OM

Operation Manual
Cardboard Packer 30 Speed
663151-0200
TechPub_2614345_0108 - OM_3047611_0102_fro.fm

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

Doc. No. OM-3047611-0102

 TechPub_2614345_0108 - OM_3047611_0102_fro.fm
Copyright © 2010 Tetra Pak Group
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.

and all Tetra Pak products are trademarks belonging to the Tetra Pak Group.
The content of this manual is in accordance with the design and construction of the machine or
equipment at the time of publishing. Tetra Pak 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 by:
Tetra Pak Packaging Solutions
Via Delfini 1
41123 Modena
Italy
Additional copies can be ordered from Tetra Pak. When ordering additional copies, always provide the
document number.
Doc. No. OM-3047611-0102
Issue 2010-04
 This manual is valid for: i Introduction

Series No./ Machine No. Sign.

ii Safety Precautions

1 General Description

OM
Operation Manual
2 Control Panels

3 Preparation

4 Start
Cardboard Packer 30 Speed
663151-0200 5 Checks

6 Supply of Materials

7 Conversion
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8 Stop

9 Care and Cleaning

10 Technical Data

Machine or equipment configurations that

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

Doc. No. OM-3047611-0102

Issue 2010-04

Tetra Pak Packaging Solutions

Valid for:
Name Drawing Specification Additional Information
and Development Step
Cardboard Packer 30 663151-0200 Optional Equipment:
Speed - Wrap Around unit 663110-0200

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 i Introduction
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Doc. No. OM-3047611-0102 i - 1 (14)

 i Introduction

About the Introduction Chapter

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

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i - 2 (14) Doc. No. OM-3047611-0102

 i Introduction Table of Contents

Abbreviations and Terminology . . . . . . . . . . . . . . i - 5

Manual Information . . . . . . . . . . . . . . . . . . . . . . . . i - 6
Delivered Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . i - 6
Page Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 7
Page Numbering. . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 8
Typographical Conventions . . . . . . . . . . . . . . . . . . i - 8
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 8

Machine Introduction . . . . . . . . . . . . . . . . . . . . . . i - 9
Intended Use of the Equipment . . . . . . . . . . . . . . . i - 9
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 9
Support and Feedback . . . . . . . . . . . . . . . . . . . . . . i - 9
Declaration of Conformity . . . . . . . . . . . . . . . . . . . . i - 9
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Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 10
CE Classification . . . . . . . . . . . . . . . . . . . . . . . . . . i - 10
Machine Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 10

Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 11
Hygiene. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 13

How to Use This OM . . . . . . . . . . . . . . . . . . . . . . i - 14

Purpose of the OM . . . . . . . . . . . . . . . . . . . . . . . . . i - 14
Operator Workflow. . . . . . . . . . . . . . . . . . . . . . . . . i - 14
Preparation Cycle . . . . . . . . . . . . . . . . . . . . . . . . . .i - 14
Production Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . .i - 14
Care Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i - 14

Doc. No. OM-3047611-0102 i - 3 (14)

 i Introduction

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i - 4 (14) Doc. No. OM-3047611-0102

 i Introduction Abbreviations and Terminology

Abbreviations and Terminology

Abbreviation/ Meaning Translation
Terminology
CBP Cardboard Packer
CE Communautés Européennes/
European Communities
CPU Central Processing Unit
EEA European Economic Area
EM Electrical Manual
IM Installation Manual
I/O Input / Output (module)
LC Line Controller
LED Light Emitting Diode
LH Left Hand
max Maximum
min Minimum
MM Maintenance Manual
OK Optional Kit
OE Optional Equipment
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OM Operation Manual
PE Polyethylene
PLC Programmable Logic Controller
PLMS Packaging Line Monitoring
System
RAM Random Access Memory
RH Right Hand
ROM Read Only Memory
SP Service Pack
SPC Spare Parts Catalogue
TBA Tetra Brik Aseptic
TD Turning Device
TPMS Tetra Pak Maintenance System
TPOP Tetra Pak Operator Panel
Tray OF Tetra Tray with Over Flaps
WA Wrap Around unit
WAIF Tetra Wrap Around box with
Inside top Flap
WASF Tetra Wrap Around box with
Side Flap

Doc. No. OM-3047611-0102 i - 5 (14)

Manual Information i Introduction

Manual Information
Tetra Pak 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.
Tetra Pak will not be held responsible for any damage to the equipment
caused by not following the instructions given in this manual.

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

TechPub_2614345_0108 - in01_3056452_01.fm
maintaining the equipment.
• OM
The Operation Manual 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 Tetra Pak.

i - 6 (14) Doc. No. OM-3047611-0102

 i Introduction Manual Information

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

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Doc. No. MM-2730517-0103 9 - 41 (60)

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

Doc. No. OM-3047611-0102 i - 7 (14)

Manual Information i Introduction

Page Numbering
A page number has three parts:
• chapter number (1)
• consecutive page number (2) within the chapter
• total number of pages (3) in the chapter.

4 - 11 (18) 1 Chapter number

2 Consecutive page number
1 2 3 3 Total number of pages

Typographical Conventions
Controls on the operator panel, emergency stop devices, and program steps
are printed in CAPITAL LETTERS.
Menu names, button names and other text displayed in software are printed
in Courier.

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Cross-references are underlined.

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.

i - 8 (14) Doc. No. OM-3047611-0102

 i Introduction Machine Introduction

Machine Introduction
Intended Use of the Equipment
The intended use of this Tetra Pak equipment is to place packages approved
by Tetra Pak into units made of corrugated cardboard.
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 has been manufactured by
Tetra Pak Packaging Solutions
Via Delfini 1
41123 Modena
Italy

Support and Feedback

If you encounter problems when operating this equipment or have other
inquiries, comments, or suggestions for improvement, contact Tetra Pak.

Declaration of Conformity
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A copy of the Declaration of Conformity can be found in the Installation

Manual. The signed Declaration of Conformity is delivered separately with
the equipment.

Doc. No. OM-3047611-0102 i - 9 (14)

Identification i Introduction

Identification
CE Classification
This equipment complies with the basic health and safety regulations of
the European Economic Area (EEA).

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 Tetra Pak 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.

View of machine with magazine unit

on the RH side

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2 1

3 4 5 6
1 Machine type
2 Drawing specifications
3 Year of manufacture
4 CE mark
5 Machine serial number
6 Manufacturer (name and address)

i - 10 (14) Doc. No. OM-3047611-0102

 i 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.
Orientation for Machines with Magazine Unit on the RH side

D
G
E

B C A

F D

E
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B
C A

B
C A
A Front
B Back
H C LH side
D RH side
E Infeed
F Outfeed - RH side
G Outfeed - Straight
H Outfeed - LH side

(Cont'd)

Doc. No. OM-3047611-0102 i - 11 (14)

Orientation i Introduction

(Cont'd)
Orientation for Machines with Magazine Unit on the LH side

G
D E

B A

D E

B
A

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C

D E
B
A

C
H A Front
B Back
C LH side
D RH side
E Infeed
F Outfeed - RH side
G Outfeed - Straight
H Outfeed - LH side

i - 12 (14) Doc. No. OM-3047611-0102

 i Introduction Hygiene

Hygiene
• Never clean the floors or the machine in the filling room (area) when the
machine is in production.
• Compressed air used for cleaning purposes is to be used only for
cleaning filters and should only be used outside of the filling room (area)
or in the final folder compartment of the filling machine.
• Disinfect your hands before touching anything that may come into
contact with the product. Use code H disinfectant. See the Technical
Data chapter of the Maintenance Manual.
• 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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How to Use This OM i Introduction

How to Use This OM

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

Operator Workflow
Beginning with Chapter 3, the content is structured to follow the operator
workflow, as described below.
Preparation Cycle
a) Preparation
Production Cycle
b) Start
c) Checks
d) Supply of Materials
e) Conversion
f) Stop
Care Cycle

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g) Care and Cleaning

i - 14 (14) Doc. No. OM-3047611-0102

 ii Safety Precautions
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Doc. No. OM-3047611-0102 ii - 1 (30)

 ii Safety Precautions

Safety Precaution Instructions

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

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 a power supply disconnector.

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ii - 2 (30) Doc. No. OM-3047611-0102

 ii Safety Precautions Table of Contents

Safety Messages Description. . . . . . . . . . . . . . . ii - 5

Personnel Requirements . . . . . . . . . . . . . . . . . . ii - 6
Skilled Person . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 6
Instructed Person. . . . . . . . . . . . . . . . . . . . . . . . . . ii - 6

Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 7
Locations of Safety Signs . . . . . . . . . . . . . . . . . . . ii - 9
Locations of Safety Signs, WA (OE). . . . . . . . . . ii - 11

Protective Devices. . . . . . . . . . . . . . . . . . . . . . . ii - 12
Emergency Stop. . . . . . . . . . . . . . . . . . . . . . . . . . ii - 12
Emergency Stop Push-Buttons . . . . . . . . . . . . . . ii - 13
Safeguards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 14
Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 18
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Audible Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 18

Personal Protection. . . . . . . . . . . . . . . . . . . . . . ii - 19
Noise Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 19
Entanglement Hazard . . . . . . . . . . . . . . . . . . . . . ii - 19
Ergonomic Hazard . . . . . . . . . . . . . . . . . . . . . . . . ii - 19

Hazardous Substances . . . . . . . . . . . . . . . . . . . ii - 20
Disposal of Chemical Substances . . . . . . . . . . . ii - 21

Supply Systems. . . . . . . . . . . . . . . . . . . . . . . . . ii - 22
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 22
Residual Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 22
Electrical Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . ii - 23
Socket Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 24
Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 25
Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 26

Doc. No. OM-3047611-0102 ii - 3 (30)

Table of Contents ii Safety Precautions

Hotmelt Equipment . . . . . . . . . . . . . . . . . . . . . . . ii - 27
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 27
Hotmelt Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 28
Hotmelt Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 29

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ii - 4 (30) Doc. No. OM-3047611-0102

 ii 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 hazardous situation

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

Warning indicates a potentially hazardous situation

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

Caution indicates a potentially hazardous situation

which, if not avoided, may result in minor or moderate
CAUTION 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,
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may result in property damage.

Doc. No. OM-3047611-0102 ii - 5 (30)

Personnel Requirements ii 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.

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ii - 6 (30) Doc. No. OM-3047611-0102

 ii Safety Precautions Safety Signs

Safety Signs
WARNING
Damaged or missing safety signs increase the risk of death or serious
injury.
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 variants 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 sign ANSI sign

1
DANGER
Hazardous voltage.
Will shock, burn, or cause death.
Follow lockout procedure
before maintenance.
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Hazardous voltage.
Will shock, burn, or cause death.
Follow lockout procedure before maintenance.
2
WARNING
Hazardous voltage.
Can shock, burn, or cause death.
Read Maintenance Manual
before using this socket outlet.

Hazardous voltage.
Can shock, burn, or cause death.
Read Maintenance Manual (MM) before using this socket outlet.
3
CAUTION
Risk of equipment
damage.
Do not let water
into this area.

Risk of equipment damage.

Do not let water into this area.
4
WARNING
Burn hazard.
Trapped heat energy.
Do not touch.

Burn hazard.
Trapped heat energy.
Do not touch.

Doc. No. OM-3047611-0102 ii - 7 (30)

Safety Signs ii Safety Precautions

Pos. ISO sign ANSI sign

5
WARNING
Hot surface.
Do not touch.
Follow lockout procedure
before maintenance.

Hot surface.
Do not touch.
Follow lockout procedure before maintenance.
6
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.

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ii - 8 (30) Doc. No. OM-3047611-0102

 ii Safety Precautions Safety Signs

Locations of Safety Signs

The illustration shows where the safety signs are located. The position
numbers refer to the table in the Safety Signs section.

1
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Side view of machine with 4 3

magazine unit on the RH side

3
(Cont'd)

Doc. No. OM-3047611-0102 ii - 9 (30)

Safety Signs ii Safety Precautions

(Cont'd)
The illustration shows where the safety signs are located. The position
numbers refer to the table in the Safety Signs section.

6
5

TechPub_2614345_0108 - sp02_3056453_01.fm
View of machine with magazine
unit on the RH side

(Cont'd)

ii - 10 (30) Doc. No. OM-3047611-0102

 ii Safety Precautions Safety Signs

(Cont'd)

Locations of Safety Signs, WA (OE)

The illustration shows where the safety signs are located. The position
numbers refer to the table in the Safety Signs section.

5
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View of machine with magazine

unit on the RH side

Doc. No. OM-3047611-0102 ii - 11 (30)

Protective Devices ii 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.

WARNING
Hazardous voltage.
Hazardous voltage remains on this equipment after activating an
EMERGENCY STOP or an interlocking device.

Emergency Stop
Emergency stop devices are used to stop this equipment immediately in an

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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.

ii - 12 (30) Doc. No. OM-3047611-0102

 ii Safety Precautions Protective Devices

Emergency Stop Push-Buttons

Push one of the EMERGENCY STOP push-buttons to stop this equipment
immediately.
The location of each EMERGENCY STOP push-button is shown by an
arrow.

Top view of machine with magazine unit

on the RH side
TechPub_2614345_0108 - sp02_3056453_01.fm

Top view of machine with magazine unit

on the LH side

Doc. No. OM-3047611-0102 ii - 13 (30)

Protective Devices ii Safety Precautions

Safeguards
WARNING
Moving machinery.
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.

WARNING
Corners and edges.
To prevent injury from corners and edges of open doors and covers, close
them unless they must be open during such work. Be careful when working
under an open door, cover or elsewhere below parts of the equipment with
corners and edges.

CAUTION
Burn hazard.

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Parts of this equipment may be hot after operation.
After installation and maintenance, and before this equipment is inched or
run, check that all safeguards are in place and that they operate correctly.
(Cont'd)

ii - 14 (30) Doc. No. OM-3047611-0102

 ii Safety Precautions Protective Devices

(Cont'd)

CAUTION
Equipment damage.
Never stop this equipment by opening an interlocking guard.
Machines with Straight Outfeed Conveyor
The location of each interlocking guard is shown by an arrow.

Top view of machine with magazine unit

on the RH side
TechPub_2614345_0108 - sp02_3056453_01.fm

Top view of machine with magazine unit

on the LH side

(Cont'd)

Doc. No. OM-3047611-0102 ii - 15 (30)

Protective Devices ii Safety Precautions

(Cont'd)
Machines with Outfeed Conveyor and Magazine Unit on the
Same Side
The location of each interlocking guard is shown by an arrow.

Top view of machine with magazine unit

on the RH side

TechPub_2614345_0108 - sp02_3056453_01.fm
Top view of machine with magazine unit
on the LH side

(Cont'd)

ii - 16 (30) Doc. No. OM-3047611-0102

 ii Safety Precautions Protective Devices

(Cont'd)
Machines with Outfeed Conveyor and Magazine Unit on Opposite
Sides
The location of each interlocking guard is shown by an arrow.

Top view of machine with magazine unit

on the RH side
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Top view of machine with magazine unit

on the LH side

Doc. No. OM-3047611-0102 ii - 17 (30)

Protective Devices ii Safety Precautions

Warning Lamp
A warning lamp is a column of warning lights:
• A red light (2) indicates a hazardous condition. This is a situation that
requires immediate action.
• A yellow light (3) indicates an abnormal or impending critical condition.
This is a condition calling for action by the operator.
• A blue light (4) indicates that operator action is required.
• A green light (5) indicates a normal condition.

Audible Alarm
The audible alarm (1) produces a warning signal every time this equipment is
about to start. The warning signal sounds for approximately three seconds
prior to starting to alert personnel.

