (3) on the safety PLC (4) is lit.

3 4

1 LED 3 Input LED I1

2 Sensor (Adam) 4 Safety PLC F09K2010

11.8-2 Safeguard - Change

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)

Sensor
a) Disconnect the cable, and replace the sensor.
b) Connect the cable.
c) Teach the new sensor. See Section 11.8-3 Safeguard - Teach on page 655.
d) Perform a test for the replaced safeguard. See Section 11.8-1 Safeguard –
.
Check on page 654.

(Cont’d)

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11 Safety System Description 11.8 Safeguard

(Cont’d)

Reflector
a) Replace the reflector.
b) Perform a test for the replaced safeguard. See Section 11.8-1 Safeguard –
.
Check on page 654.
Note! Dispose of the electrical components and batteries in special waste
management systems. Follow local regulations.
.

11.8-3 Safeguard - Teach

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)

Note! The sensor only needs teaching on first start-up. The reflector must be in
range (<15 mm) and correctly aligned.
Note! The sensor must stay in range during the teaching procedure.
Note! If the teaching procedure fails, and no code is programmed, the sensor enters
a fail-safe mode, and LED (1) begins flashing rapidly with a red light. Turn OFF the
electrical supply disconnecting device, and repeat the procedure.
a) Bring the sensor (2) within range of the reflector (3).
b) Turn ON the electrical supply disconnecting device.
c) Wait for the LED (1) to turn green.

3
2

1 LED
2 Sensor
3 Reflector
.

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11.8 Safeguard 11 Safety System Description

11.8-4 Safeguard Status Codes

Note! See Section 11.5.2.1 Location of Safeguards for the locations of the
safeguards on the machine.
The safeguards in a protecting circuit are connected in a series. When the
safeguards are closed, a dynamic signal is sent through the chain of sensors.
Before the sensor (2) is used, it needs to be configured to work with the reflector (3).
The LED (1) on the sensor (2) indicates the status of the safe guard:

LED Description
No light Loss of power supply
Fixed green light Valid reflector (3) within range
Flashing green light Valid reflector (3) within range, waiting on
reset
Flashing green/red Valid reflector (3) within range, not valid in
light signal
Fixed red light Valid reflector (3) out of range
Rapidly flashing Valid reflector (3) is within 2 mm from
green light maximum sense distance
Rapidly flashing red Fail safe mode; reprogram, or replace sensor
light
Flashing red light No reflector (3) programmed

Make sure that the stripe markings for the sensor (2) and the reflector (3) are
aligned.

3
2

1 LED
2 Sensor (Adam)
3 Reflector (Eva)
.

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11 Safety System Description 11.9 Safety PLC

11.9 Safety PLC

11.9-1 Safety PLC - Change
Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)

Note! Do not attach a safety PLC module or a safety relay expansion module closer
to another safety PLC module than distance A.

A
A > 5 mm
Note! The module can be changed without disconnecting any wires.
a) Pry away the terminal blocks (1) using a screwdriver.
b) Release the catch (2), and change the safety PLC module (3).
c) Install the safety software. See Section 11.10-6 Pluto Manager - Install Pluto
from PC.
Note! Dispose of the electrical components and batteries in special waste
management systems. Follow local regulations.

3 2 1
1 Terminal block
2 Catch
3 PLC module

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11.10 Pluto Manager 11 Safety System Description

11.10 Pluto Manager

11.10-1 Description
Note! The Pluto Manager version has to be 2.30 or higher.
a) Make sure that the Pluto has the latest firmware.
b) Write the id-fix address for the Pluto.
c) Download these programs
• Pluto program files

.spe: encrypted file (gives no possibility to change)

.hps: hexadecimal file (compiled program for Pluto)
• Access and registration codes
"Mute" Service engineer, customer. With the .spe and .hps files, you can
download programs to PLUTO and go online.
License Machine owner, line builder. Requires education. Full access to
create and change programs. Compile and download updates to a
changed program.

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11 Safety System Description 11.10 Pluto Manager

11.10-2 Pluto Manager - Install

Machine Status Electrical supply disconnecting device in position I (ON)
SPC Reference 3241503-0200

a) Download the latest Pluto Manager (1) from the supplier's web site and install.
b) Start the Pluto Manager (1).
c) Press the Register Key button (2).
d) Write MUTE as registration code (3), and click OK.
e) The program acknowledges the registration code. Click OK (4).
The PLUTO Manager is ready for downloads and online monitoring.

3 4
1 Pluto Manager
2 Register Key button
3 Registration code
4 OK
.

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11.10 Pluto Manager 11 Safety System Description

11.10-3 Pluto Manager - Set Project

Machine Status Electrical supply disconnecting device in position I
(ON)
SPC Reference 3241503-0200

A Pluto project can be set in several ways. This is an example:

a) Start the Pluto Manager (1).
b) Select the file (2), and click Open (3).
c) Select the Pluto project (4).

1 2

4
1 Pluto Manager
2 File
3 Open
4 Pluto project
.

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11 Safety System Description 11.10 Pluto Manager

11.10-4 Pluto Manager - Check Firmware and Software

Machine Status Electrical supply disconnecting device in position I (ON)
Special Equipment Pluto Programming Cable TP No. 90459-4891
SPC Reference 3241503-0200

Use this procedure to determine the software and firmware status of the Pluto unit.

a) Start the Pluto Manager (1).

b) Connect the programming cable (2) between the PC and the Pluto.
c) From the Tools menu, select OnlineInfo and then the Pluto/gateway
Connected to PC (3).
d) Read the data (4) for the Pluto.

1 Pluto Manager
2 Programming cable
3 Pluto/gateway
Connected to PC
4 Data
.

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11.10 Pluto Manager 11 Safety System Description

11.10-5 Pluto Manager - Set an IDFIX Address

Machine Status Electrical supply disconnecting device in position I
(ON)
SPC Reference 3241503-0200

To set a new IDFIX address, or to change one, use the function for programming
identifier circuits. This function is fully accessible regardless of the registration code.
a) Start by opening the Pluto project according to procedure 11.10-3 Pluto
Manager - Set Project.
b) Copy the IDFIX address (1).
c) From the Tools menu, select Write IDFIX (2).

1 IDFIX address
2 Write IDFIX
.

(Cont’d)

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11 Safety System Description 11.10 Pluto Manager

(Cont’d)

d) Paste or type in the IDFIX address (3), and click Write ID circuit (4).
Note! Never select ERASE PROTECT ID. This option makes it impossible to
reprogram the ID circuit.
e) Confirm by clicking OK (5).
f) The Pluto activates an alarm because of the changed address. If you want to
download a program, you can continue. Otherwise, restart. See 11.10-7 Pluto
Manager - Reset Alarms.

5
3 IDFIX address
4 Write ID circuit
5 OK
.

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11.10 Pluto Manager 11 Safety System Description

11.10-6 Pluto Manager - Install Pluto from PC

Machine Status Electrical supply disconnecting device in position I
(ON)
SPC Reference 3241503-0200

Using the Pluto Manager registered mute requires spe- (or sps-) and hps-files for
the program.
a) Open the Pluto project. See Procedure 11.10-3 Pluto Manager - Set Project.
b) To download the program, click Down (1).
c) Write abc80 in the Password field (2).
Note! Empty Plutos need password confirmation.
d) To begin executing the program, click Yes (3).
Note! The first time a Pluto receives a program, an alarm is activated. To reset
alarms, see Procedure 11.10-7 Pluto Manager - Reset Alarms.

abc80

2 3

1 Down
2 Password field
3 Yes
.

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11 Safety System Description 11.10 Pluto Manager

11.10-7 Pluto Manager - Reset Alarms

Machine Status Electrical supply disconnecting device in position I (ON)
SPC Reference 3241503-0200

The Pluto firmware has several status alarms (see the Pluto Hardware Manual
located in the help menu of the Pluto Manager). Many of these can be reset via the
Pluto Manager when a PC is connected to Pluto.
a) Start the Pluto Manager, and connect a communication cable between the PC
and Pluto.
b) From the Tools menu, select Reset all Plutos (1).
c) Click Yes (2) to confirm.
Note! All Plutos connected to the bus are restarted.

2
1 Reset all Plutos
2 Yes
.

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11.10 Pluto Manager 11 Safety System Description

11.10-8 Pluto Manager - Update Firmware

Machine Status Electrical supply disconnecting device in position I
(ON)
SPC Reference 3241503-0200

To check the firmware version (1), use the OnlineInfo function. See Section 11.10-4
Pluto Manager - Check Firmware and Software.
Note! To update the firmware, a full licence for Pluto Manager is required. If
registered as mute, the copy command does not work.
a) Turn off the power supply to Pluto.
b) Press the K button (2) while power is turned on, and release the K button (2).
Note! The Pluto appears to be dead in this monitor mode.
c) Start the Pluto Manager, and connect a communication cable between the
PC and the Pluto.
d) From the Tool menu, select Pluto System Software (3).

2
1 Firmware version
2 K button
3 Pluto System
Software
.

(Cont’d)

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11 Safety System Description 11.10 Pluto Manager

(Cont’d)

e) Select software for processor A (4).

f) Select software for processor B (5).
g) Wait for download of software for processor A (4) and processor B (5).
h) To update more Plutos, press the Yes button (6).

6
4 Processor A
5 Processor B
6 Yes button
.

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11.10 Pluto Manager 11 Safety System Description

11.10-9 Pluto Manager - Troubleshoot Safety System

Machine Status Electrical supply disconnecting device in position I
(ON)
SPC Reference 3241503-0200

The LED display (1) on the Pluto unit normally shows the node number for the Pluto
unit. In case of an error, the display shows an error code. For error codes not
described in the Status Messages table, explanations can be found in the Pluto
Hardware Manual located in the help menu of the Pluto Manager.

1
1 LED display

Status Messages

No: Description
-- Power up
11 Run mode (11 = SA30 station number)
Lo Program load mode state.
Flashing ‘Lo’, ready for self programming (program found in other unit).
HA Program execution stopped from PC or not started after program download. Can be started either
from PC or by power off-on.
UE Application specific user error, controlled by SR_PlutoDisplay in the PLC program.
.

(Cont’d)

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11 Safety System Description 11.10 Pluto Manager

(Cont’d)

User Faults

No: Fault and possible reason Reset action

Er10* Dynamic output short circuited to foreign voltage. Automatically reset
Er11* IQ_ for illuminated push button function. Missing diode. Automatically reset
Er12* Short circuit between two dynamic inputs. Automatically reset
Er13* Static output Q10..17 (Q20..27) short circuited to 0 V or safety Q2, Q3 Automatically reset after three
overloaded. minutes or “K” button
Er14* Static output Q10..17 (Q20..27) short circuited to 24 V. Automatically reset
Er15 Power supply below 18 V. Automatically reset after three
minutes or “K” button
Er16 Power supply above 30 V. Automatically reset after three
minutes or “K” button
Er17 Power supply below 15 V. Critically low. Automatically reset after three
minutes or “K” button
Er18 CAN-bus fault. (Short circuit, termination resistor, etc.) Automatically reset after three
minutes or “K” button
Er19 Other unit with same station number on CAN-bus.
Er20 PLC-program not loaded. Load of PLC program
Er21 PLC-program CRC-error. Reload with valid PLC-
program
Er22 Identifier problem. External identifier can not be read. Reboot
Er23 Unmatched ID. Identifier does not match declaration in program. Exchange of identifiers or
redeclaration of identifier in
program
Er24 Erroneous PLC-code. Invalid PLC-instructions. Reload with valid PLC-
program
Er25 For versions as B16 or B22. Non existing output used in program.
Er26 Baud rate conflict. Unit programmed for other baud rate than current Reprogramming or reboot
bus baud rate.
Note! Pluto must be rebooted after change of baudrate in the PLC
program.
Er27 Wrong checksum for unit member in common program. Reprogramming or reboot
Er28 PLC program does not match the Pluto family. Change to other type of Pluto
Families: [A/B/S/D 20, 16, 22], [B/S/D 45, 46], [Pluto ASi, B42 AS-i] or change the program.
Er29 Unsupported program version. The program contains instructions only Update of operating system
supported by later customer specific operating systems. **
Er30 Unsupported function block used. ** Update of operating system
Er31 IDFIX-PROG program mismatch. Load program to flash
memory with ”K” button.

*Combined with LED flashing for the affected I/O.

**Additional information can be retrieved via Pluto Manager.
.

(Cont’d)

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11.10 Pluto Manager 11 Safety System Description

(Cont’d)

I/O Faults

No: Fault and possible reason Reset action

Er40* Error safety output Q0..5. “K” button
Q2,Q3 connected together or to other negative voltage.
Q2,Q3 has to high capacitive load.
Er41* Error output Q2 or Q3. Overload or connected to foreign positive “K” button
voltage.
Er42* Error relay output. No answer from internal relay monitoring when “K” button
output is off.
Er43* Error relay output. (Self test of transistors) Reboot
Er44* Error relay output. Internal relay does not switch on. “K” button
Er45 Analogue functions not calibrated. System must be calibrated.
Can be reset with “K” button,
but analogue value will be 0.
Er46 Analogue input error. ** Automatically reset
Er47 Positive voltage on Q2 and/or Q3. Automatically reset

*Combined with LED flashing for the affected I/O.

**Additional information can be retrieved via Pluto Manager.

.
Note! Reboot can either be done from PC or by power off-on.
(Cont’d)

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11 Safety System Description 11.10 Pluto Manager

(Cont’d)

CPU Faults

No: Fault and possible reason Reset action

Er50* Input data difference between processor A and B. Reboot
Processor A and B read an input differently. The fault is often caused
by a bad sensor.
Corresponding input LED flashes.
Er51 Output data difference between processor A and B. Processor A and Reboot
B set a global variable differently. (Q0..Q3, GM0..11). ** Check PLC-program
Er52 No answer from any internal relay when output is off. Reboot
(Both relays stuck)
Er58 AS-i safety code table CRC error. Reboot
Teach AS-i safety codes
Er59 Calibration analogue functions CRC fault. Reboot
Er60 System error Twin self test monitoring. Reboot
Er61 System error Timer IRQ monitoring. Reboot
Er62 System error Internal serial communication. Reboot
Er63 Boot-flash CRC. Reboot
Er64 OS-flash CRC. Reboot,
Reload operating system (OS)
Er65 PLC-flash CRC. Reboot
Reload PLC program
Er66 5 volt under/over voltage monitoring. ** Reboot
Er67 CPU-test error. Reboot
Er68 Ram-test error. Reboot
Er69 Scan cycle time over run (PLC program to big). Reboot
Er70 System, sum of system, and stack monitoring. Reboot
Er71 Pluto used for IDFIX writing. Normal operation ceased. Reboot
Er72 System error. No communication AUX processor. Reboot
Er73 System error. Wrong program version/CRC error. Reload operating system (OS)
Er74 Remanent memory error. Reboot

*Combined with LED flashing for the affected I/O.

**Additional information can be retrieved via Pluto Manager.

.
Note! Reboot can either be made from PC or by power off-on.
(Cont’d)

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11.10 Pluto Manager 11 Safety System Description

(Cont’d)

User Error Codes

The PLUTO display shows the error by toggling between displaying UE and the
current error code.

You cannot reset the safety system before the problem causing the user error is
removed.

UE-code Fault and possible reason I/O Reset action

11 Constant reset. Check for short circuit to IQ11 Reset button on HMI panel
input.
30 Air pressure fault. Maximum allowed I30 Reset button on HMI panel
time to for air pressure removal
exceeded.
46 Missing feedback signal emergency I46 Reset button on HMI panel
stop circuit.
47 Missing feedback signal door circuit I47 Reset button on HMI panel
.

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11 Safety System Description 11.11 Safety Relay Expansion Module

11.11 Safety Relay Expansion Module

11.11-1 Safety Relay Expansion Module - Check
Machine Status Electrical supply disconnecting device in position I (ON)

a) Identify the safety relay expansion module to be tested.

b) Reset the safety system, and make sure that all LEDs on the safety relay
expansion module are lit.
c) Press an EMERGENCY STOP button.
d) Make sure that none of the LEDs on the safety relay expansion module are lit.
e) Reset the EMERGENCY STOP button and the safety system.

1
1 Expansion module
F09K2014

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11.11 Safety Relay Expansion Module 11 Safety System Description

11.11-2 Safety Relay Expansion Module - Change

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)

Note! The module can be changed without disconnecting any wires.

a) Pry the terminal blocks (1) away using a screwdriver.
b) Release the catch (2), and change the expansion module (3).
c) Perform a test on the replaced module. See Section 11.11-1 Safety Relay
Expansion Module - Check.

3 2
1 Terminal block
2 Catch
3 Expansion module
.

Note! Dispose of the electrical components and batteries in special waste

management systems. Follow local regulations.
.

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11 Safety System Description 11.12 Contactor

11.12 Contactor
11.12-1 Contactor - Check
Machine Status Electrical supply disconnecting device in position I (ON)

a) Identify the contactor(s) to be tested.

b) Reset the safety circuit.
c) Check that the contactor is engaged.
d) Press an EMERGENCY STOP button. Check that the contactor is not engaged.
e) In the electrical cabinet, check on the safety PLC that the corresponding LED
F09K2010:I46 (3) is lit.
f) Press the CONTACTOR button (4), and check that the corresponding LED
F09K2010:I46 (3) on the safety PLC is not lit.

Contactor Safety PLC input LED

F09Q1010 (1) LED F09K2010:I46 (3)
F09Q1020 (2) LED F09K2010:I46 (3)

4 1 2

1 Contactor F09Q1010
2 Contactor F09Q1020
3 LED F09K2010:I46
4 CONTACTOR button
.

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11.12 Contactor 11 Safety System Description

11.12-2 Contactor - Change

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)

a) Disconnect all connected wires, and replace the contactor.

b) Reconnect the wires.
c) Perform a test for the replaced contactor. See Section 11.12-1 Contactor -
Check.
Note! Dispose of the electrical components and batteries in special waste
management systems. Follow local regulations.
.

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11 Safety System Description 11.13 Servo Drive

11.13 Servo Drive

11.13.1 LED Description
The servo drive, Kinetix 5500, has two LEDs located on the front panel. The function
of each LED is described in detail on the following pages.

1
2

1 Module status LED

2 Network status LED
.

Module Status LED indicator

Condition Status
Steady Off No power applied to the drive.
Steady Green Drive is operational. No faults or
failures.
Flashing Green Standby (drive not configured).
Flashing Red Major recoverable fault. The drive
detected a recoverable fault, for
example, an incorrect or inconsistent
configuration.
Steady Red Major fault. The drive detected a non-
recoverable fault.
Flashing Green/Red Self-test. The drive performs self-test
during powerup.
.

(Cont’d)

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11.13 Servo Drive 11 Safety System Description

(Cont’d)

Network Status LED indicator

Condition Status
Steady Off No power applied to the drive, or IP
address is not configured.
Flashing Green Drive connection is not established, but
has obtained an IP address.
Steady Green Drive connection is established. Normal
operation.
Flashing Red Connection timeout. One or more of the
connections, for which this drive is the
target, has timed out.
Steady Red Duplicate IP address. IP address
specified is already in use.
Flashing Green/Red Self-test. The drive performs self-test
during powerup.
.

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11 Safety System Description 11.13 Servo Drive

11.13-1 Servo Drive - Check

Machine Status Electrical supply disconnecting device in position I (ON)

a) Identify the servo drives to be tested.

b) Make sure that the safety circuit is restored and that all safety expansion
modules are engaged.
c) Verify that the displays on the listed servo drives do not show a fault message.
d) Open the corresponding door to the servo drive to be tested. See the table.
e) Make sure that the following message is rolling on the servo drive display (3):
INHIBIT M05 – SAFE TORQUE OFF
f) Close the door, and reset the safety system. Make sure that the servo drive
does not show a fault message.

Servo drive Door

W30T1010 (1) Safeguard Straw Applicator
W30T1020 (2) Safeguard Straw Applicator

1 2
1 Servo drive
W30T1010
2 Servo drive
W30T1020
3 Servo drive display
.

11.13-2 Servo Drive - Change

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 3423202-0100

DANGERI
DANGER
Hazardous voltage.
Electric shock causes death or serious injury.
After the power is turned OFF, residual voltage remains in the capacitors inside the
servo drive. Do not touch the terminal immediately after turning the power OFF.
Discharge time is at least five minutes from the time power is turned OFF.
(Cont’d)

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(Cont’d)

Preparation
a) Make sure that all control and input power is removed from the servo system.
Wait five minutes for the DC bus to discharge.
b) Mark the position of the cables to disconnect.
c)
.
Disconnect the cables from the servo drive.
d) Remove the connector sets (1) that need to be removed.

1 Connector set
.

e) Remove the connector sets (2) if necessary.