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View of machine with magazine
unit on the RH side
3

1 Audible alarm
2 Red light
3 Yellow light
4 Blue light
5 Green light

ii - 18 (30) Doc. No. OM-3047611-0102

 ii Safety Precautions Personal Protection

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

Noise Hazard
CAUTION
Hazardous noise.
Risk of impaired hearing.
Hearing protection is recommended whenever this equipment is in
operation.

Entanglement Hazard
WARNING
Risk of entanglement.
Do not wear jewellery or loose clothing when working on or near this
equipment. Long hair may not be loose.

Ergonomic Hazard
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WARNING
Ergonomic hazard.
Handling materials and supplies, for the machine, can be repetitive manual
work and involve ergonomic hazards with risk for personal injury.
Materials and supplies should be located. e.g. layout design, to avoid
twisting the body or bending the back when placing them into the machine. It
is recommended to use aids such as a lifting table or lifting device for these
tasks.
Follow instructions for safe work practices.

Doc. No. OM-3047611-0102 ii - 19 (30)

Hazardous Substances ii Safety Precautions

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
• the showers work
• an eyewash device, movable or wall-mounted, is available and
operational
• additional washing facilities are nearby.

Note! Learn the locations of all washing facilities in order to act immediately
in case of an accident.

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ii - 20 (30) Doc. No. OM-3047611-0102

 ii Safety Precautions Hazardous Substances

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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Doc. No. OM-3047611-0102 ii - 21 (30)

Supply Systems ii Safety Precautions

Supply Systems
Power Supply
DANGER
Hazardous voltage and moving machinery.
The power supply disconnector must be turned off and secured with a lock
before any maintenance.
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 power supply systems to be on.
These exceptions are clearly stated in the Maintenance Manual.
The illustrations show the power supply disconnector and its location.
‘

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Residual Voltage

DANGER
Hazardous voltage.
Do not touch any terminals immediately after the power supply disconnector
is turned off. Ensure that no residual voltage remains on the capacitors
before touching. Wait five minutes. Failure to observe this information will
cause death or serious injury.
After the power supply disconnector is turned off, residual voltage remains
in the capacitor circuits.

ii - 22 (30) Doc. No. OM-3047611-0102

 ii Safety Precautions Supply Systems

Electrical Cabinet

DANGER
Hazardous voltage.
Will shock, burn, or cause death.
The power supply disconnector must be turned off and secured with a lock
before 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.
Make sure that the electrical cabinet doors are closed after working inside the
electrical cabinet. Doors with lock must be locked.
The location of the electrical cabinet is shown by an arrow.

Top view of machine with magazine unit

on the RH side
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Top view of machine with magazine unit

on the LH side

Doc. No. OM-3047611-0102 ii - 23 (30)

Supply Systems ii Safety Precautions

Socket Outlet

WARNING
Hazardous voltage.
Can shock, burn, or cause death. Read the Maintenance Manual before
using this socket outlet.
The socket outlet (1) is connected to a residual current device (2) to protect
users against electrical shock if there is an earth fault in the connected
equipment. The residual current device shall be tested each time before the
socket outlet is being used. See the MM for test procedure.
The illustrations show the socket outlet, the residual current device, and their
location inside the electrical cabinet.

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1 Socket outlet
2 Residual current device

1 2

ii - 24 (30) Doc. No. OM-3047611-0102

 ii Safety Precautions Supply Systems

Air Supply
WARNING
Compressed air and moving machinery.
Close the shut off valve and lock it before any maintenance.
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 Maintenance Manual.
The illustrations show the shut off valve (1) and its location.
Turn the knob (2) to the position showed in the illustration. Move the
lock slide (3) forward and install the padlock (4).
.
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Side view of machine with magazine unit on the RH side

1
1 Shut off valve
2 Knob
3 Lock slide
4 Padlock

Doc. No. OM-3047611-0102 ii - 25 (30)

Supply Systems ii Safety Precautions

Water Supply
CAUTION
Water under pressure.
Close the water supply valves before any maintenance.
Certain maintenance procedures may require water supply systems to be on.
These exceptions are clearly stated in the Maintenance Manual.
The illustrations show the water supply valve (1) and its location.

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1

1 Water supply valve

ii - 26 (30) Doc. No. OM-3047611-0102

 ii Safety Precautions Supply Systems

Hotmelt Equipment
General

DANGER
Risk of electrical shock.
The voltage is 400V inside the hotmelt unit. Risk of immediate danger to life
through electrical shock.

WARNING
Risk of personal injury.
All service work on the hotmelt unit must be carried out by authorised
personnel.

Always wear safety glasses, protective gloves, and other protective clothing
to avoid injuries caused by splashing hotmelt material.

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

Never remove any part or component until air and electrical supply to the
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machine have been disconnected and the pressure of the hotmelt in the
system has been relieved.
Note! Always refer to the documentation provided from Nordson
Corporation before doing any kind of work on the hotmelt equipment. The
Hotmelt Material Applicator manual is included at delivery from Tetra Pak.
The section Hotmelt equipment in this manual only deals with what is
specific for this machine.

Doc. No. OM-3047611-0102 ii - 27 (30)

Supply Systems ii Safety Precautions

Hotmelt Unit

DANGER
Risk of electrical shock.
Never flush water or any other liquid towards the hotmelt unit when cleaning
the machine. Failure to observe will result in danger to your life.

WARNING
Risk of burns.
During heating and production the hotmelt gets hot. Beware of the
entrapped heat inside the unit when service is performed!
During tank drainage never touch the drain shut!

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ii - 28 (30) Doc. No. OM-3047611-0102

 ii Safety Precautions Supply Systems

Hotmelt Guns

WARNING
Risk of electrical shock.
Never flush water or any other liquid towards the hotmelt guns when
cleaning the machine. Failure to observe will result in danger to your life.

WARNING
Risk of burns.
During PREHEATING, the cover of the hotmelt guns become very hot and
there is risk of severe burns.
Never touch the covers of the hotmelt applicators!
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Doc. No. OM-3047611-0102 ii - 29 (30)

Supply Systems ii Safety Precautions

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ii - 30 (30) Doc. No. OM-3047611-0102

 1 General Description
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Doc. No. OM-3047611-0102 1 - 1 (10)

 1 General Description

Description
This chapter contains general descriptions of the machine or equipment, its
functions, and its components.
This chapter describes the main parts of the CBP 30 Speed and the symbols
used on the machine.

WARNING
Risk of personal injury or damage to the equipment.
To ensure maximum safety, always read carefully this section and the
Chapter ii Safety Precautions before doing any work on the equipment or
making any adjustments.

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1 - 2 (10) Doc. No. OM-3047611-0102

 1 General Description Table of Contents

Main Groups of the Equipment and

Component Location. . . . . . . . . . . . . . . . . . . . . . 1 - 5
Cardboard Packer Overview . . . . . . . . . . . . . . . . . 1 - 5
Pneumatic Panel Overview . . . . . . . . . . . . . . . . . . 1 - 6
Hotmelt Equipment Overview . . . . . . . . . . . . . . . . 1 - 7

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8

Machine Symbols . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9
Base Machine, Symbols . . . . . . . . . . . . . . . . . . . . 1 - 9
Electrical Cabinet, Symbols . . . . . . . . . . . . . . . . . 1 - 9

Packing Pattern Definition . . . . . . . . . . . . . . . . 1 - 10

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Doc. No. OM-3047611-0102 1 - 3 (10)

 1 General Description

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1 - 4 (10) Doc. No. OM-3047611-0102

 Main Groups of the Equipment and
1 General Description Component Location

Main Groups of the Equipment and

Component Location
Cardboard Packer Overview
5 3 4 6 7

Top view of machine with magazine unit

on the RH side
10 9 1 8 2
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1 Warning lamp
2 Control panel/TPOP
3 Electrical cabinet
4 Hotmelt unit
5 Main switch
6 Magazine unit
7 Infeed unit
8 Grouping unit
9 Air equipment
10 Feed unit

Doc. No. OM-3047611-0102 1 - 5 (10)

Main Groups of the Equipment and
Component Location 1 General Description

Pneumatic Panel Overview

For setting data, see Chapter 10 Technical Data.

1
2
Side view of machine with magazine unit
3 on the RH side
4 5
6 7

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9

1 Shut-off valve; main air supply

2 Pressure regulator; main air supply
3 Pressure regulator; cylinder blank releasing
4 Pressure regulator; ejector suction cups
5 Pressure regulator; hotmelt applicators - RH side
6 Pressure regulator; hotmelt applicators - LH side
7 Pressure regulator; pressure rollers of carton transfer
8 Pressure regulator; clutch and brake of feed unit and of WA unit
9 Pressure guard

1 - 6 (10) Doc. No. OM-3047611-0102

 Main Groups of the Equipment and
1 General Description Component Location

Hotmelt Equipment Overview

For settings, see Section Installation, in the NORDSON manual.

2
3
4
5
6
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1 Tank
2 Pressure adjustment screw
3 Pump pressure gauge
4 Control panel
5 Keypad door
6 Power switch

Doc. No. OM-3047611-0102 1 - 7 (10)

Control Panel 1 General Description

Control Panel
The machine is equipped with a control panel which consists of two sections,
a TPOP display (1) which is touch-sensitive and the push buttons:
PROGRAM UP (2), PROGRAM DOWN (3), RESET (4) and
EMERGENCY STOP (5). For more details about the TPOP display, see
chapter 2 Control Panels.

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5 4 3 2

1 TPOP display
2 PROGRAM UP push-button
3 PROGRAM DOWN push-button
4 EMERGENCY RESET push-button
5 EMERGENCY STOP push-button

1 - 8 (10) Doc. No. OM-3047611-0102

 1 General Description Machine Symbols

Machine Symbols
Base Machine, Symbols
Air inlet Water inlet

Electrical Cabinet, Symbols

Main switch Hour counter
(on/off)
1 0
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Doc. No. OM-3047611-0102 1 - 9 (10)

Packing Pattern Definition 1 General Description

Packing Pattern Definition

With Single Pack
Each single package has a face F and a side S. As a common definition, the
packing pattern is always given as the total number FxS, as shown in the
example below.

1x1
F
S
F Face
S Side 3x9

With Multi Pack

As a common definition, the multi pack is always given as FxS and the
packing pattern is always given as the total number FxS considering the
single packages, as shown in the examples below.

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F
F 3x1

F
3x9 S

1x2

F S
F Face S
S Side 3x8

1 - 10 (10) Doc. No. OM-3047611-0102

 2 Control Panels
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Doc. No. OM-3047611-0102 2 - 1 (52)

 2 Control Panels

Description
This chapter describes how to navigate through the TPOP, what to do when
alarms occur and how to make machine settings.

CAUTION
Risk of damage to the equipment.
This chapter contains instructions for making machine settings. These
settings must only be performed by a trained operator.

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2 - 2 (52) Doc. No. OM-3047611-0102

 2 Control Panels Table of Contents

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 7
Home Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 7
Buttons - Colours Convention . . . . . . . . . . . . . . . . . . . . 2 - 7

Status Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 8
Status Icons - Colours Convention . . . . . . . . . . . . . . . . 2 - 8

Title Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 8

Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 9
Common Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 9

Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 12

Function Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 12

Program Steps . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 13
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Program Step Ladder . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 13

Program Step Status . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 14

PREHEATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 14

AIR ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 15

HOMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 15

PRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 16

EMPTYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 16

END OF PRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 17

System Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 18
Language Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 19

USER MANAGEMENT. . . . . . . . . . . . . . . . . . . . . . . . . .2 - 20
Login. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 20

Change Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 21

Machine Configuration . . . . . . . . . . . . . . . . . . . 2 - 22

Doc. No. OM-3047611-0102 2 - 3 (52)

Table of Contents 2 Control Panels

Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 24
Alarm Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 24

Alarm Module Window . . . . . . . . . . . . . . . . . . . . . . . . 2 - 25

Alarms Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 25

Alarm Indication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 26
Alarm Colour Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 26

Alarm List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 27

Alarm Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 28

Recipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 31
RECIPE Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 31
Recipe Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 32

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Additional Recipe Parameters for WA unit . . . . . . . . . 2 - 34

Additional Recipe Parameters for Lines Equipped

with Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 34

Recipes Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 35

Production Control . . . . . . . . . . . . . . . . . . . . . . 2 - 40
Production Control Modules. . . . . . . . . . . . . . . . . . . . 2 - 40

Production Control Module Window . . . . . . . . . . . . . 2 - 41

Setting Icons - Colours Convention. . . . . . . . . . . . . . . 2 - 41

Settings Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 42

Setting Step Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 42

Setting Status Icons - Colours Convention . . . . . . . . . 2 - 42

OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 43

PACKAGE COUNTER . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 44

SERVICE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 45

INFEED UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 46

2 - 4 (52) Doc. No. OM-3047611-0102

 2 Control Panels Table of Contents

ACCUMULATION UNIT . . . . . . . . . . . . . . . . . . . . . . . . .2 - 47

GROUPING UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 48

MAGAZINE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 50

FEED UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 51

WRAP AROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 52
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Doc. No. OM-3047611-0102 2 - 5 (52)

 2 Control Panels

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2 - 6 (52) Doc. No. OM-3047611-0102

 2 Control Panels Description

Description
The TPOP display is a touch sensitive screen which allows the operator to
manage and communicate with the machine control system.

1 2 3 Home Window
The TPOP home window displays the
buttons and icons used to identify the
status of the machine and to access the
different menus of the machine control
system.
Buttons - Colours Convention
The symbols of the buttons can have
different colours with the following
meanings:
• Grey: function is not available
• Black: function is available

Note! A yellow key symbol on a button

means that the button is protected by a
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password and it is not available for the

operator.
12 11 10 9 8 7 6 5 4
1 Status icons
2 Title bar
3 Program steps
4 Machine configuration button
5 System setup button
6 Maintenance button (for service technician only)
7 Yellow key
8 Time bar
9 Recipe button
10 Production control button
11 Alarms button
12 PLMS button

Doc. No. OM-3047611-0102 2 - 7 (52)

Description 2 Control Panels

Status Icons
The status icons when are activated,
notify the operator that:
1 • icon (1) - a parameter of the recipe
has been changed, but the recipe has
not been saved
• icon (2) - the machine is running
2
without packages and no tray is
produced (function available only for
service technician)
Icon active
3 • icon (3) - the lubrication of the
conveyor is activated.
Status Icons - Colours Convention
The status icons can have different
colours of background with the following
meanings:
1 Recipe changed and not saved
• Grey: icon is not active
2 Running without packages
3 Lubrication • White: icon is active.

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1 2 3 4 Title Bar
The title bar indicates:
• the current time (1)
• the current loaded recipe (2)
• the description of the current
window (3)
• the current program step (4).

2 - 8 (52) Doc. No. OM-3047611-0102

 2 Control Panels Navigation

Navigation
This section describes the commonly used buttons, icons and procedures
used to navigate through the TPOP windows.

Common Buttons
The following buttons are common to the
TPOP windows.

The CONFIRMATION button.

Touch the CONFIRMATION button to
record a data entry and close the active
window.
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The CLEAR button.

Touch the CLEAR button to clear an
incorrect entry.

Doc. No. OM-3047611-0102 2 - 9 (52)

Navigation 2 Control Panels

The FACTORY button.

Touch the FACTORY button to display
the factory setting.

The KEYBOARD button.

Touch the KEYBOARD button to display
the numeric keyboard, then proceed as
follows:
• type the value using the NUMBER
buttons (1)
2 • confirm the data entry with the
CONFIRMATION button (4)

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• discard the data entry with the
CLEAR button (5)
3 • close the window with the EXIT
button (6).
4 The value typed is displayed in the value
field (3) and on the left side is indicated
5 the range (2), with the min. and max.
value allowed.
1 6

2 - 10 (52) Doc. No. OM-3047611-0102

 2 Control Panels Navigation

The SINGLE ARROW and DOUBLE

ARROW buttons.
Touch the DOUBLE-ARROW buttons (1)
to increase or decrease a value of 10
units.
Touch the SINGLE-ARROW buttons (2)
to increase or decrease a value of 1 unit.
1 2 1
Note! The value of one single unit can
change depending by the current
dialogue window.