2 Connector set
.

(Cont’d)

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(Cont’d)

f) Loosen the screws (3), and remove the servo drive.

3 Screw
.

g) Move the connector sets (4) to the new servo drive.

4 Connector set
.

h) Assemble in the reverse order.

Note! Make sure that the zero-stack tab and cutout match.

i) Set the IP address. See Procedure 11.13-3 Servo Drive - Set.

j) Perform a test for the replaced servo drive. See Procedure 11.13-1 Servo Drive -
.
Check.
Note! Dispose of the electrical components and batteries in special waste
management systems. Follow local regulations.
.

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11.13 Servo Drive 11 Safety System Description

11.13-3 Servo Drive - Set

Display and Buttons
Four NAVIGATION buttons (1) are located below the display (2). Use them to select
items from the soft menu.

2
PRECHARAGE
192.168.1.1
DC BUS: 0.3V
SETUP MENU
1

1 NAVIGATION button
2 Display

The function of the NAVIGATION buttons (1) are shown with an icon in the
display (2).

Icon Function
ESC Press to go back. Pressing enough times displays the HOME
screen.
Pressing either arrow moves the selection to the next (or
previous) item. When changing values, pressing the UP arrow
increments the highlighted value. Values rollover after reaching
the end of the list.
Press to select values to change, moving from right to left. Values
rollover when reaching the end of the list.
Press to select a menu item.
HOME Press to return to the Home screen.

LOG Press to display the list of active fault codes.

TEXT Press to display the fault text (exception code in troubleshooting
tables). See Chapter 11.13.2 Error Codes
INFO Press to display the fault details (the problem in troubleshooting
tables). See Chapter 11.13.2 Error Codes
HELP Press to display the fault help (possible solutions in
troubleshooting tables). See Chapter 11.13.2 Error Codes

(Cont’d)

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(Cont’d)

Set the IP-address

a) Press one of the NAVIGATION buttons (3).

PRECHARAGE
192.168.1.1
DC BUS: 0.3V
SETUP MENU

3
3 NAVIGATION button
.

b) Navigate to NETWORK, and press .

SETTINGS
NETWORK
DISPLAY
ESC
.

c) Navigate to STATIC IP, and press .

d) Navigate to IP ADDRESS, SUBNET MASK, or GATEWAY, and press .
e) Change the settings, and press . See Section 10.6 IP Addresses on page 634
for the IP address.
• If the change is invalid, the value does not change.
• If the change is valid, an asterisk is displayed next to the changed attribute.

STATIC IP
IP ADDRESS*
SUBNET MASK
ESC
.

(Cont’d)

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11.13 Servo Drive 11 Safety System Description

(Cont’d)

Default settings

Attribute Default setting Description

IP address 192.168.1.1 Indicates current IP address
Subnet mask 255.255.255.000 Indicates current subnet mask
Gateway 192.168.001.001 Indicates current gateway

11.13.2 Error Codes

CAUTION
Risk of personal injury.
Do not attempt to defeat or override the drive fault circuits. Determine the cause of a
fault, and correct it before attempting to operate the system. Failure to correct the
fault could result in personal injury and damage to the equipment as a result of
uncontrolled machine operation.
When a fault is detected, the four-character status indicator scrolls the display
message. This is repeated until the fault code is cleared.

Error Code Summary

Error codes triggered by conditions that fall outside factory set limits are identified by
FL at the end of the display message.

Error codes triggered by conditions that fall outside user set limits are identified by
UL at the end of the display message.

Error Code Type Description

FLT Sxx Standard runtime anomalies.
FLT Mxx
INIT FLT Sxx Exceptions that prevent normal operation and occur
INIT FLT Mxx during the initialization process.
NODE FLTxx Exceptions that prevent normal operation of the drive.
NODE ALARM xx Exceptions that prevent normal operation of the drive,
but do not result in any action other than reporting the
alarm to the controller.
INHIBIT Mxx Exceptions that prevent normal operation and indicate
whenever the drive is active.

FLT Sxx Error Codes

Exception Code
on Display Exception Text
Problem Possible Solutions
FLT S03 – MTR Motor Overspeed Motor speed has Check control loop tuning.
OVERSPEED FL Factory Limit exceeded 125% of its
Fault. maximum speed.
FLT S05 – MTR Motor Calculations based on • Operate motor within continuous torque rating.
OVERTEMP FL Overtemperature the motor thermistor • Reduce motor ambient temperature.
Factory Limit indicate that the factory
Fault. temperature limit of the • Add motor cooling.
motor has been Available only on Kinetix VP (Bulletin VPL)
exceeded. motors. Not supported on induction motors.

(Cont’d)

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(Cont’d)

FLT Sxx Error Codes

Exception Code
on Display Exception Text Problem Possible Solutions
FLT S07 – MTR Motor Thermal. The motor thermal Modify the command profile to reduce speed or
OVERLOAD FL Overload Factory model has exceeded its increase time.
Limit Fault. factory set thermal
capacity limit of 110%.
FLT S08 – MTR Motor Thermal. The motor thermal • Modify the command profile to reduce speed or
OVERLOAD UL Overload User model has exceeded increase time.
Limit Fault. the thermal capacity
• Reduce drive ambient temperature.
limit given by Motor
Thermal Overload User • Ensure that the airflow through drive is not
Limit. obstructed.
FLT S10 – INV Inverter Inverter current has • Check motor power cable for shorts.
OVERCURRENT Overcurrent exceeded the • Ensure that the motor windings are not shorted.
Fault. instantaneous current
limit (determined by • Ensure the motor power wire gauge.
hardware). • Operate within the continuous power rating.
• Reduce acceleration times.
FLT S11 – INV Inverter The measured inverter • Increase P041, A442, A444, A446 (Accel Time
OVERTEMP FL Overtempera- temperature has x), or reduce load so drive output current does
ture. exceeded the factory not exceed the current set by parameter A484,
Factory Limit set temperature limit. A485 (Current Limit x) for too long.
Fault. • Check for overhauling load.
FLT S13 – INV Inverter Thermal The thermal model for Modify the command profile to reduce speed or
OVERLOAD FL Overload. the power transistors increase time.
Factory Limit indicates that the
Fault. temperature has
exceeded the factory
set thermal capacity
rating of 110%.
FLT S14 – INV Inverter Thermal The thermal model for Modify the command profile to reduce speed or
OVERLOAD UL Overload. the power transistors increase time.
User Limit Fault. indicates that the
temperature has
exceeded the limit
given by Inverter
Thermal Overload User
Limit.
FLT S15 – CONV Converter The measured • Reduce acceleration times of all drives sharing
OVERCURRENT Overcurrent converter current has the DC bus.
Fault. exceeded the factory
• Reduce number of shared DC follower drives.
set current limit.
• Reduce number of capacitor modules.
FLT S16 – Ground Current. The sensing circuitry in • Check motor power wiring; check power cable
GROUND Factory Limit the power stage has for shorts.
CURRENT Fault. detected excessive
• Replace motor if the fault persists.
ground current.

(Cont’d)

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(Cont’d)

FLT Sxx Error Codes

Exception Code
on Display Exception Text Problem Possible Solutions
FLT S18 – CONV Converter The measured • Reduce acceleration times of all drives sharing
OVERTEMP FL OverTemp. converter temperature the DC bus.
Factory Limit has exceeded the
• Reduce number of shared DC follower drives.
Fault. factory set temperature
limit. • Modify the command profile to reduce speed or
increase time.
• Reduce drive ambient temperature.
• Verify airflow through drive is not obstructed.
FLT S20 – CONV Converter The converter thermal • Reduce acceleration times of all drives sharing
OVERLOAD FL Thermal model indicates that the the DC bus.
Overload. temperature has
• Reduce number of shared DC follower drives.
Factory Limit exceeded the factory
Fault. set capacity rating of • Reduce duty-cycle of commanded motion.
110%.
FLT S21 – CONV Converter The converter thermal • Reduce acceleration times of all drives sharing
OVERLOAD UL Thermal model indicates that the the DC bus.
Overload. temperature has
• Reduce number of shared DC follower drives.
User Limit Fault. exceeded the limit
given by Converter • Reduce duty-cycle of commanded motion.
Thermal Overload User • Increase the Converter Thermal Overload UL
Limit.
attribute value.
FLT S23 – AC AC Single Phase A single AC input phase Check AC input voltage on all phases.
PHASE LOSS Loss Fault. was lost while the drive
was enabled.
FLT S25 – Pre-charge The pre-charge circuit • Check AC input voltage on all phases.
PRECHARGE Failure Fault. monitoring algorithm • Check input power wiring.
FAILURE detected that the DC
bus did not reach a • Replace drive if fault persists.
factory-set voltage level
after charging for a
period of time.
FLT S29 – BUS Bus Regulator The shunt thermal • Modify the duty cycle of the application.
OVERLOAD FL Thermal model has exceeded its • Add external shunt for additional capacity.
Overload Factory factory set thermal
Limit Fault. capacity limit. • Add capacitor module if needed.
FLT S30 – BUS Bus Regulator The shunt thermal • Modify the duty cycle of the application.
OVERLOAD UL Thermal model has exceeded • Add external shunt for additional capacity.
Overload. the thermal capacity
User Limit Fault. limit given by Bus • Increase the Bus Regulator Thermal Overload
Regulator Thermal UL attribute value.
Overload User Limit.
FLT S31 – BUS Bus Regulator The shunt driver IC has • Check for shorts in the shunt connector.
REGULATOR Failure. detected that the shunt • Unplug the shunt connector, and measure the
resistor is shorted.
resistance of the shunt.
• Replace drive if shunt resistor is shorted.
FLT S33 – BUS Bus DC Bus voltage level is • Verify voltage level of the incoming AC.
UNDERVOLT FL Undervoltage. below the factory set • Monitor AC power source for glitches or line
Factory Limit limit as determined by
droop.
Fault. the configured input
voltage. • Install UPS on AC input.

(Cont’d)

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(Cont’d)

FLT Sxx Error Codes

Exception Code
on Display Exception Text Problem Possible Solutions
FLT S34 – BUS Bus DC Bus voltage level is • Verify voltage level of the incoming AC.
UNDERVOLT UL Undervoltage. below the user set limit • Monitor AC power source for glitches or line
User Limit Fault. as given by Bus
droop.
Undervoltage User
Limit. • Install UPS on AC input.
• Increase Bus Undervoltage UL attribute value.
FLT S35 – BUS Bus Overvoltage. DC Bus voltage level is • Change the deceleration or motion profile of all
OVERVOLT FL Factory Limit above the factory set drives connected to the DC bus.
Fault. limit as determined by
• Unplug the shunt connector and measure the
the configured input
resistance of the shunt.
voltage.
• Replace drive if shunt resistor is open.
FLT S39 – BUS Bus Power Measured converter • Check bus power sharing configuration
POWER LEAK Leakage Fault. power exceeded attribute.
estimated inverter
• Check AC input and DC bus sharing
output power by more
than a factory limit. connections.

FLT S45 – FDBK Motor Feedback The number of • Check the motor feedback cable, and the
COMM FL Data Loss. consecutive missed or connector.
Factory Limit corrupted serial data
• Ensure that the motor power cable, and the
Fault. packets from the
feedback wire shields are secured correctly.
intelligent feedback
device has exceeded • Ensure that the motor frame is grounded
the factory set limit. correctly.
FLT S47 – FDBK Feedback Device The feedback device • Check motor feedback cable and connector.
DEVICE Failure. has detected an • Cycle control power.
FAILURE internal error.
• Replace motor if fault continues.
• Check feedback shield connection.
• Reduce shock and vibration to motor.
FLT S54 – POSN Excessive The position error of the • Check position loop tuning.
ERROR Position Error position control loop • Increase the feedforward gain.
Fault. has exceeded the value
given by Position Error • Verify sizing of the drive and motor.
Tolerance for a time • Check motor power wiring.
period given by Position
Error Tolerance Time. • Increase Position Error Tolerance and/or
Position Error Tolerance Time attribute values.
FLT S55 – VEL Excessive The velocity error of the • Check velocity loop tuning.
ERROR Velocity Error velocity control loop • Reduce acceleration.
Fault. has exceeded the value
given by Velocity Error • Verify sizing of the drive and motor.
Tolerance for a time • Check motor power wiring.
period given by Velocity
Error Tolerance Time. • Increase Velocity Error Tolerance and/or
Velocity Error Tolerance Time attribute values.

(Cont’d)

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(Cont’d)

FLT Sxx Error Codes

Exception Code
on Display Exception Text Problem Possible Solutions
FLT S56 – Overtorque Limit Motor torque has risen • Verify Torque Trim value.
OVERTORQUE Fault. above user defined • Verify motion profile.
LIMIT maximum torque level
given by Overtorque • Verify sizing of the drive and motor.
Limit for the time period • Increase Overtorque Limit and/or Overtorque
given by Overtorque Limit Time attribute values.
Limit Time.
FLT S57 – Undertorque Motor torque has • Verify motion profile.
UNDERTOR- Limit Fault. dropped below user • Verify sizing of the drive and motor.
QUE LIMIT defined minimum
torque level given by • Decrease Undertorque Limit and/or
Undertorque Limit for Undertorque Limit Time attribute values.
the time period given by
Undertorque Limit
Time.

FLT Mxx Error Codes

Exception Code Exception Text Problem Possible Solutions
on Display
FLT M02 – Motor Voltage The configured voltage Set the drive voltage to a lower value or replace
MOTOR Mismatch Fault. of the drive is greater motor with voltage rating that matches the drive.
VOLTAGE than the motor rated
voltage, for example, a
400V-class drive with a
200V-class motor.
FLT M14 – Excessive The calibration for the • Cycle control power.
CURR FDBK Current phase current feedback • Return drive for repair if fault continues.
OFFSET Feedback Offset sensors required
Fault. excessive offset to
compensate.
FLT M25 – DC Common Bus AC power was detected • Check the drive power configuration from
COMMON BUS Fault.. by the drive while controller.
configured for shared • Check wiring.
DC operation.
FLT M26 – Runtime Error. The drive firmware • Cycle control power.
RUNTIME encountered an • Reset the drive.
ERROR unrecoverable runtime
error. • Return drive for repair if fault continues.

INIT FLT Error Codes

Exception Code Exception Text Problem Possible Solutions
on Display
INIT FLT S03 – Nonvolatile Data in the nonvolatile • Cycle control power.
NVMEM memory memory has a • Reset the drive.
CHKSUM checksum error. checksum error.
• Return drive for repair if fault continues.
INIT FLT M01 – Smart Encoder The data stored in the • Cycle control power.
ENCODER Data Corruption. encoder has a • Return motor for repair if fault continues.
DATA checksum error.
INIT FLT M02 – Motor Data A motor data attribute • Cycle control power
MTR DATA Range Error stored in the encoder is • Return motor for repair if fault continues
RANGE out of range.

(Cont’d)

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(Cont’d)

INIT FLT Error Codes

Exception Code Exception Text Problem Possible Solutions
on Display
INIT FLT M03 – Motor Feedback Communication with • Cycle control power.
MTR ENC Communication the encoder could not • Check motor feedback connector.
STARTUP Startup. be established.
• Check motor power and feedback shield
terminations on the drive.
• Return motor for repair if fault continues.
INIT FLT M20 – Unknown The product code of the • Cycle control power.
UNKNOWN Module. power board is invalid. • Reset the drive.
MODULE
• Return drive for repair if fault continues.
INIT FLT M21 – Factory Factory configuration • Cycle control power.
FACTORY Configuration. data is missing or • Reset the drive.
CONFIG invalid.
• Return drive for repair if fault continues.

INHIBIT Error Codes

Exception Code Exception Text Problem Possible Solutions
on Display
INHIBIT S02 – Motor Not The motor has not been Verify motor configuration in the Logix Designer
MOTOR NOT Configured. properly configured for application.
CONFIGURED use.
INHIBIT S03 – Feedback Not The feedback has not Verify feedback configuration in the Logix
FEEDBACK Configured. been properly Designer application.
NOT configured for use.
CONFIGURED
INHIBIT M05 – Start Inhibit -Safe The safety function has • Check safety input wiring.
SAFE TORQUE Torque Off. disabled the power • Check state of safety devices.
OFF structure.

NODE FLT Error Codes

Exception Code Exception Text Problem Possible Solutions
on Display
NODE FLT 01 – Control Several consecutive • Remove unnecessary network devices from the
LATE CTRL Connection updates from the motion network.
UPDATE Update Fault. controller have been
• Change network topology so that fewer devices
lost.
share common paths.
• Use high performance network equipment.
• Use shielded cables.
• Separate signal wiring from power wiring.
NODE FLT 02 – Processor The processor on the • Cycle control power.
PROC Watchdog Fault. power board or control • Update the drive firmware.
WATCHDOG board failed to update
in a certain amount of • Return drive for repair if fault continues.
time.
NODE FLT 03 – Hardware Fault Communication with • Cycle control power.
HARDWARE 00 -PwrIF. the power board could • Update the drive firmware.
not be established.
• Return drive for repair if fault continues.

(Cont’d)

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(Cont’d)

NODE FLT Error Codes

Exception Code Exception Text Problem Possible Solutions
on Display
NODE FLT 03 – Hardware Fault - Communication with • Cycle control power.
HARDWARE 01 DSL. the encoder could not • Return motor for repair if fault continues.
be established.
NODE FLT 05 – Clock Skew The controller time and • Cycle control power.
CLOCK SKEW Fault. the drive's system time • Check controller and Ethernet switch operation.
FLT are not the same.
NODE FLT 06 – Lost Controller Communication with • Check Ethernet connection.
LOST CTRL Connection the controller has been • Check controller and Ethernet switch operation.
CONN Fault. lost.
NODE FLT 07 – Clock Sync Fault. Drive's local clock has • Check Ethernet connection.
CLOCK SYNC lost synchronization • Check controller and Ethernet switch operation.
with controller's clock
and was not able to
resynchronize within
allotted time.
NODE FLT 09 – Duplicate IP Several consecutive Select an IP address not already in use on the
DUPLICATE IP Address Fault. updates from the network.
ADDRESS controller have been
lost.

NODE ALARM Error Codes

Exception Code Exception Text Problem Possible Solutions
on Display
NODE ALARM Control Updates from the • Remove unnecessary network devices from the
01 – LATE CTRL Connection controller have been motion network.
UPDATE Update Alarm. late. • Change network topology so that fewer devices
share common paths.
• Use high performance network equipment.
• Use shielded cables.
• Separate signal wiring from power wiring.
NODE ALARM Clock Jitter The sync variance has • Check the Ethernet connection.
03 – CLOCK Alarm. exceeded the sync • Check controller and Ethernet switch operation.
JITTER threshold while the
device is running in
sync mode.
NODE ALARM Clock Sync Drive's local clock has • Check the Ethernet connection.
05 – CLOCK Alarm. lost synchronization • Check controller and Ethernet switch operation.
SYNC ALARM with controller's clock
for a short time during
synchronous operation.

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11 Safety System Description 11.14 Frequency Converter

11.14 Frequency Converter

11.14-1 Frequency Converter - Change
Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
SPC Reference 3241506-0200

DANGERI
DANGER
Hazardous voltage.
Electric shock causes death or serious injury.
After the power is turned off, residual voltage remains in the capacitors inside the
frequency converter. Do not touch the terminal immediately after turning the power
OFF. Discharge time is at least three minutes from the time power is turned off.
a) Disconnect the cables.
b) Remove the frequency converter (1).

The Ethernet address (MAC) is located behind the front cover of the frequency
converter (1).

1 Frequency converter
.

c) Make a note of the new frequency converters Ethernet address (MAC).

(Cont’d)

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(Cont’d)

d) If the frequency converter is equipped with an encoder card, move the encoder
card to the new frequency converter. See Section Encoder Card.
e) Assemble the new frequency converter.
f) Reconnect the cables.
Note! Make sure that the shield for the cables is correctly connected.
g) Set the IP address.
For Frequency Converter 525, see Procedure 1.1.1.1-1 PLC and Ethernet
Modules - Set IP Address.

For Frequency Converter 527, see Procedure 11.14-6 Frequency Converter PF

527 - Set IP-address.
h) Set the Electrical supply disconnecting device in position 0 (OFF)
i) Set the Electrical supply disconnecting device in position I (ON)
j) Check the replaced frequency converter. See Procedure 11.14-2 Frequency
Converter PF 525 - Check, or Procedure 11.14-5 Frequency Converter PF 527
.
- Check.
Note! Dispose of the electrical components and batteries in special waste
management systems. Follow local regulations.
.

Encoder Card
a) Press and hold the catch on both sides of the frame cover, then pull out and
swing upwards to remove.

(Cont’d)

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b) To unlock it from the power module, press down and slide out the top cover of
the control module.

c) Hold the sides and top of the control module firmly, then pull out to separate it
from the power module.