The ENABLE ICONS button.

Touch the ENABLE ICONS button to
enable the grey icons in the module
window.
The icons in the module window become
white.
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The CHANGE WINDOW buttons.

Touch one of the CHANGE WINDOW
buttons to navigate among the alarms/
production control/maintenance control
windows within the same module.

The EXIT button.

Touch the EXIT button to close an active
window.

Doc. No. OM-3047611-0102 2 - 11 (52)

Navigation 2 Control Panels

Symbols
Process • Process - current value.
• Set point - value that has been set for
the particular function.
Set point

Function Buttons
All the available icons are white, when
an icon is selected its colour changes to
blue.
Touch the icon of a particular function to
display the dialogue window.
The function can be selected, with the ON

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button (1), and deselected with the OFF
button (2), then confirm with the
CONFIRMATION button (3).
Note! A green dot (4) close to the
symbol indicates that the function has
been activated or selected.

1 2 3 4

2 - 12 (52) Doc. No. OM-3047611-0102

 2 Control Panels Program Steps

Program Steps
This section describes the program steps displayed on the TPOP display to
indicate the machine status.

Program Step Ladder

The program stepladder shows the
6 machine status and what the machine can
do next. The icons indicate the following
program steps:
5 • PREHEATING (1)
• AIR ON (2)
4 • HOMING (3)
• PRODUCTION (4)
• EMPTYING (5)
3 • END OF PRODUCTION (6).

2
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A flashing light indicates that the

machine is ready to begin a program step.

A fixed light indicates the current

program step.

Doc. No. OM-3047611-0102 2 - 13 (52)

Program Steps 2 Control Panels

Program Step Status

The machine status goes from STEP 0 to
Ready for PREHEATING STEP 6.
(IDLE) STEP 0 means the machine status is
OFF. When the power supply
disconnector (main switch) is set to ON,
the control panel is energized, the electric
lights are turned ON and the machine
sensors receive low voltage. There are no
component movements.
The flashing light signals that the
machine is ready for the next step,
PREHEATING, and in IDLE condition.

STEP 0 - MACHINE OFF

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1
STEP 1 - PREHEATING PREHEATING
STEP 1 is PREHEATING. The
PREHEATING of the hotmelt unit starts,
a time bar displays the time remaining to
complete the preheating sequence, the
sequence takes about 30 minutes.
When the hotmelt adhesive reach the
correct temperature, the green LED on
the hotmelt unit control panel is lit and
the flashing light signals that the machine
Ready for AIR ON
is ready for the next step, AIR ON.

2 - 14 (52) Doc. No. OM-3047611-0102

 2 Control Panels Program Steps

2
AIR ON
STEP 2 is AIR ON. All the electrical
STEP 2 - AIR ON devices are energized and the pneumatic
system is pressurised.

The flashing light signals that the

machine is ready to go to the next step.
Automatically the program recognizes,
depending on certain condition, if the
machine is ready for:
• HOMING, (continue from item 3)
or
• PRODUCTION (continue from
item 4).
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Ready for HOMING Ready for PRODUCTION

3
HOMING
STEP 3 - HOMING STEP 3 is HOMING. The fixed light on
the icon indicates the homing procedure
of some servomotors, this happens
automatically in the following cases:
• at the first start up
• after a change of recipe
• after a change of dimension of the
packing pattern
• during the FAST INCHING phase.
Ready for PRODUCTION

WARNING
Risk of injury.
During the HOMING procedure the
machine moves for some seconds.
The flashing light signals that the
machine is ready for the next step,
PRODUCTION.

Doc. No. OM-3047611-0102 2 - 15 (52)

Program Steps 2 Control Panels

4
STEP 4 - PRODUCTION PRODUCTION
STEP 4 is PRODUCTION. The fixed
light shows that the machine is in
PRODUCTION.
When the emptying signal is received
from the line controller, or if the manual
emptying has been activated from the
TPOP, the light starts to flash and signals
that the machine is ready for the next
Ready for EMPTYING step, EMPTYING.

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5
STEP 5 - EMPTYING EMPTYING
STEP 5 is EMPTYING. The fixed light
shows that the machine is in
EMPTYING.
The flashing light signals that the
machine is ready for the next step, END
OF PRODUCTION.

Ready for END OF

PRODUCTION

2 - 16 (52) Doc. No. OM-3047611-0102

 2 Control Panels Program Steps

1
END OF PRODUCTION
STEP 6 is END OF PRODUCTION.
For a very short instant, the fixed light
shows that the machine is in END OF
STEP 4 - END OF PRODUCTION PRODUCTION, then the machine goes
back to STEP 0.
TechPub_2614345_0108 - 0202_3056461_01.fm

Doc. No. OM-3047611-0102 2 - 17 (52)

System Setup 2 Control Panels

System Setup
This section describes how to:
• set the language used by the TPOP
• login, logout and change password.

1
Touch the SYSTEM SETUP button to
display the SETUP window.

2
On the SETUP window are displayed the
following buttons:

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• LANGUAGE (1)
• INSTALLATION LIST (2)
• USER MANAGEMENT (3)
• DIAGNOSTIC (4)
• SHUT DOWN (5).
1 2 3 4 5

2 - 18 (52) Doc. No. OM-3047611-0102

 2 Control Panels System Setup

Language Setting
1
Touch the LANGUAGE button to display
the LANGUAGE window.
Note! The LANGUAGE window will take
about 1 minute to open, locking
temporary the TPOP.
TechPub_2614345_0108 - 0202_3056461_01.fm

2
Touch the required LANGUAGE button
and wait for a few seconds.

3
Touch the EXIT button.

Doc. No. OM-3047611-0102 2 - 19 (52)

System Setup 2 Control Panels

USER MANAGEMENT
1
Touch the USER MANAGEMENT button
to display the USER MANAGEMENT
window.

2
In the USER MANAGEMENT window are
displayed:
• the LOGOUT button (1)
• the LOGIN button (2)
• the CHANGE PASSWORD button (3)
• the actual user (4).

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Note! The change of password could be
1 2 3 4 not available for the operator.

3
Login
Touch the LOGIN button.

2 - 20 (52) Doc. No. OM-3047611-0102

 2 Control Panels System Setup

3a
Touch the USER button (1) and the
PASSWORD button (2) to display the
keyboard, then type the data entry.
Touch the ENTER button (3) to confirm
the data entry or touch the ESC button (4)
to close the LOGIN window.

1 2 3 4

4
Change Password
If available, touch the CHANGE
PASSWORD button.
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4a
1 Note! After any change, the system will
not accept any old passwords.
Touch the OLD PASSWORD button (1),
the NEW PASSWORD button (2) and the
CONFIRM button (3) to display the
keyboard, then type the data entry.
Touch the ENTER button (4) to confirm
the data entry or touch the ESC button (5)
to close the LOGIN window.

2 3 4 5

Doc. No. OM-3047611-0102 2 - 21 (52)

Machine Configuration 2 Control Panels

Machine Configuration
This section describes how to enable/disable the available machine options
through the TPOP.

1
Touch the MACHINE CONFIGURATION
button to display the MACHINE
CONFIGURATION window.

2
This is a read only page for operators.
8 7 The window displays the actual
configuration of the machine, through the

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following icons:
• MACHINE NUMBER (1)
• SWITCH (2)
• MAGAZINE SIDE (3)
• LINE AUTOMATION (4)
• LINE COMMUNICATION
ETHERNET CARD IP
ADDRESS (5)
• MACHINE OUTFEED SIDE (6)
• OPTION WRAP AROUND
1 2 3 4 5 6 UNIT (7)
• OPTION TURNING DEVICE (8).

2 - 22 (52) Doc. No. OM-3047611-0102

 2 Control Panels Machine Configuration

1
3
Note! A green dot (1) close to the
symbol indicates that the function has
been activated.
Note! The mark “X” over an icon, means
that the optional equipment is not
installed on the machine.
Touch one of the icons available, the icon
becomes blue and the corresponding
configuration window is displayed.
TechPub_2614345_0108 - 0202_3056461_01.fm

Doc. No. OM-3047611-0102 2 - 23 (52)

Alarms 2 Control Panels

Alarms
This section describes the machine alarms and how to manage the alarms
with the TPOP.

Alarm Modules
Alarms show where there is a problem on
the machine and how to resolve it.
Alarms are divided into modules. When
an alarm is activated, an alarm window is
displayed with the activated alarm lit up.
If no alarms appear, touch the ALARM
3 4 5 6 7 8 9 10 button.
The ALARM MODULES window is
displayed showing the alarm modules.
Each ALARM MODULE button opens the
corresponding alarm window.

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2 1
1 Safety 6 Magazine unit
2 Alarm list 7 Grouping unit
3 Service parts 8 Communication
4 Infeed unit 9 Feed Unit
5 Accumulation unit 10 Wrap Around (optional)

2 - 24 (52) Doc. No. OM-3047611-0102

 2 Control Panels Alarms

Alarm Module Window

1 2 On each ALARM MODULE window are
displayed: the ALARMS tab (1) and the
ALARM icons (2).
With no alarms activated, all the
available alarm icons are white, when an
icon is selected its colour changes to
blue.
Touch the ALARM icons (2) to display the
instruction window.
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Alarms Tab
Touch the tabs to display the
corresponding ALARM MODULE
window.
1 2 3 4 5 6 7 8 9 10

1 Alarm list 6 Accumulation unit

2 Communication 7 Grouping unit
3 Safety 8 Magazine unit
4 Service parts 9 Feed unit
5 Infeed unit 10 Wrap Around (optional)

Doc. No. OM-3047611-0102 2 - 25 (52)

Alarms 2 Control Panels

Alarm Indication
The presence of an alarm is displayed on
the control panel display and on the
warning lamp.
Active alarms are highlighted in red,
yellow or blue depending on its alarm
condition, see Alarm Colour Codes.

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Alarm Colour Codes
The alarms are colour coded:
• RED (1) - hazardous condition
• YELLOW (2) - abnormal condition
1 • BLUE (3) - information or operator
action.
2
A red or yellow alarm must be
3 acknowledged. There is no need to
acknowledge blue alarms, they disappear
when the cause is corrected.
Note! If the ALARM window does not
close after pressing the ACKNOWLEDGE
button, the alarm still exists.

2 - 26 (52) Doc. No. OM-3047611-0102

 2 Control Panels Alarms

Alarm List
1
Touch the ALARM LIST button.

2
All the alarms occurred on the machine
1 are listed in the ALARM LIST window.
2 Use the NEXT WINDOW button (1) to
display a window with only the alarms
detected for PLMS, then use the
3 PREVIOUS WINDOW button (4) to go
back to the ALARM LIST window.
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2 For each alarm are reported: the time, the

alarm event code and the alarm message.
5 The letter V beside the alarms, indicates
that they have been acknowledged,
except for the MANUAL STEP DOWN
that is an event and not an alarm, so it
4 will not be acknowledged.
2 Use the ARROW buttons (2) and (3) to
consult the list.
3 Touch the EXIT button (5) to return to
the ALARM SYSTEM window

2
5

Doc. No. OM-3047611-0102 2 - 27 (52)

Alarms 2 Control Panels

Alarm Handling
1
When an alarm appears, touch the
ALARM SYSTEM button.

2
The ALARM MODULE button (1) and the
ALARM list (2) are displayed, then
proceed as follows:
• touch the ALARM MODULE
button (1), to display the active alarm
(continue from item 3)
or

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• touch the ALARM list (2) to display
the list of the alarms occurred.

2 1

2 - 28 (52) Doc. No. OM-3047611-0102

 2 Control Panels Alarms

3
When a safety alarm happens, make sure
to close all the doors and to reset the
safety relays, then touch the flashing
ACKNOWLEDGE button to acknowledge
the alarm.
If in the meantime other alarms are
happened, on the TPOP will be displayed
the next ALARM MODULE window.
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1
4
Display the INSTRUCTION window by
touching the ALARM icon (1).

Doc. No. OM-3047611-0102 2 - 29 (52)

Alarms 2 Control Panels

5
The ALARM icon (1) becomes blue and
the INSTRUCTION window is
displayed.
1
Follow the instructions in the order
given, then touch the flashing
ACKNOWLEDGE button to acknowledge
the alarm.

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6
Touch the EXIT button to return to the
ALARM SYSTEM window.

2 - 30 (52) Doc. No. OM-3047611-0102

 2 Control Panels Recipes

Recipes
This section describes how to load, save and delete a recipe with the TPOP.
A recipe is a set of parameters related to a certain type of production: when a
recipe is loaded, the machine adapts its working parameters to the ones
stored in the recipe.

RECIPE Window
1
Note! The machine can produce only if a
recipe has been selected.
Touch the RECIPE button to display the
RECIPE window.
The current recipe name (1) is shown on
1 the top side of the RECIPE window.
Each recipe includes the machine settings
necessary for that specific type of
production.
The RECIPE window is normally
TechPub_2614345_0108 - 0202_3056461_01.fm

composed by two windows, touch the

NEXT WINDOW button (2) and the
PREVIOUS WINDOW button (3), to
move from one window to the other.
Note! The second RECIPE window, is
available for the Power Operator and the
2 Operator, only if this function has been
enabled by the Supervisor.

Doc. No. OM-3047611-0102 2 - 31 (52)

Recipes 2 Control Panels

2
Recipe Parameters
1 2 3 4 5 For each recipe can be selected the
following parameters in the first window:
• PACKAGE TYPE (1)
• INFEED PACKAGE UNIT (2)
• OUTFEED PACKING
PATTERN (3)
• T-URNED/NOT TURNED (4)
• BOX TYPE (5).
Touch the NEXT WINDOW button to
display the other parameters
Note! For standard machines the
parameter (4) is always set as NOT
TURNED. Only for machines equipped
with TD, the parameter (4) can be
selected as TURNED.
Note! For standard machines the
parameter (5) is always set as TRAY.

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Only for machines equipped with WA
unit, the parameter (5) can be selected
as WASF, WAIF or as TRAY OF.

2 - 32 (52) Doc. No. OM-3047611-0102

 2 Control Panels Recipes

2a
For each recipe can be selected the
following parameters in the second
window:
• SIDE FLAP WIDTH (1)
7 • NOMINAL CAPACITY (2)
1 • OVER CAPACITY (3)
13 • DIVIDER OFFSET (4)
2
• CYLINDER BLANK SUPPLY
3 8 START POSITION (5)
4 • FEEDER BELT SPEED
9 OFFSET (6)
5 • BOX LENGTH (7)
6 12 11 10 • INFEED CONVEYOR SPEED
OFFSET (8)
• INFEED BELT BRAKE SPEED
OFFSET (9)
• DIVIDER CONVEYOR SPEED
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OFFSET (10)
• QUEUE ALARM ACTIVATION
DELAY (11)
• QUEUE ALARM DEACTIVATION
DELAY (12)
• FLAP FOLDER PHASE
OFFSET (13).
Note! Set the parameters (2), (3), (8)
and (9) according to the Machine
Capacity Setting Values on page 10-6.

Doc. No. OM-3047611-0102 2 - 33 (52)

Recipes 2 Control Panels

2b
Additional Recipe Parameters for
WA unit

Note! The following instruction is valid

only for machines equipped with WA
unit.
If previously has been set WAIF or
1
WASF for the box type, the following
additional recipe parameters are
displayed:
2
• WA BOX LENGTH (1)
• WA HOTMELT GUN (2).

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2c
Additional Recipe Parameters for
Lines Equipped with Switch

Note! The following instruction is valid

only for machines installed in lines
1 equipped with the switch.
If previously has been configurated the
switch, then the following additional
2
recipe parameters are displayed:
• SWITCH (1)
• QUEUE PHOTOCELL (2).

2 - 34 (52) Doc. No. OM-3047611-0102

 2 Control Panels Recipes

3
1 2 3 4 Recipes Handling
Note! Make sure that the machine is in
STEP ZERO.
Touch the OPEN button (1), to open an
5 existing recipe, or touch the DELETE
button (3), to delete an existing recipe,
then continue as follows:
• select a recipe with the ARROW
6 buttons (5)
• confirm the recipe selected with the
CONFIRMATION button (4), or
abort the selection with the CLEAR
button (6).
Touch the NEW RECIPE button (2) to
create a new recipe from the beginning.
TechPub_2614345_0108 - 0202_3056461_01.fm

Doc. No. OM-3047611-0102 2 - 35 (52)

Recipes 2 Control Panels

3a
Touch and set the correct value for the
recipe parameters, following the order
1 4 5 6 7 given:
• PACKAGE TYPE (1)
• INFEED PACKAGE UNIT
FACE (2)
• INFEED PACKAGE UNIT
SIDE (3)
• OUTFEED PACKING PATTERN
FACE (4)
• OUTFEED PACKING PATTERN
SIDE (5)
2 3 8 • TURNED/NOT TURNED (6)
• BOX TYPE (7)
• BOX SIDE CLOSURE (8).
Note! During the selection of the
package type (1), pay attention that they
are listed as follows:

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- TBA 200B
- TBA 250B
- TBA 200M
- TBA 250S
- TBA 200S
- TBA 1000B
- TBA 1000S
- TBA 1000Sq
- TBA 125S.
Note! For standard machines the
parameter (6) is always set as NOT
TURNED. Only for machines equipped
with TD, the parameter (6) can be
selected as TURNED.

2 - 36 (52) Doc. No. OM-3047611-0102

 2 Control Panels Recipes

3b
Touch the ARROW button to display the
second RECIPE window.

3c
Touch and set the correct value for the
following parameters:
7
• SIDE FLAP WIDTH (1)
1 • NOMINAL CAPACITY (2)
2 13 • OVER CAPACITY (3)
• DIVIDER OFFSET (4)
3 8
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• CYLINDER BLANK SUPPLY

4 9 START POSITION (5)
• FEEDER BELT SPEED
5
OFFSET (6)
6 12 11 10 • BOX LENGTH (7)
• INFEED CONVEYOR SPEED
OFFSET (8)
• INFEED BELT BRAKE SPEED
OFFSET (9)
• DIVIDER CONVEYOR SPEED
OFFSET (10)
• QUEUE ALARM ACTIVATION
DELAY (11)
• QUEUE ALARM DEACTIVATION
DELAY (12)
• FLAP FOLDER PHASE
OFFSET (13).
Note! Set the parameters (2), (3), (8)
and (9) according to the Machine
Capacity Setting Values on page 10-6.

Doc. No. OM-3047611-0102 2 - 37 (52)

Recipes 2 Control Panels

3d
Note! The following instruction is valid
only for machines equipped with WA unit
and in the case that the recipe includes a
WAIF box or a WASF box.
1
Touch and set the correct value for the
following parameters:
2 • WA BOX LENGTH (1)
• WA HOTMELT GUN (2).

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3e
Note! The following instruction is valid
only for machines installed in lines
equipped with the switch.
1 Touch and set the correct value for the
following parameters:
2 • SWITCH (1)
• QUEUE PHOTOCELL (2).

2 - 38 (52) Doc. No. OM-3047611-0102

 2 Control Panels Recipes

1 2 3 3f
Note! The RECIPE STATUS icon (1)
when activated, signals that one or more
of the previous recipe parameters are
changed; save the recipe otherwise all
the parameters that are changed will be
lost.
Touch the SAVE button (2), to save the
recipe with the same name, or touch the
SAVE AS button (3), to save the recipe
with a new name, in this case, type a new
name using the KEYBOARD (4), then
touch the ENTER button (5).

5 4
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3g
Touch the EXIT button twice to return to
the HOME window.

Doc. No. OM-3047611-0102 2 - 39 (52)

Production Control 2 Control Panels

Production Control
This section describes how to use the TPOP to check and change machine
settings, view process parameters, run machine functions and view package
counters.

Production Control Modules

Touch the PRODUCTION CONTROL
button to view the buttons corresponding
to the various settings grouped by
machine modules or function.
Touch one of the module buttons to open
the associated dialogue window.

4 5 6 7 8 9

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3 2 1

1 Overview 6 Magazine unit

2 Package counter 7 Grouping unit
3 Service parts 8 Feed unit
4 Infeed unit 9 Wrap Around (optional)
5 Accumulation unit

2 - 40 (52) Doc. No. OM-3047611-0102

 2 Control Panels Production Control

1 2 3 Production Control Module

Window
In the PRODUCTION CONTROL
MODULE window are displayed: the
SETTINGS tab (1), the SETTING
icons (2) and the SETTING STEP
ladder (3).
Touch one of the SETTING icons (2)
available, the icon becomes blue and the
corresponding SETTING window (4) is
displayed.

Setting Icons - Colours

Convention
The SETTING icons can have different
colours with the following meanings:
TechPub_2614345_0108 - 0202_3056461_01.fm

• White: setting is available

• Grey: setting is not available.

Touch an icon to display the

INSTRUCTION window.
Note! When an icon is selected, the
colour of the icon changes to blue.

Doc. No. OM-3047611-0102 2 - 41 (52)

Production Control 2 Control Panels

Settings Tab
Touch the tabs to display the
corresponding SETTING GROUP
window.
1 2 3 4 5 6 7 8 9
1 Package counter 6 Grouping unit
2 Overview 7 Magazine unit
3 Service parts 8 Feed unit
4 Infeed unit 9 Wrap Around (optional)
5 Accumulation unit

Setting Step Ladder

There are two SETTING STEP ladders,
4 Icon active one for the Infeed Unit and one for the
Grouping Unit, they show the status
during the setting sequence. The icons

TechPub_2614345_0108 - 0202_3056461_01.fm
indicate the following setting status:
3 5
• WAITING (1)
• RECEIVE (2)
• RECEIVE/DELIVER (3)
2 3 • DELIVER (4)
• EMPTYING (5).

1 2 Setting Status Icons - Colours

Convention
The status icons can have different
Infeed unit Grouping unit
colours with the following meanings:
• Grey background: icon is not active
• White background: icon is active.

2 - 42 (52) Doc. No. OM-3047611-0102

 2 Control Panels Production Control

OVERVIEW
1
Touch the OVERVIEW button to display
the OVERVIEW window.

2
This is a read only page. The window
displays the position of the servo motors
used to control the position of the main
groups. The movement is either
classified as linear (mm) or angular
(deg).
TechPub_2614345_0108 - 0202_3056461_01.fm

3
Touch the EXIT button to return to the
PRODUCTION CONTROL window.

Doc. No. OM-3047611-0102 2 - 43 (52)

Production Control 2 Control Panels

PACKAGE COUNTER
1
Touch the PACKAGE COUNTER button
to display the PACKAGE COUNTER
window.

2
This window shows the number of
packages in and out of the machine.
The RESET button allows the counter to
be reset to zero.

TechPub_2614345_0108 - 0202_3056461_01.fm

3
Touch the EXIT button to return to the
PRODUCTION CONTROL window.

2 - 44 (52) Doc. No. OM-3047611-0102

 2 Control Panels Production Control

SERVICE PARTS
1
Touch the SERVICE PARTS button to
display the SERVICE PARTS window.

2
On the SERVICE PARTS window are
normally displayed the following icons:
• LUBRICATION (1)
• LIGHT (2)
• INCHING (3)
• ZERO POSITIONING (4)
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• MACHINE EMPTYING (5)

• ONE CYCLE EMPTYING (6).
Touch the icons to display the dialogue
window, then make the changes or
perform the action required.
Note! The icons (1) and (3) are available
1 2 3 4 5 6 for the Power Operator and the Operator,
only if enabled by the Supervisor.
Note! Set the parameter (3) according to
the Machine Capacity Setting Values on
page 10-6.

3
Touch the EXIT button to return to the
PRODUCTION CONTROL window.

Doc. No. OM-3047611-0102 2 - 45 (52)

Production Control 2 Control Panels

INFEED UNIT
1
Touch the INFEED UNIT button to
display the INFEED UNIT window.

2
6 On the INFEED UNIT window are
normally displayed the following icons:
• WAITING TIME (1)
• DIVIDER CONVEYOR SPEED
OFFSET (2)
• RUN OF DIVIDER
CONVEYOR (3)

TechPub_2614345_0108 - 0202_3056461_01.fm
• INFEED BELT BRAKE SPEED
OFFSET (4)
• INFEED CONVEYOR SPEED
OFFSET (5)
• INFEED CONVEYOR TIME TO
STOP (6).
1 2 3 4 5 Touch the icon to display the SETTING
window, then make the changes required.
Note! All the icons except the (3) are
available for the Power Operator and the
Operator, only if enabled by the
Supervisor.
Note! Set the parameters (4) and (5)
according to the Machine Capacity
Setting Values on page 10-6.

2 - 46 (52) Doc. No. OM-3047611-0102

 2 Control Panels Production Control

3
Touch the EXIT button to return to the
PRODUCTION CONTROL window.

ACCUMULATION UNIT
1
Touch the ACCUMULATION UNIT
button to display the ACCUMULATION
UNIT window.
TechPub_2614345_0108 - 0202_3056461_01.fm

2
On the ACCUMULATION UNIT window
are normally displayed the following
icons:
• ACCUMULATION CONVEYOR
SPEED OFFSET (1)
• RUN OF ACCUMULATION
CONVEYOR (2).
Touch the icon to display the SETTING
window, then make the changes required.
Note! The icon (1) is available for the
Power Operator and the Operator, only if
enabled by the Supervisor.
1 2

Doc. No. OM-3047611-0102 2 - 47 (52)

Production Control 2 Control Panels

3
Touch the EXIT button to return to the
PRODUCTION CONTROL window.

GROUPING UNIT
1
Touch the GROUPING UNIT button to
display the GROUPING UNIT window.

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2 - 48 (52) Doc. No. OM-3047611-0102

 2 Control Panels Production Control

2
On the GROUPING UNIT window are
displayed the following icons:
• STOP FLIGHT BAR - STOP
POSITION (1)
• RUN OF GROUPING
CONVEYOR (2)
• GROUPING CONVEYOR SPEED
OFFSET (3)
• STOPPER (4)
• RUN OF INDEXING
CONVEYOR (5)
• INDEXING CONVEYOR OVER
TRAVEL (6).

Touch the icons to display the SETTING

1 2 3 4 5 6 window, then make the changes required.
Note! All the icons except the (2) and (5)
are available for the Power Operator and
TechPub_2614345_0108 - 0202_3056461_01.fm

the Operator, only if enabled by the

Supervisor.

3
Touch the EXIT button to return to the
PRODUCTION CONTROL window.

Doc. No. OM-3047611-0102 2 - 49 (52)

Production Control 2 Control Panels

MAGAZINE UNIT
1
Touch the MAGAZINE UNIT button to
display the MAGAZINE UNIT window.

1 2 2
On the MAGAZINE UNIT window are
displayed the following icons:
• SIDE FLAP WIDTH (1)
• FEEDER BELT SPEED
OFFSET (2)
• VACUUM ARM (3)

TechPub_2614345_0108 - 0202_3056461_01.fm
• CYLINDER BLANK SUPPLY
START POSITION (4)
• TEST BLANK FEEDING (5).
Touch the icons to display the SETTING
window, then make the changes required.
Note! All the icons are available for the
Power Operator and the Operator, only if
5 4 3 enabled by the Supervisor.

3
Touch the EXIT button to return to the
PRODUCTION CONTROL window.

2 - 50 (52) Doc. No. OM-3047611-0102

 2 Control Panels Production Control

FEED UNIT
1
Touch the FEED UNIT button to display
the FEED UNIT window.

2
On the FEED UNIT window are
displayed the following icons:
4
• EXTERNAL DISCHARGE
CONVEYOR SPEED OFFSET (1)
• HOTMELT GUNS (2)
• FEED MOTOR REPHASING (3)
TechPub_2614345_0108 - 0202_3056461_01.fm

• BOX LENGTH (4).

Touch the icons to display the SETTING
window, then make the changes required.
Note! The icons (1), (2) and (4) are
available for the Power Operator and the
Operator, only if enabled by the
Supervisor.

1 2 3

3
Touch the EXIT button to return to the
PRODUCTION CONTROL window.

Doc. No. OM-3047611-0102 2 - 51 (52)

Production Control 2 Control Panels

WRAP AROUND
1
Note! The following instructions are valid
only for machines equipped with WA unit
and when running with WAIF and WASF
cardboard blanks.
Touch the WRAP AROUND button to
display the WA window.

2
On the WA window are displayed the
following icons:
• WA LIFT (1)
• WA TOP BOX LENGTH (2)
• WA HOTMELT GUN (3).
Touch the icons to display the dialogue

TechPub_2614345_0108 - 0202_3056461_01.fm
window, then make the changes or
perform the action required.
Note! The icons (2) and (3) are available
for the Power Operator and the Operator,
1 2 3 only if enabled by the Supervisor.

3
Touch the EXIT button to return to the
PRODUCTION CONTROL window.

2 - 52 (52) Doc. No. OM-3047611-0102

 3 Preparation
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Doc. No. OM-3047611-0102 3 - 1 (12)

 3 Preparation

Description
This chapter describes all tasks that must be performed before the equipment
can be started for PRODUCTION.

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3 - 2 (12) Doc. No. OM-3047611-0102

 3 Preparation Table of Contents

Main Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 5

TPOP and Warning Lamps. . . . . . . . . . . . . . . . . . . . . . .3 - 5

Lamp & Hooter Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 6

Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 7

Hotmelt Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 8

Machine Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 9

Carton Magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 9

Emergency Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 10

Doors and Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 10

Step up to Preheating. . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11
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Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 12

Doc. No. OM-3047611-0102 3 - 3 (12)

 3 Preparation

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3 - 4 (12) Doc. No. OM-3047611-0102

 3 Preparation

Main Switch
1
Make sure that the MAIN SWITCH is in
position ON. It should always be in ON
position.
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TPOP and Warning Lamps

2
Check that the TPOP display lights up.

Doc. No. OM-3047611-0102 3 - 5 (12)

 3 Preparation

Lamp & Hooter Test

1
Note! Perform this test regularly once a
week.
Touch the PRODUCTION CONTROL
button.
Touch the SERVICE PARTS button to
display the SERVICE PARTS window.

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2
1 Touch the LAMP & HOOTER TEST
icon (1).
Touch the ON button (2) and the OK
button (3) to start the test for:
• the lamps of the warning lamp
• the lamps of the EMERGENCY
2 3 RESET, STEP UP and STEP DOWN
push-buttons
• audible alarm.

3 - 6 (12) Doc. No. OM-3047611-0102

 3 Preparation

3
Check that:
• the lamp of the EMERGENCY
RESET, STEP UP and STEP DOWN
push-buttons and all the lamps on the
warning lamp light for 3 seconds
• the audible alarm sounds steadily for
3 seconds.
If some lamp or the audible alarm does
not work correctly, replace them.
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Air Pressure
4
This section describes the preparations to
be made regarding the air pressure.
Note! Make sure that the main air supply
at production site is more than 5.5 bar
(0.55 MPa).

4a
Open the shut off valve (1) by turning the
knob (2) clockwise.
Note! The picture shows the valve in
position CLOSED.
2

Doc. No. OM-3047611-0102 3 - 7 (12)

 3 Preparation

4b
Check on the pressure gauge (1) that the
air pressure is 5.5 bar (0.55 MPa). Adjust
2 if necessary by turning the regulating
knob (2).