(Cont’d)

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(Cont’d)

d) CAUTION
Risk of damage the encoder card.
Do not remove the encoder card from the bottom, as this action can damage
the card and the locking mechanism on the control module.
Hold the top of the encoder card firmly, and pull out to remove.

e) Put the encoder card on the back of the control module. Ensure that the tabs on
the encoder card are aligned with the slots on the control module.

f) Press down firmly on the encoder card until it snaps together with the control
module.

(Cont’d)

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g) Align the connectors on the power module and the control module, then push
the control module firmly onto the power module.

h) Insert the catch at the top of the frame cover into the power module. Swing the
frame cover to snap the side catches onto the power module.

Note! Dispose of the electrical components and batteries in special waste

management systems. Follow local regulations.
.

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11.14 Frequency Converter 11 Safety System Description

11.14-2 Frequency Converter PF 525 - Check

Machine Status Electrical supply disconnecting device in position I
(ON)
SPC Reference 3241506-0200

DANGERI
DANGER
Hazardous voltage.
Electric shock will cause death or serious injury.
After the power is turned off, residual voltage remains in the capacitors inside the
frequency converter. Do not touch the terminal immediately after turning the power
OFF. Discharge time is at least three minutes from the time power is turned off.

1 2 3

1 Frequency converter
W10T1010
2 Frequency converter
W90T1010
3 Frequency converter
W40T1030

(Cont’d)

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a) Identify the frequency converter(s) to be tested.

b) Change so that parameter b006 is displayed on all the frequency converter(s) to
be tested. For navigating parameters, see Section 11.14-3 Frequency Converter
PF 525 - Parameters.
c) Check that the first digit on the display (4) is 0 on all drives.

6
FWD

ENET LINK
EtherNet/IP

4 Display
.

d) Open the corresponding door/hatch to the frequency drive to be tested.

Frequency drive Door

W10T1010 (1) Safeguard Straw Applicator
W90T1010 (2) Safeguard Straw Applicator
W40T1030 (3) Safeguard Straw Applicator

e)
.
Check that the first digit on the display (4) is 1.

(Cont’d)

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(Cont’d)

f) Turn the electrical supply disconnecting device to position OFF.

g) Disconnect the wire at terminal S1 (5) on the frequency drive.
h) Turn the electrical supply disconnecting device to position ON.
i) Reset the safety system.
j) Check that the alarm F111 is displayed on the drive.
k) Turn the electrical supply disconnecting device to position OFF.
l) Reconnect the wire at terminal S1 (5) on the frequency drive.
m) Disconnect the wire at terminal S2 (6) on the frequency drive.
n) Turn the electrical supply disconnecting device to position ON.
o) Reset the safety system.
p) Check that the alarm F111 is displayed on the drive.
q) Turn the electrical supply disconnecting device to position OFF.
r) Reconnect the wire at terminal S2 (6) on the frequency drive.
s) Turn the electrical supply disconnecting device to position ON.
t) Reset the safety system, and check that no alarm is displayed on the frequency
drive.
S+
S1
S2

7 8
5 Terminal S1
6 Terminal S2
.

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11.14-3 Frequency Converter PF 525 - Parameters

Machine Status Electrical supply disconnecting device in position I (ON)
SPC Reference 3241506-0200

9
8
FWD

ENET LINK
EtherNet/IP

7
6
2
5

4 3
1 Display 4 DOWN / DECREASE 7 UP / INCREASE
2 Error Status LED FREQUENCY button FREQUENCY button
3 ENTER button 5 SELECT button 8 ENET indicator
6 ESCAPE button 9 LINK indicator

Note! When the machine is stepped up, the PLC automatically sets all parameters.

Navigate Parameters

Step / Action Button Display

1. Manoeuvre to the top level by pressing the ESCAPE button until the
top level is reached.

2. Press the SELECT button to go to the group menu. The group menu
letter flashes (for example, b). FWD

3. Press the UP button or the DOWN button to scroll through the group
menu. The group menu consists of b, P, t, C, L, d, A, f, N, M, and Gx.
4. Press the SELECT button or the ENTER button to select a group. The
right digit of the last viewed parameter in that group flashes. FWD

5. Press the UP button or the DOWN button to scroll through the

parameters in the group.

(Cont’d)

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(Cont’d)

Step / Action Button Display

6. Press the ENTER button to show the value for a parameter. Press the FWD
ESCAPE button to go back to the parameter list.

7. Press the SELECT button or the ENTER button to go to program state.

Use the SELECT button to switch between the digits, and change the FWD

value of each digit by pressing the UP button or the DOWN button. PROGRAM

8. Press the ENTER button to save the change, and exit the program FWD
state. Press the ESCAPE button to cancel the change, and exit the
program state.

9. Press ESCAPE to return to the parameter list. Continue to press

ESCAPE to back out of the programming menu. FWD

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11 Safety System Description 11.14 Frequency Converter

11.14-4 Frequency Converter PF 525 - Error Codes

SPC Reference 3241506-0200

If there is a fault connected to the frequency converter, it turns off. An error code
shows on the display (1).

FWD

ENET LINK
EtherNet/IP

1 Display

No. Fault Description Action

F000 No Fault No fault present. -
F002 Auxiliary Input External trip (Auxiliary) • Check remote wiring.
input. • Verify communications programming for intentional
fault.
F003 Power Loss Single phase operation • Monitor the incoming AC line for low voltage or line
detected with excessive power interruption.
load.
• Check input fuses.
• Reduce load.
F004 UnderVoltage DC bus voltage fell Monitor the incoming AC line for low voltage or line
below the minimum power interruption.
value.
F005 OverVoltage DC bus voltage Monitor the AC line for high line voltage or transient
exceeded maximum conditions. Bus overvoltage can also be caused by motor
value. regeneration. Extend the decel time, or install dynamic
brake option.
F006 Motor Stalled Drive is unable to • Increase P041, A442, A444, A446 (Accel Time x), or
accelerate or reduce load so drive output current does not exceed
decelerate motor. the current set by parameter A484, A485 (Current Limit
x) for too long.
• Check for overhauling load.
F007 Motor Overload Internal electronic • An excessive motor load exists. Reduce load so drive
overload trip. output current does not exceed the current set by
parameter P033 (Motor OL Current).
• Verify A530 (Boost Select) setting.

(Cont’d)

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11.14 Frequency Converter 11 Safety System Description

(Cont’d)

No. Fault Description Action

F008 Heatsink Heatsink/Power Module • Check for blocked or dirty heatsink fins. Ensure that
OvrTmp temperature exceeds a ambient temperature has not exceeded the rated
predefined value. ambient temperature.
• Check fan.
F009 CC OvrTmp Control module • Check product ambient temperature.
temperature exceeds a • Check for airflow obstruction.
predefined value.
• Check for dirt or debris.
• Check fan.
F012 HW OverCurrent The drive output current Check programming. Check for excess load, improper
has exceeded the A530 (Boost Select) setting, DC brake volts set too high,
hardware current limit. or other causes of excess current.
F013 Ground Fault A current path to Check the motor and external wiring to the drive output
ground has been terminals for a grounded condition.
detected at one or more
of the drive output
terminals.
F015 Load Loss The output torque • Verify connections between motor and load.
current is below the • Verify level and time requirements.
value programmed in
A490 (Load Loss Level)
for a time period greater
than the time
programmed in A491
(Load Loss Time).
F021 Output Ph Loss Output Phase Loss (if • Verify motor wiring.
enabled). Configure • Verify motor.
with A557 (Out Phas
Loss En).
F029 Analog In Loss An analog input is • Check for broken or loose connections at inputs.
configured to fault on • Check parameters.
signal loss. A signal
loss has occurred.
Configure with t094
(Anlg In V Loss) or t097
(Anlg In mA Loss).
F033 Auto Rstrt Tries Drive unsuccessfully Correct the cause of the fault, and manually clear.
attempted to reset a
fault and resume
running for the
programmed number of
A541 (Auto Rstrt Tries).
F038 Phase U to Gnd A phase to ground fault • Check the wiring between the drive and motor.
F039 Phase V to Gnd has been detected • Check motor for grounded phase.
between the drive and
F040 Phase W to Gnd motor in this phase. • Replace drive if fault cannot be cleared.
F041 Phase UV Short Excessive current has • Check the motor and drive output terminal wiring for a
F042 Phase UW Short been detected between shorted condition.
these two output
F043 Phase VW Short • Replace drive if fault cannot be cleared.
terminals.
F048 Params The drive was • Clear the fault or cycle power to the drive.
Defaulted commanded to write • Program the drive parameters as needed.
default values to
EEPROM.

(Cont’d)

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11 Safety System Description 11.14 Frequency Converter

(Cont’d)

No. Fault Description Action

F059 Safety Open Both of the safety Check safety input signals. If not using safety, verify and
inputs (Safety 1, Safety tighten jumper for I/O terminals S1, S2, and S+.
2) are not enabled.
Configure with t105
(Safety Open En).
F063 SW OverCurrent Programmed A486, • Verify connections between motor and load.
A488 (Shear Pinx • Verify level and time requirements.
Level) has been
exceeded for a time
period greater than the
time programmed in
A487, A489 (Shear Pin
x Time).
F064 Drive Overload Drive overload rating Reduce load or extend Accel Time.
has been exceeded.
F070 Power Unit Failure has been • Check maximum ambient temperature has not been
detected in the drive exceeded.
power section.
• Cycle power.
• Replace drive if fault cannot be cleared.
F071 DSI Net Loss Control over the • Cycle power.
Modbus or DSI • Check communications cabling.
communication link has
been interrupted. • Check Modbus or DSI setting.
• Check Modbus or DSI status.
F072 Opt Net Loss Control over the • Cycle power.
network option card’s • Check communications cabling.
remote network has
been interrupted. • Check network adapter setting.
• Check external network status.
F073 EN Net Loss Control through the • Cycle power.
embedded Ethernet/IP • Check communications cabling.
adapter has been
interrupted. • Check Ethernet/IP setting.
• Check external network status.
F080 Autotune Failure The autotune function Restart procedure.
either failed or was
cancelled by the user.
F081 DSI Comm Loss Communications • Cycle power.
between the drive and • Check communications cabling.
the Modbus or DSI
master device have • Check Modbus or DSI setting.
been interrupted. • Check Modbus or DSI status.
• Modify using C125 (Comm Loss Action).
• Connecting I/O terminals C1 and C2 to ground may
improve noise immunity.
• Replace wiring, Modbus master device, or control
module.