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Hotmelt Unit
5
WARNING
Risk of burns.
During HEATING and PRODUCTION
the cover gets hot. Do not touch the
cover!
Make sure that the POWER SWITCH on
the hotmelt unit is turned ON.
Make sure that the tank is full, see
Hotmelt Supply on page 6-8.

3 - 8 (12) Doc. No. OM-3047611-0102

 3 Preparation

Machine Settings
6
WARNING
Risk of personal injuries.
Only skilled service technicians are
allowed to do the necessary adjustments
of the machine according to the MM.

CAUTION
Risk of damage to equipment.
Only skilled service technicians are
allowed to do the necessary adjustments
of the machine according to the MM.
Make sure that the machine is set for the
correct packing pattern length, packing
pattern width and type of box. If it is not
set in a correct way, call a service
technician.
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Carton Magazine
7
Load the carton magazine with cardboard
blanks, see Cardboard Blanks Supply on
page 6-5.

Doc. No. OM-3047611-0102 3 - 9 (12)

 3 Preparation

Emergency Stops
8
Check that no EMERGENCY STOP
buttons are pressed.
Note! See the section Emergency Stop
Push-Buttons in the chapter
ii Safety Precautions, for the location on
the machine.

Doors and Covers

9
Check that all doors are closed and that
all covers are fitted.
Note! For more details regarding the
location of doors, see ii Safety
Precautions.

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Machine with magazine Machine with magazine

unit on the LH side and unit on the RH side and
outfeed conveyor straight outfeed conveyor straight

3 - 10 (12) Doc. No. OM-3047611-0102

 3 Preparation

Step up to Preheating
10
This section describes how to step up the
machine to PREHEATING.

10 a
Press the STEP UP button.
The PREHEATING symbol lights up
with fixed light and the preheating of the
hotmelt unit starts. A time bar displays
the time remaining to complete the
preheating sequence, the sequence takes
about 30 minutes.
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If the PREHEATING takes an

abnormally long time, check the hotmelt
unit. If any fault is detected, call a service
technician.

10 b
When the hotmelt reach the correct
temperature, the green LED on the
hotmelt unit control panel is lit, the AIR
ON symbol and the STEP UP button will
start to flash.

Doc. No. OM-3047611-0102 3 - 11 (12)

 3 Preparation

Alarm acknowledge button Alarms

11
Make sure that no alarm is indicated on
the TPOP display.
If necessary, follow the alarm
instructions, take corrective action then
Emergency reset push-button
touch the ALARM ACKNOWLEDGE
button or press the EMERGENCY
RESET push-button.

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3 - 12 (12) Doc. No. OM-3047611-0102

 TechPub_2614345_0108 - 0402_3056463_01.fm

Doc. No. OM-3047611-0102

4 - 1 (8)
4 Start
 4 Start

Description
This chapter describes how to start the machine for PRODUCTION.
The Start chapter begins after all of the pre-production preparations have
been completed.
To start the machine after a stop, see the 8 Stop chapter.

CAUTION
Hazardous noise.
Risk of impaired hearing.
Hearing protection is recommended whenever this equipment is in
operation.

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4 - 2 (8) Doc. No. OM-3047611-0102

 4 Start Table of Contents

Step up to AIR ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5

Test Blank Feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5

Step up to HOMING . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 7

Step up to PRODUCTION . . . . . . . . . . . . . . . . . . . . . . . .4 - 8
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Doc. No. OM-3047611-0102 4 - 3 (8)

 4 Start

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4 - 4 (8) Doc. No. OM-3047611-0102

 4 Start

Step up to AIR ON
1
Press the STEP UP button.
The AIR ON symbol becomes fixed
light, all the electrical devices are
energized and the pneumatic system is
pressurized.
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Test Blank Feeding

1
Note! Perform the following test after
every change of production, in order to
verify the correct setting of the magazine
unit.
Touch the PRODUCTION CONTROL
button to display the PRODUCTION
CONTROL window.

Doc. No. OM-3047611-0102 4 - 5 (8)

 4 Start

1a
a) Touch the TEST BLANK
FEEDING (1), as a result the icon
becomes blue and the dialogue
1 window is displayed.
b) Touch the ON button (2) to select the
function.
2 3 4 Note! The glue is not applied during the
test.
c) Touch the CONFIRMATION
button (4), if necessary the arm (5)
will move towards the magazine to
pick up a blank that will be
transferred in the position between
the grouping unit and the feed unit. If
the blank is not transferred correctly
call a service technician.
d) Touch the OFF button (3) to deselect
the function.
7

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6

4 - 6 (8) Doc. No. OM-3047611-0102

 4 Start

2
The STEP UP button and the next
program step will start to flash. If the
next program step flashing is:
• HOMING, continue as follows from
item 3
• PRODUCTION, continue as follows
from item 4.
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Step up to HOMING
3
Press the STEP UP button for 3 seconds.
The HOMING symbol becomes fixed
light and the servomotors start to move
until they reach the synchronized stop
position, wait until the homing procedure
is completely finished.

Doc. No. OM-3047611-0102 4 - 7 (8)

 4 Start

3a
When the homing procedure is finished
the STEP UP button and the
PRODUCTION symbol will start to
flash.

Step up to PRODUCTION
4
Press the STEP UP button for 3 seconds.
The PRODUCTION symbol becomes
fixed light and the production can start
only if the machine is receiving packages
from the line and the are no Outfeed
Queue alarms displayed, see Machine in

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Standby on page 8-10.

4 - 8 (8) Doc. No. OM-3047611-0102

 5 Checks
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Doc. No. OM-3047611-0102 5 - 1 (10)

 5 Checks

Description
This chapter describes all checks the operator must perform during the
PRODUCTION step.
When there is a fault or a fault cannot be eliminated, call a service
technician.

CAUTION
Hazardous noise.
Risk of impaired hearing.
Hearing protection is recommended whenever this equipment is in
operation.

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5 - 2 (10) Doc. No. OM-3047611-0102

 5 Checks Table of Contents

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 5

Hotmelt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 6

Cardboard Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 7

Carton Magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 8

Conveyor Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 9
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Doc. No. OM-3047611-0102 5 - 3 (10)

 5 Checks

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5 - 4 (10) Doc. No. OM-3047611-0102

 5 Checks

Alarms
1
When an alarm is activated the warning
lamps start to flash and at the same time
the alarm is notified on the TPOP
display. For further information
regarding alarms and corrective actions,
see the chapter 2 Control Panels.
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Doc. No. OM-3047611-0102 5 - 5 (10)

 5 Checks

Hotmelt
2
WARNING
Risk of burns.
1 During HEATING and PRODUCTION
the cover and the hotmelt inside the
hotmelt unit gets hot.
Use a metal or plastic scoop to refill the
tank. Never use bare hands.

2 WARNING
Risk of hotmelt vapours.
3 When the tank lid (1) is open, hotmelt
vapours could be released. Vent the
application area or wear respirator to
1 Tank lid remove airborne particles.
2 Tank fill line
3 Screen CAUTION
Risk of damage to equipment.
Do not overfill the tank! Adding too much

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hotmelt causes tank overflow, damaging
the hotmelt pump.
Check the level of hotmelt periodically.
Refill if the level is below 50% of the
inside height of the tank by:
– opening the tank lid (1)
– refilling the tank with hotmelt up
to the tank fill line (2). The line is
marked on the screen (3) that
protects the tank float switch
– closing the tank lid (1)
immediately.
Check that all temperatures are set as
recommended, see 10 Technical Data.
Note! There is an alarm for the low level
of hotmelt in the tank (blue warning
lamp).

5 - 6 (10) Doc. No. OM-3047611-0102

 5 Checks

Cardboard Boxes
3
Tray
Check that:
• the packages are correctly positioned
in the box
• the box is properly folded and glued.
If not, check the machine and/or call a
service technician.

WAIF box

WASF box
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Tray OF

Doc. No. OM-3047611-0102 5 - 7 (10)

 5 Checks

Carton Magazine
4
When the level of cardboard blanks in the
carton magazine has decreased at a
certain level, the blank magazine alarm is
triggered and displayed on the TPOP, at
the same time the blue warning lamps
flashes.
Note! There are two blank magazine
alarms, one for low level (blue warning
lamp), and one for empty magazine
(yellow warning lamp)!

TechPub_2614345_0108 - 0502_3056464_01.fm
4a
Load the carton magazine with cardboard
blanks, see Cardboard Blanks Supply on
page 6-5.

5 - 8 (10) Doc. No. OM-3047611-0102

 5 Checks

Conveyor Lubrication
5
Check that all the nozzles spray regularly
and they are not clogged by lime scale
deposits. If necessary clean the nozzles,
see section Weekly Care included in
chapter 9 Care and Cleaning.
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Doc. No. OM-3047611-0102 5 - 9 (10)

 5 Checks

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5 - 10 (10) Doc. No. OM-3047611-0102

 6 Supply of Materials
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Doc. No. OM-3047611-0102 6 - 1 (10)

 6 Supply of Materials

Description
This chapter contains information about how cardboard blanks and hotmelt
adhesive should be supplied, stored and protected. Environmental factors are
included, such as recommended storage humidity and temperature range.

TechPub_2614345_0108 - 0602_3056465_01.fm

6 - 2 (10) Doc. No. OM-3047611-0102

 6 Supply of Materials Table of Contents

Cardboard Blanks Supply. . . . . . . . . . . . . . . . . . 6 - 5

Carton Magazine Loading . . . . . . . . . . . . . . . . . . . . . . .6 - 5
All Cardboard Blanks . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6

WAIF and WASF Cardboard Blanks. . . . . . . . . . . . . . . . 6 - 7

Hotmelt Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 8
Hotmelt Tank Refilling . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 8

Storage and Use of Materials . . . . . . . . . . . . . . . 6 - 9

Cardboard Blanks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 9
Handling and Transport . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 9

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 9

Storage Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 9
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Relative Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 9

Order of Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 9

After Daily Production. . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 10

Hotmelt Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 10
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 10
Storage Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 10

Order of Consumption . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 10

Doc. No. OM-3047611-0102 6 - 3 (10)

 6 Supply of Materials

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6 - 4 (10) Doc. No. OM-3047611-0102

 6 Supply of Materials Cardboard Blanks Supply

Cardboard Blanks Supply

1 Carton Magazine Loading
1

CAUTION
Moving parts. Risk of minor or
moderate injury.
Be careful the belts (1) are moving
during the PRODUCTION.
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2
2 Slightly lift the support (1), using the
handle (2), then move it at the end of the
carton magazine.

Doc. No. OM-3047611-0102 6 - 5 (10)

Cardboard Blanks Supply 6 Supply of Materials

CAUTION
Ergonomic hazard.
Loading material into the machine is
repetitive manual work and involve
ergonomic hazards. The workplace
should provide the operators with
devices to facilitate the work for example
lifting table adjustable in height and
transport trolleys. Place the blanks in
order to avoid carrying materials, twisting
the body and bending the back during
handling.

TechPub_2614345_0108 - 0602_3056465_01.fm
4
1 All Cardboard Blanks
Load the cardboard blanks (1) in the
carton magazine, slightly leaned against
2 the top guide (2), the two brackets (3)
and the two stops (4) and with their
outside leaning downwards.

6 - 6 (10) Doc. No. OM-3047611-0102

 6 Supply of Materials Cardboard Blanks Supply

5
WAIF and WASF Cardboard Blanks

Note! This instruction is valid only for

machines equipped with WA unit and
that runs with the WAIF and WASF
WAIF cardboard blanks.
Load the carton magazine, making sure
that:
• the flap (1) is on the bottom, with the
WAIF cardboard blanks
1
• the flap (2) is on the top, with the
WASF cardboard blanks.
2

WASF
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6
3 Slightly lift the support (1) using the
handle (2), then gently push it against the
last cardboard blank (3) loaded in the
2 carton magazine.

Doc. No. OM-3047611-0102 6 - 7 (10)

Hotmelt Supply 6 Supply of Materials

Hotmelt Supply
Hotmelt Tank Refilling

WARNING
Risk of burns.
During HEATING and PRODUCTION
the cover and the hotmelt inside the
hotmelt unit gets hot.
Use a metal or plastic scoop to refill the
tank. Never use bare hands.
1
WARNING
Risk of hotmelt vapours.
When the tank lid (1) is open, hotmelt
vapours could be released. Vent the
application area or wear respirator to
2 remove airborne particles.
3 CAUTION
Risk of damage to equipment.

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Do not overfill the tank! Adding too much
1 Tank lid hotmelt causes tank overflow, damaging
2 Tank fill line the hotmelt pump.
3 Screen Refill if the level is below 50% of the
inside height of the tank by:
– opening the tank lid (1)
– refilling the tank with hotmelt up
to the tank fill line (2). The line is
marked on the screen (3) that
protects the tank float switch
– closing the tank lid (1)
immediately
Check that all temperatures are set as
recommended, see 10 Technical Data.

6 - 8 (10) Doc. No. OM-3047611-0102

 6 Supply of Materials Storage and Use of Materials

Storage and Use of Materials

Cardboard Blanks
1
Handling and Transport
The cardboard blanks should be
protected from knocks and bumps, water
and other liquids, dust and dirt.
The cardboard blanks should be stacked
horizontally on pallets. The height must
not exceed two meters. On top of the
stacked blanks, a wooden board should
be placed before strapping.
The whole stack should preferably be
covered with shrink film.
Before using the blanks, break the pallet
load gradually.
Storage
TechPub_2614345_0108 - 0602_3056465_01.fm

Store the material in a dry place with

good ventilation.
The material should be stored separately
from the packaging material used in the
filling machines.
Note! It is important to transport the
cardboard blanks in the production area
at least 24 hours before they are used.
Storage Temperature
The temperature of the storing facility
must be included between 0 and 30° C
(32 and 85° F).
Relative Humidity
Approximately 65%. Variations in
humidity might change the dimensions of
the blanks.
Order of Consumption
The first pallet in should be the first
pallet out.

Doc. No. OM-3047611-0102 6 - 9 (10)

Storage and Use of Materials 6 Supply of Materials

2
After Daily Production
Keep the remaining blanks on the pallets
with a wooden board on top.
The blanks must be protected from water
when the machine is being cleaned.
In order to condition a pallet load of
blanks to the surrounding atmosphere,
remove the strapping and shrink film.

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Hotmelt Adhesive
1
Storage
Never mix different types of hotmelt.
The hotmelt adhesive can be stored for a
maximum of one year. The storing
facility should be cold and dry.
Note! Avoid dust and damp in the
storage facility.
Storage Temperature
The temperature of the storing facility
should be included between 10 and 30° C
(50 and 85° F).
Order of Consumption
The first box in should be the first box
out.

6 - 10 (10) Doc. No. OM-3047611-0102

 7 Conversion
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Doc. No. OM-3047611-0102 7 - 1 (10)

 7 Conversion

Description
This chapter contains all the instructions for conversions that the operator
can perform. Conversions include, a change of the recipe, like for example
the change of package volume.

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7 - 2 (10) Doc. No. OM-3047611-0102

 7 Conversion Table of Contents

Machine Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 5

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 5

Open Recipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 6

Recipe Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 6

Package Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 7

Infeed Package Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 7

Outfeed Packing Pattern . . . . . . . . . . . . . . . . . . . . . . . .7 - 7

Turned/Not Turned . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 8

Box Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 8

Other Recipe Parameters. . . . . . . . . . . . . . . . . . . . . . . .7 - 9

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Additional Recipe Parameters for WA unit. . . . . . . . .7 - 10

Additional Recipe Parameters for Lines Equipped

with Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 10

Doc. No. OM-3047611-0102 7 - 3 (10)

 7 Conversion

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7 - 4 (10) Doc. No. OM-3047611-0102

 7 Conversion

Machine Settings
1
WARNING
Risk of personal injuries.
Only skilled service technicians are
allowed to do the necessary adjustments
of the machine according to the MM.