(Cont’d)

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11.14 Frequency Converter 11 Safety System Description

(Cont’d)

No. Fault Description Action

F082 Opt Comm Loss Communications • Cycle power.
between the drive and • Reinstall option card in drive.
the network option card
have been interrupted. • Modify using C125 (Comm Loss Action).
• Replace wiring, port expander, option card, or control
module.
F083 EN Comm Loss Internal • Cycle power.
communications • Check Ethernet/IP setting.
between the drive and
the embedded • Check drive’s Ethernet settings and diagnostic
EtherNet/IP adapter parameters.
have been interrupted. • Modify using C125 (Comm Loss Action).

• Replace wiring, Ethernet switch, or control module.

F091 Encoder Loss Requires differential • Check Wiring.
encoder. • If P047, P049, P051 (Speed Referencex) = 16
One of the 2 encoder “Positioning” and A535 (Motor Fdbk Type) = 5 “Quad
channel signals is Check”, swap the Encoder channel inputs, or swap any
missing. two motor leads.
• Replace encoder.
F094 Function Loss “Freeze-Fire” (Function Close input to the terminal and cycle power.
Loss) input is inactive;
input to the
programmed terminal is
open.
F100 Parameter Drive parameter non- Set P053 (Reset To Defalts) to 2 “Factory Rset”.
Chksum volatile storage is
corrupted.
F101 External Storage External non-volatile Set P053 (Reset To Defalts) to 2 “Factory Rset”.
storage has failed.
F105 C Connect Err Control module was Clear fault and verify all parameter settings. Do not
disconnected while remove or install the control module while power is
drive was powered. applied.
F106 Incompat C-P The PowerFlex 525 • Change to a different power module.
control module does • Change to a PowerFlex 523 control module.
not support power
modules with 0.25 HP
power rating.
F107 Replaced C-P The control module • Change to a different power module.
could not recognize the • Replace control module if changing power module
power module.
does not work.
Hardware failure.
F109 Mismatch C-P The control module was Set P053 (Reset To Defalts) to 3 “Power Reset”.
mounted to a different
drive type power
module.
F110 Keypad Keypad membrane • Cycle power.
Membrane failure or disconnected. • Replace control module if fault cannot be cleared.
F111 Safety Hardware Safety input enable • Check safety input signals. If not using safety, verify
hardware malfunction. and tighten jumper for I/O terminals S1, S2, and S+.
One of the safety inputs • Replace control module if fault cannot be cleared.
is not enabled.

(Cont’d)

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11 Safety System Description 11.14 Frequency Converter

(Cont’d)

No. Fault Description Action

F114 uC Failure Microprocessor failure. • Cycle power.
• Replace control module if fault cannot be cleared.
F122 I/O Board Fail Failure has been • Cycle power.
detected in the drive • Replace drive or control module if fault cannot be
control and I/O section.
cleared.
F125 Flash Update The firmware in the Perform a firmware flash update operation to attempt to
Req drive is corrupt, load a valid set of firmware.
mismatched, or
incompatible with the
hardware.
F126 Non Recoverabl A non-recoverable • Clear fault or cycle power to the drive.
Err firmware or hardware • Replace drive or control module if fault cannot be
error was detected. The
cleared.
drive was automatically
stopped and reset.
F127 DSI Flash Updat A critical problem with Perform a firmware flash update operation using DSI
Req the firmware was communications to attempt to load a valid set of
detected, and the drive firmware.
is running using backup
firmware that only
supports DSI
communications.

11.14-5 Frequency Converter PF 527 - Check

Machine Status Electrical supply disconnecting device in position I (ON)
SPC Reference 3241506-0200

DANGERI
DANGER
Hazardous voltage.
Electric shock will cause death or serious injury.
After the power is turned off, residual voltage remains in the capacitors inside the
frequency converter. Do not touch the terminal immediately after turning the power
OFF. Discharge time is at least three minutes from the time power is turned off.
Note! Before starting the test, the parameters must be transferred to the frequency
converter drive. This is made automatically when the machine is stepped up.
(Cont’d)

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11.14 Frequency Converter 11 Safety System Description

(Cont’d)

1 2

1 Frequency converter
W40T1010
2 Frequency converter
W40T1020

(Cont’d)

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11 Safety System Description 11.14 Frequency Converter

(Cont’d)

a) Identify the frequency converter(s) to be tested.

b) Check that the safety circuit is restored and all safety expansion modules are
engaged.
c) Verify that the display (3) on the frequency drives does not display any error
message.
d) Open the corresponding door/hatch to the frequency drive to be tested.

Frequency drive Door

W40T1010 (1) Safeguard Straw Applicator
W40T1020 (2) Safeguard Straw Applicator

e) Check that the message INHIBIT M05 – SAFE TORQUE OFF is rolling on the
display (3).
f) Close the door.
g) Reset the safety system.
h) Check that the display (3) on the frequency drives does not display any error
message.

3
FWD

ENET LINK
EtherNet/IP

3 Display
.

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11.14 Frequency Converter 11 Safety System Description

11.14-6 Frequency Converter PF 527 - Set IP-address

From the axis state screen, press or to access the following

information menu:

Screen Option Description Example Display 1

Version Info Provides information on HW Ver 1.1
the hardware and FW Ver 1.6.1885
software versions.
Device Info Provides information on PowerFlex 527
the drive type, network Static IP 192.168.1.193
configuration, and IP
address.
Settings Allows configuration of See Section Network
network settings, Configuration for
changing the display instructions on how to
language, and resetting configure the IP address.
the drive.

Network Configuration
Through the settings option, you can configure the drive IP address.
Select STATIC IP and set IP address, subnet mask and gateway address.
Note! To change an IP address, you must set the new value and then power cycle
the drive.

Settings Sub Menu Attributes Default Description

Menu Selections
Selections
Network Static IP IP address 192.168.1.193 Indicates
or current IP
192.168.1.194 address.
Subnet mask 255.255.255.0 Indicates
current subnet
mask.
Gateway 192.168.1.1 Indicates
current
gateway.

Configuring Network Settings

Step / Action Button Display

1
On the Device/Axis state screen, press UP to go to the Settings menu.
2
Press ENTER to display the Network Settings screen.

3
Press UP or DOWN and select Static IP.

(Cont’d)

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11 Safety System Description 11.14 Frequency Converter

(Cont’d)

Step / Action Button Display

4
Press ENTER.

5
Configure the IP address, subnet mask, and gateway address for your
drive manually.
Press UP or DOWN to scroll to the IP address.
6
Press ENTER to display the first octet of the IP address.

7
Press UP or DOWN to scroll through the four octets of the IP address.

8
Press SELECT to edit an octet. The rightmost digit of the octet will flash.

9
Press UP or DOWN to change the digit.
10
Press SELECT to edit the digits on the left.

11
Press ENTER to save a change and exit the edit mode.
or
press ESCAPE to cancel a change and exit the edit mode.
12
Repeat step 7 to step 11 to edit the values of the other octets.
13
After you have finished configuring the IP address, press ESCAPE to go
back to the Static IP menu.

14
Repeat step 5 to step 12 to configure the subnet mask and the gateway
address.
15
Power cycle the drive to store the new IP settings.

®
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11.14 Frequency Converter 11 Safety System Description

11.14-7 Frequency Converter PF 527 - Drive Status Indicators

The fault status indicator is located between the LCD display and keypad. There are
also four status indicators located at the bottom right of the drive that can be seen
through the front cover of the control module.

2
3
4
5
1 Fault status
2 Module status
3 Network status
4 Link A status (Ethernet
port 1)
5 Link B status (Ethernet
port 2)

Fault Status Indicator

Condition Safety Supervisor CIP Motion Axis Governing Object Identity State
State State
Steady Red Any State 1 Aborting Motion Axis Major Recoverable
or Major
Unrecoverable
Steady Red Any State 1 Major Faulted Motion Axis Major Recoverable
or Major
Unrecoverable
Steady Red Abort Any State 1 Safety Supervisor Major Recoverable
Steady Red Critical Fault Any State 1 Safety Supervisor Major Unrecoverable

1 “Any State” means any state that has lower precedence.

(Cont’d)

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11 Safety System Description 11.14 Frequency Converter

(Cont’d)

Module Status Indicator

Condition Safety Supervisor CIP Motion Axis Governing Object Identity State
State State
Flashing Green/Red Self-Testing Any State 1 Safety Supervisor Device Self-Testing
Flashing Green/Red Any State 1 Self-Testing Motion Axis Device Self-Testing
Steady Red Self-Test Exception Any State 1 Safety Supervisor Major Unrecoverable
Flashing Green/Red Waiting for TUNID 2 Any State 1 Safety Supervisor Standby
Flashing Green/Red Configuring Any State 1 Safety Supervisor Standby
Flashing Green Idle Any State 1 Safety Supervisor Standby
Flashing Green • Waiting for TUNID • Initialising Motion Axis Standby
with Torque • Pre-Charge
Permitted 2, 3
• Shutdown
• Executing
• Start Inhibit
• Executing with
Steady Green • Stopped Motion Axis Operational
Torque Permitted 4
• Stopping
• Starting
• Running
• Testing
Flashing Red or Any State 1 Aborting Motion Axis Major Recoverable
Steady Red or Major
Unrecoverable
Flashing Red Any State 1 Major Faulted Motion Axis Major Recoverable
or Major
Unrecoverable
Flashing Red Abort Any State 1 Safety Supervisor Major Recoverable
Steady Red Critical Fault Any State 1 Safety Supervisor Major Unrecoverable

1 “Any State” means any state that has lower precedence.

2After Propose_TUNID service request, the Network Status indicator flashes
Green/Red (fast flash) until successful Apply_TUNID.
3 Unlike many Safety I/O devices, a CIP Motion Safety Drive is free to operate in its
“Out-of-Box” state. This behaviour is made explicit by the device specific Safety
Supervisor state, Waiting for TUNID with Torque Permitted. In this “Out-of-Box” state,
operation of the CIP Motion Safety Drive is the same as that of a CIP Motion Drive to
facilitate commissioning.
4 Unlike many Safety I/O devices, a CIP Motion Safety Drive may be operated when
the Safety Output assemblies Run/Idle bit is set to Idle. If in the Executing state, the
Run/Idle bit is set to Idle, the device is forced to a Safe State. However, if in this
condition, the Safety Controller sends a Mode_Change service request with Torque
Permitted to the Safety Stop Functions object, drive operation is permitted while the
Run/Idle bit remains Idle. See the Safety Stop Function object for details on the
Mode_Change service.
(Cont’d)

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11.14 Frequency Converter 11 Safety System Description

(Cont’d)

Network Status Indicator

Condition Status
Off No power applied to the drive or IP address is not configured.
Flashing Green Drive connection is not established, but has obtained an IP
address.
Steady Green Drive is online and has connections in the established state.
Flashing Red One or more Exclusive Owner connections has timed out.
Steady Red Duplicate IP address. IP address specified is already in use.
Flashing The drive performs self-test during powerup.
Green/Red (slow
flash)
Flashing Safety Supervisor is waiting for “Apply TUNID” service request.
Green/Red (fast
flash)

Link A Status Indicator (Ethernet Port 1)

Condition Status
Off Drive is not connected to the network.
Steady Green Drive is connected to the network but not transmitting data.
Flashing Green. Drive is connected to the network and transmitting data.

Link B Status Indicator (Ethernet Port 2)

Condition Status
Off Drive is not connected to the network.
Steady Green Drive is connected to the network but is not transmitting data.
Flashing Green. Drive is connected to the network and is transmitting data.

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11 Safety System Description 11.14 Frequency Converter

11.14.1 Frequency Converter PF 527 - Troubleshoot the

Safe Torque-Off Function
Exception Code on Drive Fault Message Problem Possible Solutions
Display Logix Designer
SAFE FLT 09 - SS IN GuardStopInputFault Safe torque-off function Verify safety wiring and
mismatch. connections:
System does not allow • Wire terminations at safe
motion. torque-off (STO)
Safe torque-off mismatch connector
is detected when safety • Cable/header not seated
inputs are in a different
correctly
state for more than 1.0
second. • +24V power
Check state of safety
inputs.
Reset error and run proof
test.
Return drive for repair if
fault continues.
SAFE FLT S01 - SAFETY CPUWatchdogFault (1) Drive safety diagnostic Cycle power.
CORE INTERNAL detected internal STO Return drive for repair if
design failure. fault continues.
SAFE FLT S03 - SAFE SafeTorqueOffFault (2) Drive safety diagnostic Cycle power.
TORQUE OFF detected internal STO Execute STO function.
design failure.
Return drive for repair if
fault continues.
(1) Displayed in the LCD display as Module Fault.
(2) Displayed in the LCD display as Safety Fault.

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11.14 Frequency Converter 11 Safety System Description

11.14-8 Frequency Converter PF 527 - Error Codes

SPC Reference 3241506-0200

If there is a fault connected to the frequency converter, it turns off. An error code
shows and scroll across the display (1).

1 INIT FLT M12 INVALID FPGA REV

FWD

ENET LINK
EtherNet/IP 2 3 4

1 Display
2 Fault type
3 Fault code
4 Fault description

Fault Code Summary

Fault Code Type Description

FLT Sxx
Standard runtime axis exceptions.
FLT Mxx
INIT FLT Sxx Exceptions that prevent normal operation and occur during the
INIT FLT Mxx initialisation process.
INHIBIT Sxx Exceptions that prevent normal operation and indicate
INHIBIT Mxx whenever the drive is active.
NODE FLTxx Exceptions that prevent normal operation of the drive.
NODE ALARM xx Exceptions that prevent normal operation of the
drive, but do not result in any action other than reporting the
alarm to the controller.

Note! Fault codes triggered by conditions that fall outside factory set limits are
identified by FL at the end of the display message, for example, FLT S07 – MTR
OVERLOAD FL. Fault codes triggered by conditions that fall outside user set limits
are identified by UL at the end of the display message, for example, FLT S08 – MTR
OVERLOAD UL.
(Cont’d)

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11 Safety System Description 11.14 Frequency Converter

(Cont’d)

FLT Sxx Fault Codes

Exception Code on Exception Text Problem Possible Solutions
Display
FLT S03 – MTR Motor Overspeed Factory Fault Motor speed has Check control loop tuning.
OVERSPEED FL Limit exceeded 590 Hz.
FLT S04 – MTR Motor Overspeed User Fault Motor speed has Check control loop tuning.
OVERSPEED UL Limit exceeded the user defined
speed limit given by Motor
Overspeed User Limit.
FLT S07 – MTR Motor Thermal Overload The motor thermal model Modify the command
OVERLOAD FL Factory Limit Fault has exceeded its factory profile to reduce speed or
set thermal capacity limit of increase time.
110%.
FLT S08 – MTR Motor Thermal Overload The motor thermal model • Modify the command
OVERLOAD UL User Limit Fault has exceeded the thermal profile.
capacity limit given by
• Increase the Motor
Motor
Thermal Overload UL
Thermal Overload User attribute value.
Limit.
FLT S10 – INV Inverter Overcurrent Fault Inverter current has • Check motor power
OVERCURRENT exceeded the cable for shorts.
instantaneous current limit
• Verify motor windings are
(determined by hardware).
not shorted.
• Verify motor power wire
gauge.
• Operate within the
continuous powerrating.
• Reduce acceleration
times.
FLT S11 – INV Inverter Overtemperature The measured inverter • Modify the command
OVERTEMP FL Factory Limit Fault temperature has exceeded profile to reduce speed
the factory set temperature or increase time.
limit.
• Reduce drive ambient
temperature.
• Verify that airflow through
drive is not obstructed.
FLT S13 – INV Inverter Thermal Overload The thermal model for the Modify the command
OVERLOAD FL Factory Limit Fault power transistors indicates profile to reduce speed or
that the temperature has increase time.
exceeded the factory set
thermal capacity rating of
110%.
FLT S16 – GROUND Ground Current Factory The sensing circuitry in the • Check motor power
CURRENT Limit Fault power stage has detected wiring; check power
excessive ground current. cable for shorts.
• Replace motor if the fault
persists.
FLT S23 – AC PHASE AC Single Phase Loss A single AC input phase Check AC input voltage on
LOSS Fault was lost while the drive all phases.
was enabled.

(Cont’d)

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11.14 Frequency Converter 11 Safety System Description

(Cont’d)

Exception Code on Exception Text Problem Possible Solutions

Display
FLT S25 – PRECHARGE Pre-charge Failure Fault The pre-charge circuit • Check AC input voltage
FAILURE monitoring algorithm on all phases.
detected that the DC bus
• Check input power
did not reach a factory set
voltage level after charging wiring.
for a period of time. Replace drive if fault
persists.
FLT S29 – BUS Bus Regulator Thermal The shunt thermal model • Modify the duty cycle of
OVERLOAD FL Overload Factory Limit has exceeded its factory the application.
Fault set thermal capacity limit.
• Add external shunt for
additional capacity.
• Add capacitor module if
needed.
FLT S34 – BUS Bus Undervoltage User DC Bus voltage level is • Verify voltage level of the
UNDERVOLT UL Limit Fault below the user set limit as incoming AC.
given by Bus Undervoltage
• Monitor AC power source
User Limit.
for glitches or line droop.
• Install UPS on AC input.
• Decrease Bus
Undervoltage UL
attribute value.
FLT S35 – BUS Bus Overvoltage Factory DC Bus voltage level is • Change the deceleration
OVERVOLT FL Limit Fault above the factory set limit or motion profile of all
as determined by the drives connected to the
configured input voltage. DC bus.
• Unplug the shunt
connector and measure
the resistance of the
shunt.
• Replace drive if shunt
resistor is open.
FLT S37 – BUS POWER Bus Power Loss DC Bus voltage level is • Verify voltage level of the
LOSS below the Bus Power Loss incoming AC.
Threshold for more than • Monitor AC power source
the timeout period
for glitches or line droop.
specified Bus Power Loss
Time value. • Install UPS on AC input.
FLT S41 – FDBK SIGNAL Feedback Signal Noise Noise induced A/B channel • Check motor feedback
NOISE FL Fault state changes (illegal cable and
states) from a feedback connector.
device were detected by
• Cycle power.
the drive, specifically, the
number of these noise • Check feedback shield
events that have occurred connection.
on this channel has
• Reduce shock and
exceeded the Feedback
Noise Factory Limit. The vibration to motor.
offending feedback • Replace motor if fault
channel number is continues.
encoded in the associated
Fault/Alarm Sub Code.

(Cont’d)

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11 Safety System Description 11.14 Frequency Converter

(Cont’d)

Exception Code on Exception Text Problem Possible Solutions

Display
FLT S45 – FDBK COMM Motor Feedback Data Loss The number of consecutive • Check motor feedback
FL Factory Limit Fault missed or corrupted serial cable and connector.
data packets from the
• Check motor power
intelligent feedback device
cable and feedback wire
has exceeded a factory set
limit. shields are secured
correctly.
• Check motor frame is
grounded correctly.
FLT S50 – HARDWARE Hardware Overtravel Axis moved beyond the • Check wiring.
OVERTRAVEL POSITIVE Positive physical travel limits in the • Verify motion profile.
positive direction and
activated the Negative • Verify axis configuration
Overtravel limit switch. in software.
FLT S51 – HARDWARE Hardware Overtravel Axis moved beyond the • Check wiring.
OVERTRAVEL NEGATIVE Negative physical travel limits in the • Verify motion profile.
negative direction and
activated the Negative • Verify axis configuration
Overtravel limit switch. in software.
FLT S54 – POSN ERROR Excessive Position Error The position error of the • Check position loop
Fault position control loop has tuning.
exceeded the value given
• Increase the feedforward
by Position Error Tolerance
gain.
for a time period given by
Position Error Tolerance • Verify sizing of the drive
Time. and motor.
• Check motor power
wiring.
• Increase Position Error
Tolerance and/or
Position Error Tolerance
Time attribute values.
FLT S55 – VEL ERROR Excessive Velocity Error The velocity error of the • Check velocity loop
Fault velocity control loop has tuning.
exceeded the value given • Reduce acceleration.
by Velocity Error Tolerance
for a time period given by • Verify sizing of the drive
Velocity Error Tolerance and motor.
Time.
• Check motor power
wiring.
• Increase Velocity Error
Tolerance and/or Velocity
Error Tolerance Time
attribute values.
FLT S56 – OVERTORQUE Overtorque Limit Fault Motor torque has risen • Verify Torque Trim value.
LIMIT above user defined • Verify motion profile.
maximum torque level
given by Overtorque Limit • Verify sizing of the drive
for a time period given by and motor.
Overtorque Limit Time. • Increase Overtorque
Limit and/or Overtorque
Limit Time attribute
values.