CAUTION
Risk of damage to equipment.
Only skilled service technicians are
allowed to do the necessary adjustments
of the machine according to the MM.
Make sure that the machine is set for the
correct packing pattern length, packing
pattern width and type of tray. If it is not
set in a correct way, call a service
technician.
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Preparation
2
Step the machine in PREHEATING or in
IDLE condition.

Ready for PREHEATING STEP 1 - PREHEATING

(MACHINE IDLE)

Doc. No. OM-3047611-0102 7 - 5 (10)

 7 Conversion

Open Recipe
3
Touch the RECIPE button to display the
RECIPE window.

1 2
3a
Touch the OPEN button (1)
Select a recipe using the ARROW
buttons (4).
4
Open the recipe selected with the
CONFIRMATION button (2), or abort the
selection by touching the CLEAR
3

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button (3).

Recipe Name
4
Check that the correct recipe name is
displayed.

7 - 6 (10) Doc. No. OM-3047611-0102

 7 Conversion

Package Type
5
Check that the correct package volume
and shape is displayed.

Infeed Package Unit

6
Check that the correct infeed package
unit (single pack or multi pack) is
displayed.
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Outfeed Packing Pattern

7
Check that the correct outfeed packing
pattern is displayed.

Doc. No. OM-3047611-0102 7 - 7 (10)

 7 Conversion

Turned/Not Turned
8
Note! For standard machines the
parameter is always set as NOT
TURNED. Only for machines equipped
with TD, the parameter can be selected
as TURNED.
Check that the correct turned or not
turned option is displayed.

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Box Type
9
Note! For standard machines the
parameter is always set as TRAY. Only
for machines equipped with WA unit, the
parameter can be selected as WASF,
WAIF or as TRAY OF.
Check that the correct box type is
displayed.

7 - 8 (10) Doc. No. OM-3047611-0102

 7 Conversion

10
Touch the NEXT WINDOW button to
display the second RECIPE window.
Note! The second RECIPE window is
available for the Power Operator and the
Operator, only if this function has been
enabled by the Supervisor.

Other Recipe Parameters

11
Check that the correct value for the
following parameters is displayed:
7 • SIDE FLAP WIDTH (1)
• NOMINAL CAPACITY (2)
1
• OVER CAPACITY (3)
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2 13 • DIVIDER OFFSET (4)

• CYLINDER BLANK SUPPLY
3 8 START POSITION (5)
4 9 • FEEDER BELT SPEED
OFFSET (6)
5
• BOX LENGTH (7)
6 12 11 10 • INFEED CONVEYOR SPEED
OFFSET (8)
• INFEED BELT BRAKE SPEED
OFFSET (9)
• DIVIDER CONVEYOR SPEED
OFFSET (10)
• QUEUE ALARM ACTIVATION
DELAY (11)
• QUEUE ALARM DEACTIVATION
DELAY (12)
• FLAP FOLDER PHASE
OFFSET (13).
Note! Set the parameters (2), (3), (8)
and (9) according to the Machine
Capacity Setting Values on page 10-6.

Doc. No. OM-3047611-0102 7 - 9 (10)

 7 Conversion

Additional Recipe Parameters

for WA unit
12
Note! The following instruction is valid
only for machines equipped with WA unit
and in the case that the recipe includes a
WAIF box or a WASF box.
1 Check that the correct value for the
following parameters is displayed:
• WA BOX LENGTH (1)
2 • WA HOTMELT GUN (2).

Additional Recipe Parameters

for Lines Equipped with

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Switch
13
Note! The following instruction is valid
1 only for machines installed in lines
equipped with the switch.
2 Touch and set the correct value for the
following parameters:
• SWITCH (1)
• QUEUE PHOTOCELL (2).

14
Touch the EXIT button to return to the
SETTING SYSTEM window.

7 - 10 (10) Doc. No. OM-3047611-0102

 TechPub_2614345_0108 - 0802_3056467_01.fm

Doc. No. OM-3047611-0102

8 Stop

8 - 1 (18)
 8 Stop

Description
This chapter contains instructions for all methods of stopping the machine.

CAUTION
Hazardous noise.
Risk of impaired hearing.
Hearing protection is recommended whenever this equipment is in
operation.

CAUTION
Risk of damage to the equipment.
When possible, the machine should normally be stopped in a NORMAL
STOP during PRODUCTION.

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8 - 2 (18) Doc. No. OM-3047611-0102

 8 Stop Table of Contents

Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 5

Normal Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 9
Machine in Standby . . . . . . . . . . . . . . . . . . . . . . 8 - 10
No Packages from the Line . . . . . . . . . . . . . . . . . . . . .8 - 10

Outfeed Queue Alarms. . . . . . . . . . . . . . . . . . . . . . . . . 8 - 11

Production Finished Stop . . . . . . . . . . . . . . . . . 8 - 12

MACHINE EMPTYING . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 13

ONE CYCLE PERFORMING . . . . . . . . . . . . . . . . . . . . .8 - 15

Abort Emptying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 16
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Doc. No. OM-3047611-0102 8 - 3 (18)

 8 Stop

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8 - 4 (18) Doc. No. OM-3047611-0102

 8 Stop Emergency Stop

Emergency Stop
When there is a risk of serious danger to people or to the machine, push
any of the EMERGENCY STOP push-buttons as quickly as possible.

1
Note! See the section Emergency Stop
Push-Buttons in the chapter
ii Safety Precautions, for the location on
the machine.
Press the nearest EMERGENCY STOP
button, as a result:
• the machine stops immediately
• the pneumatic system is
de-pressurized completely
• the machine program steps down to
step ZERO
• the red alarm for emergency stop is
displayed on the TPOP
• the warning lamps flashes with red
TechPub_2614345_0108 - 0802_3056467_01.fm

light.
Note! When an EMERGENCY STOP
button is pressed, the temperature of the
hotmelt unit will be maintained for 60
STEP 0 minutes; if also the STEP DOWN button
is pressed, then the temperature of the
hotmelt unit will be maintained for 5
minutes, after that it will be turned OFF.

Doc. No. OM-3047611-0102 8 - 5 (18)

Emergency Stop 8 Stop

2
Take appropriate action to eliminate the
cause of the emergency stop.
Remove the packages damaged or
incorrectly grouped, in the infeed unit
and/or the grouping unit.
Remove the cardboard blanks damaged
or incorrectly positioned in the pack
position.
Remove the trays that have not been
glued in the feeder unit.

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Machine with magazine Machine with magazine
unit on the LH side unit on the RH side

8 - 6 (18) Doc. No. OM-3047611-0102

 8 Stop Emergency Stop

3
a) Make sure that no doors are open.
b) Twist and release the EMERGENCY
STOP button (1) previously
activated.
1
c) Touch the ALARM ACKNOWLEDGE
button (2).
d) Press the EMERGENCY RESET
push-button (3).
2 3
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4
Press the STEP UP button to restart the
preheating of the hotmelt, the
PREHEATING symbol lights up with
fixed light.
Note! If the machine has been stopped
for more than 60 minutes, the time bar
appears to display the time remaining to
complete the PREHEATING sequence.

Doc. No. OM-3047611-0102 8 - 7 (18)

Emergency Stop 8 Stop

4a
When the hotmelt reach the correct
temperature, the green LED on the
hotmelt unit control panel is lit, the AIR
ON symbol and the STEP UP button will
start to flash, then continue from Chapter
4 Start.

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8 - 8 (18) Doc. No. OM-3047611-0102

 8 Stop Normal Stop

Normal Stop
Use NORMAL STOP to stop the machine during PRODUCTION.

1
Press the STEP DOWN button.
The machine continues the
PRODUCTION, until the packing
pattern present in the grouping unit, has
been pushed onto the cardboard blank,
the glue has been applied and the box has
been transported between the pressure
guides in the feed unit, then the machine
is stopped synchronized.
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1a
After a while the STEP UP button and
the PRODUCTION symbol will start to
flash.

2
Press the STEP UP button for 3 seconds.
The PRODUCTION symbol becomes
fixed light and the production restarts.

Doc. No. OM-3047611-0102 8 - 9 (18)

Machine in Standby 8 Stop

Machine in Standby
The machine goes in STANDBY condition, when during PRODUCTION no
packages are received from the line or an Outfeed Queue Alarm happens, in
both cases the machine does not produce any box.

No Packages from the Line

1
During PRODUCTION, if the Line
Controller or the Genius Communication
(depending by the configuration of the
plant), signals to the machine that the
production of packages will be stopped,
then a countdown bar will be displayed
on the TPOP to inform that after 10
seconds the machine will stop in
STANDBY condition.
The machine remains in STANDBY
condition (the PRODUCTION symbol
has fixed light) for the time necessary
when it is waiting for the packages.

TechPub_2614345_0108 - 0802_3056467_01.fm
1a
2 The machine restart automatically, in the
following cases:
• when the Line Controller or the
Genius Communication signals that
the production of packages is
restarting
or
1 • when all the indicators (1) of the min
queue accumulation (2) are lifted by
the packages and the downstream
equipment is ready.

8 - 10 (18) Doc. No. OM-3047611-0102

 8 Stop Machine in Standby

Outfeed Queue Alarms

2
During PRODUCTION, the machine
will stop in STANDBY condition if one
of the following alarms is displayed on
the TPOP:
• OUTFEED QUEUE AND
DOWNSTREAM EQUIPMENT NOT
READY (1) (indicated with a blue
icon), that means:
- that the photocells on the outfeed
conveyor have detected the presence
of a queue, and
- the Line Controller or the Genius
Communication (depending by the
configuration of the plant), signals to
the machine that the Downstream
Equipment is not ready
• OUTFEED QUEUE (2) (indicated
with a yellow icon), that means:
1
TechPub_2614345_0108 - 0802_3056467_01.fm

- that the photocells on the outfeed

conveyor have detected the presence
of a queue, and
- the Line Controller or the Genius
Communication (depending by the
configuration of the plant), signals to
the machine that the Downstream
Equipment is ready.
The machine remains in STANDBY
condition (the PRODUCTION symbol
has fixed light) for the time necessary to
2 solve the alarm and until the Downstream
Equipment is ready, then the machine
restart automatically.

Doc. No. OM-3047611-0102 8 - 11 (18)

Production Finished Stop 8 Stop

Production Finished Stop

Use PRODUCTION FINISHED if this is the planned time to end
PRODUCTION.

1
The machine continues to produce units,
as long as there are enough packages at
the infeed lanes, to form complete
packing patterns, then the machine stops.
Rearrange the remaining packages at the
infeed lanes in order to form complete
packing patterns.

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Machine with magazine unit
on the RH side

8 - 12 (18) Doc. No. OM-3047611-0102

 8 Stop Production Finished Stop

2
Touch the PRODUCTION CONTROL
button to display the PRODUCTION
CONTROL window.

3
Touch the SERVICE PARTS button to
display the SERVICE PARTS window.
Then according to the quantity of
packages, empty the machine using the
following functions:
• MACHINE EMPTYING (1),
see item 4 below
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• ONE CYCLE PERFORMING (2),

see item 6 on page 8-15.

1 2

MACHINE EMPTYING
4
Use the MACHINE EMPTYING
function to empty the machine from the
remaining packages, producing a certain
number of packing pattern for each
emptying cycle.

Doc. No. OM-3047611-0102 8 - 13 (18)

Production Finished Stop 8 Stop

4a
Touch the MACHINE EMPTYING
icon (1), as a result the icon becomes
blue and the dialogue window is
1 displayed.
4 5
Check if the number of packing pattern to
produce displayed in the field (2) is
correct. If not, touch the field (2) and set
a new value using: the FACTORY
button (4), the ARROW keys (3), or the
KEYBOARD button (5).

2 3

TechPub_2614345_0108 - 0802_3056467_01.fm
4b
a) Touch the ON button (1) to select the
function.
1 2 3
b) Touch the CONFIRMATION
button (3), to activate MACHINE
EMPTYING, the machine will
produce the number of packing
pattern previously set, then the
machine will stop. If there are
packages enough, touch again the
CONFIRMATION button (3) to
repeat the function.
c) Touch the OFF button (2) to deselect
the function.

8 - 14 (18) Doc. No. OM-3047611-0102

 8 Stop Production Finished Stop

5
Touch the EXIT button to return to the
SERVICE PARTS window.

ONE CYCLE PERFORMING

6
Use the ONE CYCLE PERFORMING
function to empty the machine from the
remaining packages, producing a single
packing pattern for each emptying cycle.
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6a
a) Touch the ONE CYCLE
PERFORMING icon (1), as a result
the icon becomes blue and the
dialogue window is displayed.
1
b) Touch the ON button (2) to select the
function.
2 3 4 c) Touch the CONFIRMATION
button (4), to activate the ONE
CYCLE PERFORMING, the machine
will produce one packing pattern. If
there are packages enough, touch the
CONFIRMATION button (4) to
repeat the function.
d) Touch the OFF button (3) to deselect
the function.

Doc. No. OM-3047611-0102 8 - 15 (18)

Production Finished Stop 8 Stop

7
Touch the EXIT button twice to return to
the PRODUCTION CONTROL window.

8
Abort Emptying
Press the STEP DOWN button.
The machine continues the
PRODUCTION, until the packing
pattern present in the grouping unit, has
been pushed onto the cardboard blank,
the glue has been applied and the box has

TechPub_2614345_0108 - 0802_3056467_01.fm
been transported between the pressure
guides in the feed unit, then the machine
is stopped synchronized.

8a
1 2 a) Touch the OFF button (1) to deselect
the function.
b) Touch the CONFIRMATION
button (4).

8 - 16 (18) Doc. No. OM-3047611-0102

 8 Stop Production Finished Stop

9
Press the STEP UP button, the END OF
PRODUCTION symbol remains lit for a
very short instant, then the machine goes
back to STEP 0.
Remove the remaining packages.
Continue with Daily Care,
see Chapter 9 Care and Cleaning.
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Doc. No. OM-3047611-0102 8 - 17 (18)

Production Finished Stop 8 Stop

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8 - 18 (18) Doc. No. OM-3047611-0102

 9 Care and Cleaning
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Doc. No. OM-3047611-0102 9 - 1 (38)

 9 Care and Cleaning

Description
This chapter contains instructions for all tasks to be performed on the
machine or equipment at regular, described intervals after production.
Perform Daily Care after every PRODUCTION run, or after every 24 hours
of operation. Perform Weekly Care once a week or after every 120 hours of
operation.
Perform Cleaning after Smashed Packages when a package crash occurs in
the machine.

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9 - 2 (38) Doc. No. OM-3047611-0102

 9 Care and Cleaning Table of Contents

Daily Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 5
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 5
Remove Cardboard Blanks . . . . . . . . . . . . . . . . . . . . . . 9 - 5

Protect Suction Cups . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 6

Check Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 6

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 6
Remove Dust and Cardboard Residues . . . . . . . . . . . . 9 - 7

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 9

Rinsing and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10

Remove Hotmelt Waste. . . . . . . . . . . . . . . . . . . . . . . . . 9 - 11

Clean Photocells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 11

Infeed Unit Photocells. . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 12

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Magazine Unit Photocells . . . . . . . . . . . . . . . . . . . . . . . 9 - 12

Grouping Unit Photocells . . . . . . . . . . . . . . . . . . . . . . . 9 - 13

Feed Unit Photocells . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 13

Base Unit Photocells. . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 14

Hotmelt Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 14

Pneumatic Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 16

Check for Lubricant Leakages . . . . . . . . . . . . . . . . . .9 - 17

Infeed Belt Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 17

Outfeed Belt Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 18

Stop Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 18

Flight Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 19

WA Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 19

Weekly Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20
Check Divider Conveyor . . . . . . . . . . . . . . . . . . . . . . .9 - 20
Start Divider Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 21

Doc. No. OM-3047611-0102 9 - 3 (38)

Table of Contents 9 Care and Cleaning

Check Accumulation Conveyor . . . . . . . . . . . . . . . . . 9 - 22

Start Accumulation Conveyor. . . . . . . . . . . . . . . . . . . . 9 - 23

Check Indexing Conveyor. . . . . . . . . . . . . . . . . . . . . . 9 - 24

Start Indexing Conveyor . . . . . . . . . . . . . . . . . . . . . . . . 9 - 25

Check Grouping Conveyor . . . . . . . . . . . . . . . . . . . . . 9 - 25

Start Grouping Conveyor . . . . . . . . . . . . . . . . . . . . . . . 9 - 26

Clean Conveyor Chains. . . . . . . . . . . . . . . . . . . . . . . . 9 - 27

Clean Infeed Conveyor . . . . . . . . . . . . . . . . . . . . . . . . 9 - 28

Clean Pivot Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 28

Clean Guide Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 29

Clean Push Flight Bars . . . . . . . . . . . . . . . . . . . . . . . . 9 - 29

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Clean Conveyor Lubrication Nozzles. . . . . . . . . . . . . 9 - 30

Check Cylinders and Valves . . . . . . . . . . . . . . . . . . . . 9 - 30

Cleaning after Smashed Packages. . . . . . . . . . 9 - 31

Remove Smashed Packages . . . . . . . . . . . . . . . . . . . 9 - 31

Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 31
Remove Cardboard Blanks . . . . . . . . . . . . . . . . . . . . . . 9 - 32

Protect Suction Cups . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 32

Check Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 33

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 33
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 34

Rinsing and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 35

Clean Conveyor Chains. . . . . . . . . . . . . . . . . . . . . . . . . 9 - 36

Clean Feeder Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 37

Clean Photocells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 37

Restart the PRODUCTION . . . . . . . . . . . . . . . . . . . . . . 9 - 38

9 - 4 (38) Doc. No. OM-3047611-0102

 9 Care and Cleaning Daily Care

Daily Care
Carry out Daily Care after every PRODUCTION run, or at least every 24
operating hours.

Preparations
1
This section describes the necessary
preparations to be made.
Step down the machine to STEP 0.
Make sure that there are no packages and
boxes in the machine.

1a
2 Remove Cardboard Blanks
a) Slightly lift the support (1) using the
handle (2), then move it at the end of
TechPub_2614345_0108 - 0902_3056468_01.fm

the carton magazine.

b) Remove all the remaining cardboard
blanks (3) from the magazine unit.

3
1

Doc. No. OM-3047611-0102 9 - 5 (38)

Daily Care 9 Care and Cleaning

1b
Protect Suction Cups
Before cleaning, the suction cups must be
covered and protected from water.
Note! Do not flush water into the suction
cups.

1c
Check Doors
Make sure that the doors of the electrical
cabinets are closed.

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Cleaning
2
This section describes the steps in the
cleaning process.

9 - 6 (38) Doc. No. OM-3047611-0102

 9 Care and Cleaning Daily Care

2a
Remove Dust and Cardboard
Residues
Use the compressed air, to remove the
dust and the cardboard residues from the
transfer guide (1) and from the two
guides (2) of the magazine unit.
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Doc. No. OM-3047611-0102 9 - 7 (38)

Daily Care 9 Care and Cleaning

2b
Use a vacuum cleaner to remove the dust
and the cardboard residues from the
bottom of the magazine unit.

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9 - 8 (38) Doc. No. OM-3047611-0102

 9 Care and Cleaning Daily Care

2c
General
During the cleaning of the machine, use
water and cleaning compound code D.
Note! For cleaning compound code
information, see the Cleaning Compound
Table on page 10-9.

DANGER
Risk of immediate danger to life.
Do not flush water or any other liquid
towards the electrical cabinets, the
hotmelt unit and the hotmelt nozzles.
Failure to observe will result in danger to
your life and damage to the equipment.

CAUTION
Risk of burns.
Water with a temperature above 55° C
(131° F) may result in injuries caused
TechPub_2614345_0108 - 0902_3056468_01.fm

from burning.

WARNING
Risk of personal injuries.
Before you begin to handle the
detergents, you should read and follow
the warnings on the container labels.
Also read the ii Safety Precautions.
Note! Do not flush water towards the
electrical and pneumatic components
like for example: photocells,
servomotors, connection boxes,
Armorblocks, distribution blocks, valves,
etcetera.

WA gun

Doc. No. OM-3047611-0102 9 - 9 (38)

Daily Care 9 Care and Cleaning

2d
Rinsing and Cleaning
Note! Do not use high-pressure water!
Note! Water with a temperature above
60° C (140° F) will denaturate the
proteins, which then become much more
difficult to clean.
a) Rinse the machine with water to
remove any loose soil, sugar, or fats.
b) Clean with cleaning compound
code D, to remove any remaining
proteins or fats by using a soft brush
or cloth.
c) After cleaning, rinse thoroughly with
drinking water.
d) Dry using the machine’s compressed
air.
e) Finish the cleaning process using a
clean cloth.

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9 - 10 (38) Doc. No. OM-3047611-0102

 9 Care and Cleaning Daily Care

2e
1 Remove Hotmelt Waste
Remove hotmelt waste from the feeder
unit.
Check that the slide plates (1), the
2 guides (2) and the carrier chains (3) are
clean, if required clean using a cloth
dampened with the cleaning compound
3 code D, then dry with a soft and clean
cloth.
TechPub_2614345_0108 - 0902_3056468_01.fm

2f
Clean Photocells
Note! A dirty lens may cause reading
errors during PRODUCTION.
Note! Do not lose the covers (1).
a) If necessary remove the covers (1).
2 b) Use a clean and soft cloth to wipe off
any dirt from the lenses of the
photocells (2).
c) Fit back the covers (1).
1 Note! See the following pages for the
location of the photocells installed on the
2 machine.

Doc. No. OM-3047611-0102 9 - 11 (38)

Daily Care 9 Care and Cleaning

2g
Infeed Unit Photocells
Check if the lenses of the photocells
installed in the Infeed Unit are cleaned, if
required clean them as described in Clean
Photocells on page 9-11.

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2h
Magazine Unit Photocells
Check if the lenses of the photocells
installed in the Magazine Unit are
cleaned, if required clean them as
described in Clean Photocells on
page 9-11.

9 - 12 (38) Doc. No. OM-3047611-0102

 9 Care and Cleaning Daily Care

2i
Grouping Unit Photocells
Check if the lenses of the photocells
installed in the Grouping Unit are
cleaned, if required clean them as
described in Clean Photocells on
page 9-11.
TechPub_2614345_0108 - 0902_3056468_01.fm

2j
Feed Unit Photocells
Check if the lenses of the photocells
installed in the Feed Unit are cleaned, if
required clean them as described in Clean
Photocells on page 9-11.

Doc. No. OM-3047611-0102 9 - 13 (38)

Daily Care 9 Care and Cleaning

2k
Base Unit Photocells
Check if the lenses of the photocells
installed in the Base Unit are cleaned, if
required clean them as described in Clean
Photocells on page 9-11.

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Hotmelt Unit
3
This section describes the actions to take
regarding the hotmelt unit.

9 - 14 (38) Doc. No. OM-3047611-0102

 9 Care and Cleaning Daily Care

3a
WARNING
Risk of burns.
During HEATING and PRODUCTION
the cover and the hotmelt inside the
hotmelt unit gets hot.
1 Use a metal or plastic scoop to refill the
tank. Never use bare hands.

WARNING
Risk of hotmelt vapours.
When the tank lid (1) is open, hotmelt
2 vapours could be released. Vent the
application area or wear respirator to
3 remove airborne particles.

CAUTION
Risk of damage to equipment.
1 Tank lid Do not overfill the tank! Adding too much
2 Tank fill line hotmelt causes tank overflow, damaging
3 Screen the hotmelt pump.
TechPub_2614345_0108 - 0902_3056468_01.fm

Refill if the level is below 50% of the

inside height of the tank by:
– opening the tank lid (1)
– refilling the tank with hotmelt up
to the tank fill line (2). The line is
marked on the screen (3) that
protects the tank float switch
– closing the tank lid (1)
immediately
For correct hotmelt type, see Chapter
10 Technical Data.

Doc. No. OM-3047611-0102 9 - 15 (38)

Daily Care 9 Care and Cleaning

3b
WARNING
Risk of burns.
During HEATING and PRODUCTION
the cover and the hotmelt inside the
hotmelt unit gets hot.
Clean the exterior surfaces of the hotmelt
unit.
Keep the hot melt supply clean and free
of contaminants to prevent poor pump
performance.

CAUTION
Let the switch (arrow) on the hotmelt
unit remain ON.

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Pneumatic Panel
4
Close the shut off valve (1) by turning the
knob (2) counter clockwise.

2 Note! The picture shows the valve in

position OPEN.

9 - 16 (38) Doc. No. OM-3047611-0102

 9 Care and Cleaning Daily Care

4a
Check that all the liquid is drained from
the two filter regulators (1), the level is
shown in the level glasses (2). The drain
system is fully automatic, if there is
liquid left, call a service technician.

1
2

1
2

Check for Lubricant Leakages

5
CAUTION
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Hygiene.
Make sure that there are no lubricant
leakages, the lubricant may drip on the
conveyor, the feed unit, the packages
and the boxes.

1 5a
Infeed Belt Brake
Check:
• the gearboxes (1) and the shafts (3)
for oil leakages
• the trolleys (2) for grease leakages.
Call a service technician if any leakages
are found.

2 Make sure that there is no excessive

grease on the guide rail (4), if required
remove the grease residues with a clean
cloth.

4
3

Doc. No. OM-3047611-0102 9 - 17 (38)

Daily Care 9 Care and Cleaning

5b
1 Outfeed Belt Brake
2 Check the trolleys (1) for grease
leakages. Call a service technician if any
leakages are found.
Make sure that there is no excessive
grease on the guide rails (2), if required
remove the grease residues with a clean
cloth.

2
1

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2

5c
Stop Unit
Check the gearbox (1) for oil leakages.
Call a service technician if any leakages
are found.

9 - 18 (38) Doc. No. OM-3047611-0102

 9 Care and Cleaning Daily Care

5d
1 Flight Bar
Check the gearboxes (1) for oil leakages.
Call a service technician if any leakages
are found.
TechPub_2614345_0108 - 0902_3056468_01.fm

5e
WA Unit
1 Check:
• the gearbox (1) for oil leakages
• the flange bearings (2) for grease
leakages.
Call a service technician if any leakages
are found.

Doc. No. OM-3047611-0102 9 - 19 (38)

Weekly Care 9 Care and Cleaning

Weekly Care
Carry out Weekly Care once a week, or at least every 120 operating hours.
Note! Make sure that the Daily Care has been carried out before.

Touch the PRODUCTION CONTROL

button.

Check Divider Conveyor

1
Check the condition of the conveyor

TechPub_2614345_0108 - 0902_3056468_01.fm
chains, especially the edges. If worn or
damaged, call a service technician.
In order to check the condition of the
underneath part of the conveyor chains,
run the divider conveyor as follows.

1a
Touch the INFEED UNIT button to
display the INFEED UNIT window.

9 - 20 (38) Doc. No. OM-3047611-0102

 9 Care and Cleaning Weekly Care

1b
Start Divider Conveyor
With the machine in PREHEATING
(STEP 1), proceed as follows:
• touch the icon indicated with the
arrow
• select the function by touching the
ON button (1)
• start the divider conveyor by
touching the CONFIRMATION
button (3)
• deselect the function by touching the
OFF button (2).

1 2 3
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1c
Touch the EXIT button to return to the
PRODUCTION CONTROL window.

Doc. No. OM-3047611-0102 9 - 21 (38)

Weekly Care 9 Care and Cleaning

Check Accumulation
Conveyor
2
Check the condition of the conveyor
chain, especially the edges. If worn or
damaged, call a service technician.
In order to check the condition of the
underneath part of the conveyor chain,
run the accumulation conveyor as
follows.

TechPub_2614345_0108 - 0902_3056468_01.fm
2a
Touch the ACCUMULATION UNIT
button to display the ACCUMULATION
UNIT window.

9 - 22 (38) Doc. No. OM-3047611-0102

 9 Care and Cleaning Weekly Care

2b
Start Accumulation Conveyor
With the machine in PREHEATING
(STEP 1), proceed as follows:
• touch the icon indicated with the
arrow
• select the function by touching the
ON button (1)
• start the accumulation conveyor by
touching the CONFIRMATION
button (3)
• deselect the function by touching the
OFF button (2).

1 2 3
TechPub_2614345_0108 - 0902_3056468_01.fm

2c
Touch the EXIT button to return to the
PRODUCTION CONTROL window.

Doc. No. OM-3047611-0102 9 - 23 (38)

Weekly Care 9 Care and Cleaning

Check Indexing Conveyor

3
Check the condition of the conveyor
chain, especially the edges. If worn or
damaged, call a service technician.
In order to check the condition of the
underneath part of the conveyor chain,
run the accumulation conveyor as
follows.

TechPub_2614345_0108 - 0902_3056468_01.fm
3a
Touch the GROUPING UNIT button to
display the GROUPING UNIT window.

9 - 24 (38) Doc. No. OM-3047611-0102

 9 Care and Cleaning Weekly Care

3b
Start Indexing Conveyor
With the machine in PREHEATING
(STEP 1), proceed as follows:
• touch the icon indicated with the
arrow
• select the function by touching the
ON button (1)
• start the indexing conveyor by
touching the CONFIRMATION
button (3)
• deselect the function by touching the
OFF button (2).

1 2 3
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Check Grouping Conveyor

4
Check the condition of the conveyor
chain, especially the edges. If worn or
damaged, call a service technician.
In order to check the condition of the
underneath part of the conveyor chain,
run the grouping conveyor as follows.

Doc. No. OM-3047611-0102 9 - 25 (38)

Weekly Care 9 Care and Cleaning

4a
Start Grouping Conveyor
With the machine in PREHEATING
(STEP 1), proceed as follows:
• touch the icon indicated with the
arrow
• select the function by touching the
ON button (1)
• start the indexing conveyor by
touching the CONFIRMATION
button (3)
• deselect the function by touching the
OFF button (2).

1 2 3

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4b
Touch the EXIT button to return to the
PRODUCTION CONTROL window.

9 - 26 (38) Doc. No. OM-3047611-0102

 9 Care and Cleaning Weekly Care

Clean Conveyor Chains

5
Note! Do not use high-pressure water!
Note! Water with a temperature above
60° C (140° F) will denaturate the
proteins, which then become much more
difficult to clean.
a) If required run the different
conveyors, see previous pages, in
order to clean the underneath part of
the conveyor chains.
b) Rinse the conveyor chains with water
to remove any loose soil, sugar or
fats.
c) Clean with cleaning compound
code D, to remove any remaining
proteins or fats by using a soft brush
or cloth.
d) After cleaning, rinse thoroughly with
drinking water.
TechPub_2614345_0108 - 0902_3056468_01.fm

e) Dry using the air gun.

Water gun Air gun f) Finish the cleaning process using a
clean cloth.

Doc. No. OM-3047611-0102 9 - 27 (38)

Weekly Care 9 Care and Cleaning

Clean Infeed Conveyor

6
Clean the guide rails (1) from any lime
scale deposits and the area between the
divider conveyor (2) and the infeed
conveyor (3) from the accumulation of
packaging material dust, using a cloth
dampened with the cleaning compound
code D, then dry with a soft and clean
cloth.
3
1

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Clean Pivot Arm
7
Clean the pivot arm from any lime scale
deposits, using a cloth dampened with
the cleaning compound code D, then dry
with a soft and clean cloth.