(Cont’d)

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11.14 Frequency Converter 11 Safety System Description

(Cont’d)

Exception Code on Exception Text Problem Possible Solutions

Display
FLT S57 – Undertorque Limit Fault Motor torque has dropped • Verify motion profile.
UNDERTORQUE LIMIT below user defined • Verify sizing of the drive
minimum torque level
and motor.
given by Undertorque Limit
for a time period given by • Decrease Undertorque
Undertorque Limit Time. Limit and/or Undertorque
Limit Time attribute
values.
FLT S61 – ENABLE INPUT Enable Input Deactivated Enable Input has been • Verify Enable Input level.
DEACTIVATED deactivated while the axis • Check Enable Input
power structure is in
wiring.
Running state enabled and
is supplying current to the
DC Bus or motor.

FLT Mxx Fault Codes

Exception Code on Exception Text Problem Possible Solutions
Display
FLT M10 – CONTROL Control Module The temperature sensor on • Reduce drive ambient
MODULE Overtemperature Fault the Main Control Board temperature.
OVERTEMPERATURE FL detected excessive heat.
• Verify that airflow
through drive is not
obstructed.
• Check control module
internal fan. Replace if
error persists.
FLT M19 – DECEL Decel Override The drive is not following a • Reprogram Bus
OVERRIDE commanded deceleration Regulator Action to
because it is attempting to eliminate any “Adjustable
limit bus voltage. Freq” selection.
• Reprogram Bus
Regulator Action to
Shunt Regulator and add
external shunt.
• Correct AC input line
instability or add an
isolation transformer.
• Reset drive.
FLT M21 – MOTOR TEST Motor Test Failure The Motor Test procedure • Verify sizing of the drive
FAILURE has failed. and motor.
• Verify motor data.
• Check motor power
wiring.

(Cont’d)

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11 Safety System Description 11.14 Frequency Converter

(Cont’d)

Exception Code on Exception Text Problem Possible Solutions

Display
FLT M26 – RUNTIME Runtime Error The drive firmware • Cycle power.
ERROR encountered an • Reset the drive.
unrecoverable runtime
error. • Return drive for repair if
fault continues.
FLT M28 – SAFETY Safety Module Error in communicating to • Cycle power.
MODULE COM ERROR Communication Error the Safety module. • Replace module.

INIT FLT Fault Codes

Exception Code on Exception Text Problem Possible Solutions
Display
INIT FLT S03 – NVMEM Nonvolatile memory Data in the nonvolatile • Cycle power.
CHKSUM checksum error memory has a checksum • Reset the drive.
error.
• Return drive for repair if
fault continues.
INIT FLT M14 – INVALID Invalid Safety Firmware The safety firmware is not • Cycle power.
SAFETY FIRMWARE compatible with the drive • Upgrade drive firmware.
firmware, or the main
safety firmware is missing. • Return drive for repair if
fault continues.
INIT FLT M15 – POWER Power Board Checksum The power board has a • Cycle power.
BOARD Error checksum error. • Reset the drive.
• Return drive for repair if
fault continues.

INHIBIT Fault Codes

Exception Code on Exception Text Problem Possible Solutions
Display
INHIBIT S01 – AXIS Axis Enable Input Axis Enable Input is not • Verify Enable Input level.
ENABLE INPUT active. • Check Enable Input
wiring.
INHIBIT S02 – MOTOR Motor Not Configured The motor has not been Verify motor configuration
NOT CONFIGURED properly configured for in the Logix Designer
use. application.
INHIBIT M05 – SAFE Start Inhibit - Safe Torque The safety function has • Check safety input
TORQUE OFF Off disabled the power wiring.
structure.
• Check state of safety
devices.

(Cont’d)

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11.14 Frequency Converter 11 Safety System Description

(Cont’d)

NODE FLT Fault Codes

Exception Code on Exception Text Problem Possible Solutions
Display
NODE FLT 01 – LATE Control Connection Several consecutive • Remove unnecessary
CTRL UPDATE Update Fault updates from the controller network devices from the
have been lost. motion network.
• Change network
topology so that fewer
devices share common
paths.
• Use high performance
network equipment.
• Use shielded cables.
• Separate signal wiring
from power wiring.
NODE FLT 02 – PROC Processor Watchdog Fault The processor on the • Cycle power.
WATCHDOG nn power board or control • Update the drive
board failed to update in a
firmware.
certain amount of time.
The nn sub-codes 00…05 • Return drive for repair if
are internal and result in fault continues.
the same possible solution.
NODE FLT 03 – Hardware Fault -PwrIF Communication with the • Cycle power.
HARDWARE 00 power board could not be • Update the drive
established.
firmware.
• Return drive for repair if
fault continues.
NODE FLT 03 – Hardware Fault - Piccolo DSP chip on the power • Cycle power.
HARDWARE 01 HW board failure. • Return motor for repair if
fault continues.
NODE FLT 03 – Hardware Fault - DSL Communication with the • DSL feedback wiring is
HARDWARE 02 encoder could not be incorrect (check against
established. wiring diagram).
• DSL feedback wiring is
shorted or open.
• DSL feedback cable is
defective.
• Bulletin VPL motor
feedback device is
defective.
• Cycle power.
• Return drive for repair if
fault continues.
NODE FLT 03 – DSL External Memory Errors were detected by • Check DSL feedback
HARDWARE 03 Interface Fault the DSL external memory device, wiring, and cable.
interface.
• Cycle power.
• Return drive for repair if
fault continues.

(Cont’d)

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11 Safety System Description 11.14 Frequency Converter

(Cont’d)

Exception Code on Exception Text Problem Possible Solutions

Display
NODE FLT 05 – CLOCK Clock Skew Fault The controller time and the • Cycle power.
SKEW FLT drive's system time are not • Check controller and
the same.
Ethernet switch
operation.
NODE FLT 06 – LOST Lost Controller Connection Communication with the • Check Ethernet
CTRL CONN Fault controller has been lost. connection.
• Check controller and
Ethernet switch
operation.
NODE FLT 07 – CLOCK Clock Sync Fault Drive's local clock has lost • Check Ethernet
SYNC synchronisation with connection.
controller's clock and was
• Check controller and
not able to resynchronise
within allotted time. Ethernet switch
operation.
NODE FLT 09 – Duplicate IP Address Fault Several consecutive Select an IP address not
DUPLICATE IP ADDRESS updates from the controller already in use on the
have been lost. network.

NODE ALARM Fault Codes

Exception Code on Exception Text Problem Possible Solutions
Display
NODE ALARM 01 – LATE Control Connection Update Updates from the controller • Remove unnecessary
CTRL UPDATE Alarm have been late. network devices from the
motion network.
• Change network
topology so that fewer
devices share common
paths.
• Use high performance
network equipment.
• Use shielded cables.
• Separate signal wiring
from power wiring.
NODE ALARM 03 – Clock Jitter Alarm The sync variance has • Check the Ethernet
CLOCK JITTER exceeded the sync connection.
threshold while the device
• Check controller and
is running in sync mode.
Ethernet switch
operation.
NODE ALARM 04 – Clock Skew Alarm The controller time and the • Check the Ethernet
CLOCK SKEW ALARM drive's system time are not connection.
the same.
• Check controller and
Ethernet switch
operation.
NODE ALARM 05 – Clock Sync Alarm Drive's local clock has lost • Check the Ethernet
CLOCK SYNC ALARM synchronisation with connection.
controller's clock for a short
• Check controller and
time during synchronous
operation. Ethernet switch
operation.

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11.15 Safety Valve 11 Safety System Description

11.15 Safety Valve

11.15.1 Description
The valve is an electro-pneumatic soft-start/quick-exhaust safety valve.

3
2

1 Safety valve
2 Flow control
3 Pressure switching

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11 Safety System Description 11.15 Safety Valve

11.15-1 Safety Valve - Check

Machine Status Electrical supply disconnecting device in position I (ON)
Main air valve ON
SPC Reference 2839813-0400

a) Identify the safety valves to be tested.

b) Step up the machine until the safety valve is activated.
c) Make sure that the corresponding input LEDs are lit on the safety PLC.
d) Press an EMERGENCY STOP button.
e) Make sure that the input LEDs are no longer lit.
f) Reset the EMERGENCY STOP button and the safety system.

Safety Valve Corresponding input LED

F09K2040 (1) F09K2010: I30 (2)

1 Safety Valve
F09K2040
2 LED F09K2010: I30
.

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11.15 Safety Valve 11 Safety System Description

11.15-2 Safety Valve - Change

Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
Main air valve LOCKED in OFF position
SPC Reference 2839813-0400

a) Remove the brackets (1) and the brackets (2).

b) Remove the module connectors (3).
c) Remove and replace the safety valve (4).
d) Move the connector (5) to the new safety valve.
e) Move the silencer (6) to the new safety valve.
f) Assemble in the reverse order.
g) Set the safety valve (4). See Section 11.15-3 Safety Valve - Set on page 725.
h) Perform a test for the replaced safety valve (4). See Section 11.15-1 Safety
Valve - Check on page 723.

1 3 2
2 3 1 4

5
6
1 Bracket 4 Safety valve
2 Bracket 5 Connector
3 Module connector 6 Silencer
.

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11 Safety System Description 11.15 Safety Valve

11.15-3 Safety Valve - Set

Machine Status Electrical supply disconnecting device in position I (ON)
Main air valve ON
SPC Reference 2839813-0400

Flow Control
Turning the flow control screw (1) on the safety valve (2) to the left increases the air
flow during the soft start. Turning the screw to the right decreases the air flow. The
safety valve (2) must be set so that the flow-control screws are in their most open
position.

a) Turn the screw (1) on the safety valve (2) fully to the left.

1 Screw 2 Safety valve

.

(Cont’d)

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11.15 Safety Valve 11 Safety System Description

(Cont’d)

Pressure Switching Point

Note! The pressure switching point is factory set and normally is not adjusted.
If the pressure switching point is not correctly set, it can cause problems with the
safety valve.

Malfunction Possible cause Solution

Valve switches abruptly. Pressure switch over Turning the pressure
point set to low. Working switching screw (1) on the
pressure (5.5 bar) is safety valve (2) to the left
above the flow control increases the pressure
valve switch over point, switch over point.
and open before the
pressure is built up to
working pressure.
Valve does not switch. Pressure switch over Turning the pressure
point set to high. Working switching screw (1) on the
pressure (5.5 bar) is safety valve (2) to the
below the flow control right decreases the
valve switch over point, pressure switch over
and never open. point.

1 Pressure switching
screw
2 Safety valve
.

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