9 - 28 (38) Doc. No. OM-3047611-0102

 9 Care and Cleaning Weekly Care

Clean Guide Rails

8
Clean the guide rails from any lime scale
deposits, using a cloth dampened with
the cleaning compound code D, then dry
with a soft and clean cloth.
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Clean Push Flight Bars

9
In order to maintain a good working of
the grouping unit, clean all the push
flight bars from any PE or film residues,
using a wet sponge with the cleaning
compound code D, then dry with a soft
and clean cloth.

Doc. No. OM-3047611-0102 9 - 29 (38)

Weekly Care 9 Care and Cleaning

Clean Conveyor Lubrication

Nozzles
1
10
a) Remove the nozzles (1), the
2 gaskets (2) and the filters (3).
b) Clean the parts (1), (2) and (3) from
3 the lime scale deposits, as follows:
• clean using a sponge or a brush with
the cleaning compound code D
• rinse with drinking water
• blow and dry with compressed air.
c) Fit back the parts (1), (2) and (3) in
the reverse order.

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Check Cylinders and Valves
11
Check all the air connections between the
pneumatic panel, the valves and the
cylinders, for any leakages.
If any part is defective, call a service
technician.

9 - 30 (38) Doc. No. OM-3047611-0102

 9 Care and Cleaning Cleaning after Smashed Packages

Cleaning after Smashed Packages

Carry out Cleaning after Smashed Packages when packages have been
smashed during PRODUCTION and package content has soiled the
machine.

Remove Smashed Packages

1
Remove all smashed packages from the
place, where the crash has occurred.

Preparations
2
This section describes the necessary
TechPub_2614345_0108 - 0902_3056468_01.fm

preparations to be made.

Doc. No. OM-3047611-0102 9 - 31 (38)

Cleaning after Smashed Packages 9 Care and Cleaning

2a
2 Remove Cardboard Blanks
Remove remaining blanks from the
magazine if the smashed packages have
splashed over the magazine unit.
a) Slightly lift the support (1), using the
handle (2), then move it at the end of
the carton magazine.
3 b) Remove all the remaining cardboard
1 blanks (3) from the magazine unit.

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2b
Protect Suction Cups
Before cleaning, the suction cups must be
covered and protected from water.
Note! Do not flush water into the suction
cups.

9 - 32 (38) Doc. No. OM-3047611-0102

 9 Care and Cleaning Cleaning after Smashed Packages

2c
Check Doors
Make sure that the doors of the electrical
cabinets are closed.
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Cleaning
3
This section describes the steps in the
cleaning process.

Doc. No. OM-3047611-0102 9 - 33 (38)

Cleaning after Smashed Packages 9 Care and Cleaning

3a
General
During the cleaning of the machine, use
water and cleaning compound code D.
Note! For cleaning compound code
information, see the Cleaning Compound
Table on page 10-9.

DANGER
Risk of immediate danger to life.
Do not flush water or any other liquid
towards the electrical cabinets, the
hotmelt unit and the hotmelt nozzles.
Failure to observe will result in danger to
your life and damage to the equipment.

CAUTION
Risk of burns.
Water with a temperature above 55° C
(131° F) may result in injuries caused

TechPub_2614345_0108 - 0902_3056468_01.fm
from burning.

WARNING
Risk of personal injuries.
Before you begin to handle the
detergents, you should read and follow
the warnings on the container labels.
Also read the ii Safety Precautions.
Note! Do not flush water towards the
electrical and pneumatic components
like for example: photocells,
servomotors, connection boxes,
Armorblocks, distribution blocks, valves,
etcetera.

WA gun

9 - 34 (38) Doc. No. OM-3047611-0102

 9 Care and Cleaning Cleaning after Smashed Packages

3b
Rinsing and Cleaning
Note! Do not use high-pressure water!
Note! Water with a temperature above
60° C (140° F) will denaturate the
proteins, which then become much more
difficult to clean.
a) Rinse the machine with water to
remove any loose soil, sugar, or fats.
b) Clean with cleaning compound
code D, to remove any remaining
proteins or fats by using a soft brush
or cloth.
c) After cleaning, rinse thoroughly with
drinking water.
d) Dry using the air gun.
e) Finish the cleaning process using a
soft and clean cloth.
TechPub_2614345_0108 - 0902_3056468_01.fm

Doc. No. OM-3047611-0102 9 - 35 (38)

Cleaning after Smashed Packages 9 Care and Cleaning

3c
Clean Conveyor Chains
Note! Do not use high-pressure water!
Note! Water with a temperature above
60° C (140° F) will denaturate the
proteins, which then become much more
difficult to clean.
a) If required run the different
conveyors, see Weekly Care, in order
to clean the underneath part of the
conveyor chains.
b) Rinse the conveyor chains with water
to remove any loose soil, sugar or
fats.
c) Clean with the cleaning compound
code D, to remove any remaining
proteins or fats by using a soft brush
or cloth.
d) After cleaning, rinse thoroughly with
drinking water.

TechPub_2614345_0108 - 0902_3056468_01.fm
e) Dry using the air gun.
Water gun Air gun f) Finish the cleaning process using a
clean cloth.

9 - 36 (38) Doc. No. OM-3047611-0102

 9 Care and Cleaning Cleaning after Smashed Packages

3d
1
Clean Feeder Unit
Clean the feeder unit after smashed
packages.

2 Check that the slide plates (1), the

guides (2) and the carrier chains (3) are
clean, if required clean using a cloth
dampened with the cleaning compound
3 code D, then dry with a soft and clean
cloth.
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3e
Clean Photocells
Note! A dirty lens may cause reading
errors during PRODUCTION.
Note! Do not lose the covers (1).
If smashed packages have splashed over
the photocells (2) proceed as follows:
• if necessary remove the covers (1)
2
• use a clean and soft cloth to wipe off
any dirt from the lenses of the
photocells (2)
1 • fit back the covers (1).

Doc. No. OM-3047611-0102 9 - 37 (38)

Cleaning after Smashed Packages 9 Care and Cleaning

Restart the PRODUCTION

4
Restart the PRODUCTION according to
the current stop condition of the machine:
• machine in NORMAL STOP, press
the STEP UP button
• machine in EMERGENCY STOP,
follow the instructions in section
Emergency Stop on page 8-5.

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9 - 38 (38) Doc. No. OM-3047611-0102

 10 Technical Data
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Doc. No. OM-3047611-0102 10 - 1 (10)

 10 Technical Data

Description
This chapter provides the pressure and temperature setting values that must
be check or set by the operator, the chapter also includes the information on
the recommended types of hotmelt adhesive and the cleaning compounds to
be used.

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10 - 2 (10) Doc. No. OM-3047611-0102

 10 Technical Data Table of Contents

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 5
Pressure Setting Values . . . . . . . . . . . . . . . . . . . 10 - 5
Recommended Hotmelt Types and
Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 5
Machine Capacity Setting Values . . . . . . . . . . . . 10 - 6

Cleaning Compounds . . . . . . . . . . . . . . . . . . . . 10 - 8
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Doc. No. OM-3047611-0102 10 - 3 (10)

 10 Technical Data

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10 - 4 (10) Doc. No. OM-3047611-0102

 10 Technical Data Technical Data

Technical Data
This section provides the correct setting values for this machine.
Also are listed the recommended types of hotmelt adhesive and the
corresponding temperature settings.

Pressure Setting Values

See chapter 1 General Description for the location of the regulators.

Function Pressure
(bar) (MPa)
Working pressure (main air supply) 5.5 0.55
Cylinder blank releasing Must be done by a service technician,
see the MM
Ejector suction cups 5.0 0.50
Hotmelt unit pump 3.0 0.30
Hotmelt applicators - RH side (*) 4.0 0.40
Hotmelt applicators - LH side (*) 4.0 0.40
Pressure rollers of carton transfer 2.0 0.20
Clutch and brake of feed unit and of WA unit 4.0 0.40
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(*) For machines equipped with WA unit (OE), the WA Hotmelt applicator is
connected to the pneumatic circuit of Hotmelt applicators RH side, or to the
pneumatic circuit of Hotmelt applicators LH side, depending by the machine
configuration (with the Magazine Unit on the RH side or the LH side).

Recommended Hotmelt Types and Temperatures

Type of hotmelt Ambient Tank Hose Gun temperature
temperature temperature temperature
Jowatherm 25510 5-40°C ~165°C ~170°C ~175°C
TP No. 90458-1101
Jowatherm 25850 5-30°C ~155°C ~160°C ~165°C
TP No. 90459-3248
National Instant-Pak 2500 5-10°C ~165°C ~175°C ~180°C
TP No.
National Instant-Pak 2400 11-50°C ~160°C ~165°C ~170°C
TP No. 90458-1487
National Instant-Pak 2300 5-30°C ~155°C ~160°C ~165°C
TP No. 90458-1486

Doc. No. OM-3047611-0102 10 - 5 (10)

Technical Data 10 Technical Data

Machine Capacity Setting Values

Settings for Lines With Line Controller
Use the following table to define the capacity to be set for each package and
the most appropriate range of values to be set by the TPOP for the speed
offset of the Infeed Belt Brake and of the Infeed Conveyor, in order to allow
to the machine to remain in capacity after the filling sequence.
Note! When setting the offset speed reduction on the TPOP, for the Infeed
Belt Brake and the Infeed Conveyor parameters, make sure that the value is
always preceded by the “-” (minus) and never by the “+” (plus).
Capacity set by Line Controller

Reduction of speed offset [*]

Reduction of speed offset [*]

Overspeed automatically set

Infeed Belt Brake -

Infeed conveyor -
Real speed (p/h)
Volume/Shape
Package type

by PLC
(p/h)

(%)

(%)

(%)

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Portion 250B ≥ 29000 + 12 31200 + 12% = 34944 - (15 ÷ 20) - (10 ÷ 15)
200B
< 29000 + 12 25000 + 12% = 28000 - (15 ÷ 20) - (10 ÷ 15)
200M ≥ 29000 +5 31200 + 5% = 32760 - (10 ÷ 15) - (5 ÷ 10)
< 29000 +5 25000 + 5% = 26250 - (10 ÷ 15) - (5 ÷ 10)
200S 25000 ÷ 31200 n/a Same value set for 0 0
250S capacity
125S
Family 1000B ≥ 19000 + 12 [**] 19500 + 12% = 21840 - (15 ÷ 20) - (10 ÷ 15)
1000S
< 19000 + 12 [**] 15000 + 12% = 16800 - (15 ÷ 20) - (10 ÷ 15)
1000Sq ≥ 19000 + 7[**] 19500 + 7% = 20865 - (10 ÷ 15) - (5 ÷ 10)
< 19000 + 7[**] 15000 + 7% = 16050 - (10 ÷ 15) - (5 ÷ 10)
[*] The values indicated in the columns are recommended.
[**] The overspeed value indicated is not valid when the machine has to
produce the packing pattern (2X3) with family packages.
(Cont'd)

10 - 6 (10) Doc. No. OM-3047611-0102

 10 Technical Data Technical Data

(Cont'd)
Settings for Lines Without Line Controller
Use the following table to define the capacity to be set for each package and
the most appropriate range of values to be set by the TPOP for the speed
offset of the Infeed Belt Brake and of the Infeed Conveyor, in order to allow
to the machine to remain in capacity after the filling sequence.
Note! When setting the offset speed reduction on the TPOP, for the Infeed
Belt Brake and the Infeed Conveyor parameters, make sure that the value is
always preceded by the “-” (minus) and never by the “+” (plus).

Reduction of speed offset [*]

Reduction of speed offset [*]

Capacity set by TPOP [*]

Infeed Belt Brake -

Infeed conveyor -
Volume/Shape
Package type

(p/h)

(%)

(%)
Portion 250B 28000 - (15 ÷ 20) - (10 ÷ 15)
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200B
200M 26500 - (10 ÷ 15) - (5 ÷ 10)
200S 25000 0 0
250S
125S
Family 1000B 17000 - (15 ÷ 20) - (10 ÷ 15)
1000S
1000Sq 16000 - (10 ÷ 15) - (5 ÷ 10)
[*] The values indicated in the columns are recommended.

Doc. No. OM-3047611-0102 10 - 7 (10)

Cleaning Compounds 10 Technical Data

Cleaning Compounds
WARNING
Risk of explosion.
Cleaning with not recommended cleaning agents, for example agents
including alcohol, could cause explosion. Use only Tetra Pak recommended
cleaning agents when cleaning or disinfecting parts that can come into
contact with hydrogen peroxide.
It is strongly recommended, in order to optimize the cleaning efficiency, to
use water characterised by the following physicochemical parameters:
• water quality; chlorine free, drinkable water
• pH; between 6 and 8 pH units
• water hardness; between 5 and 10 °f French degrees of hardness
(between 3 and 6 German degrees of hardness)
• chlorides; lower than 50 ppm
• silicates; lower than 10 ppm.

(Cont'd)

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10 - 8 (10) Doc. No. OM-3047611-0102

 10 Technical Data Cleaning Compounds

(Cont'd)
Cleaning Compound Table
Comparable qualities from other suppliers may be selected in compliance
with the technical requirements listed in the table. All cleaning compounds
must comply with local legal requirements.
The supplier recommendations for concentration and temperature should be
followed. When dosing the products automatically, the concentration should
be checked.

Example
071119
Cleaning TP Code Detergent Raw Material Formulated Products
Type Type
Name Max Use Use Ecolab Use Use Johnson Use Use
Conc Conc Temp Conc. Temp. Diversey Conc. Temp.
w/w w/w °C w/w °C vol/vol °C
CIP A 1 Alkali NaOH 30% 1.50% 80 P3-mip CIP 2.0% 80 VC 13 3.0% 80
VC 7 4.5%
B 1 Acid HNO3 50% 1.00% 60 P3-horolith 1.0% 60 VA 5 2.0% 60
L31
1 Alkali P3-Topax 12 3.0% 25 VF 9 3.0% 25
foam (*)
2 Alkali P3-mip 2.0% 55 VK 12 1.0% 55
External
solution (**) FPC
Cleaning C
TechPub_2614345_0108 - 1002_3056469_01.fm

(automatic) 3 Disinfection P3-Topax 99 2.0% 25 VS 1 1.0% 25

foam (***)
4 Acid foam P3-Topax 56 25 VF 11 2.0% 25
(***)
Manual
Cleaning D 1 Alkali P3-mip FPC 2.0% 25 VK 12 1.0% 25
(wiping)
1 Low P3-Topax 99 2.0% 25 VS 1 1.0% 25
alkali
Manual 2 Low P3-Steril 2.0% 25 VT 1 1.0% 25
Disinfection F alkali
(immersion)
3 Acid Peracetic Oxonia
solution acid 15% 200ppm 25 Active 0.50% 25 VT 6 0.10% 25
solution
1 Alcoholic Isopropanol 70% 25 Spitaderm Pure 25 VT 10 pure 25
solution
Manual 2 Alcoholic Ethanol 70% 25 Alcodes Pure 25 pure 25
Disinfection G
solution
(spraying)
3 Acid Peracetic Oxonia
solution acid 15% 200ppm 25 Active 0.50% 25 VT 6 0.10% 25
solution
Hand H 1 Manodes pure 25 H34 pure 25
Disinfection
Deliming K 1 Citric acid Lime-A-Way pure 25
agent compound Special
(***)

(*) To be used on TBA/21, TBA/22, TP A3/Flex, TP A3/CompactFlex, TP A3/Speed, TB/21, TP C3/Flex.

(**) To be used on TBA/8, TBA/9, TBA/19, TB/8, TB/9, TB/19.
(***) To be used only on C3/Flex.

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Cleaning Compounds 10 Technical Data

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10 - 10 (10) Doc. No. OM-3047611-0102

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