MM

Maintenance Manual
Cardboard Packer 30 Speed
663151-0200
TechPub_2614345_0107 - MM_3047612_0101fro.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. MM-3047612-0101

 TechPub_2614345_0107 - MM_3047612_0101fro.fm
Copyright © 2009 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
41100 Modena
Italy
Additional copies can be ordered from Tetra Pak. When ordering additional copies, always provide the
document number.
Doc. No. MM-3047612-0101
Issue 2009-09
 This manual is valid for: i Introduction

Series No./ Machine No. Sign.

ii Safety Precautions

1 Infeed Unit

MM
Maintenance Manual
2 Magazine Unit

3 Grouping Unit

4 Feed Unit
Cardboard Packer 30 Speed
663151-0200 5 Base Unit

6 Electrical System

7 Wrap Around Unit

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8 Machine Conversion

9 General

iii Index

Machine or equipment configurations that

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

Doc. No. MM-3047612-0101

Issue 2009-09

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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 Update Log for Doc. No. MM-3047612-0101
This table shows all changes made to this manual, including installed
rebuilding kits, added or removed pages. Page numbering on added pages
begins with UP.

Date Installed Kit Added Pages Removed Pages Signature

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

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 i Introduction
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Doc. No. MM-3047612-0101 i - 1 (16)

 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 (16) Doc. No. MM-3047612-0101

 i Introduction Table of Contents

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

Manual Information . . . . . . . . . . . . . . . . . . . . . . . . i - 7
Delivered Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . i - 7
Page Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 8
Page Numbering. . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 9
Typographical Conventions . . . . . . . . . . . . . . . . . . i - 9
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 9

Machine Introduction . . . . . . . . . . . . . . . . . . . . . i - 10
Intended Use of the Equipment . . . . . . . . . . . . . . i - 10
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 10
Support and Feedback . . . . . . . . . . . . . . . . . . . . . i - 10
Declaration of Conformity . . . . . . . . . . . . . . . . . . . i - 10
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Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 11
CE Classification . . . . . . . . . . . . . . . . . . . . . . . . . . i - 11
Machine Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 11

Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 12
Hygiene. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 14

How to Use This MM . . . . . . . . . . . . . . . . . . . . . . i - 15

Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 15
Procedure Start Table . . . . . . . . . . . . . . . . . . . . . . .i - 15
TPMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 16
Planned Maintenance Program . . . . . . . . . . . . . . .i - 16
Checklists and Spare Parts Recommendations . .i - 16

Doc. No. MM-3047612-0101 i - 3 (16)

 i Introduction

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i - 4 (16) Doc. No. MM-3047612-0101

 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
HMI Human Machine Interface
IM Installation Manual
I/O Input / Output (module)
LC Line Controller
LED Light Emitting Diode
LH Left Hand
max Maximum
min Minimum
MKC Mandatory Kit Corrective
MKS Mandatory Kit Human and
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Product Safety
MM Maintenance Manual
OK Optional Kit
OE Optional Equipment
OM Operation Manual
PLC Programmable Logic Controller
PLMS Packaging Line Monitoring
System
RAM Random Access Memory
RH Right Hand
RK Rebuilding Kit
ROM Read Only Memory
SP Service Pack
SPC Spare Parts Catalogue
TBA Tetra Brik Aseptic
TCF Tetra Conveyor Flexi
TD Turning Device
TeM Technical Manual
TPC Tetra Package Conveyor
TPMS Tetra Pak Maintenance System
TPOP Tetra Pak Operator Panel
Tray OF Tetra Tray with Over Flaps
UC Conveyor Unit
UK Upgrade Kit
WA Wrap Around unit

Doc. No. MM-3047612-0101 i - 5 (16)

Abbreviations and Terminology i Introduction

WAIF Tetra Wrap Around box with

Inside top Flap
WASF Tetra Wrap Around box with
Side Flap

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i - 6 (16) Doc. No. MM-3047612-0101

 i Introduction Manual Information

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_0107 - in01_3056454_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

Doc. No. MM-3047612-0101 i - 7 (16)

Manual Information i Introduction

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

1 2

9 General 9.2 Technical Data

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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

i - 8 (16) Doc. No. MM-3047612-0101

 i Introduction Manual Information

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.

Doc. No. MM-3047612-0101 i - 9 (16)

Machine Introduction i 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
41100 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.

i - 10 (16) Doc. No. MM-3047612-0101

 i Introduction Identification

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)

Doc. No. MM-3047612-0101 i - 11 (16)

Orientation i Introduction

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

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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)

i - 12 (16) Doc. No. MM-3047612-0101

 i Introduction Orientation

(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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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

Doc. No. MM-3047612-0101 i - 13 (16)

Hygiene i Introduction

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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i - 14 (16) Doc. No. MM-3047612-0101

 i Introduction How to Use This MM

How to Use This MM

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

1.5-3 Outfeed Servo - Change Bearings

Maintenance procedures in this manual are connected to the Tetra Pak

Maintenance System, TPMS. See the TPMS section.
Procedure Start Table
Procedures in this manual begin with a table providing information needed to
begin the procedure.
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• Machine Status (1) shows actuator status, program step, and any other
machine status necessary to begin the procedure.
• Special Equipment (2) shows a list of personal protective equipment and
special tools that are not normally carried by a service technician, but are
needed in the procedure.
• Consumables (3) shows items, such as lubricants, that are required to
perform the procedure. Consumables do not include replacement parts.
• SPC Reference (4) shows the assembly number, found in the index of
the SPC.

Machine Status Power supply disconnector OFF

Air valve OFF
1 Water valve OFF
Special Equipment Hook spanner TP No. 777170-0105
2 Dial indicator
Consumables Grease code F
3 SPC Reference 2501234-0100
4
1 Machine Status 3 Consumables
2 Special Equipment 4 SPC Reference

Doc. No. MM-3047612-0101 i - 15 (16)

How to Use This MM i Introduction

TPMS
To ensure uninterrupted production, all machines and equipment must be
maintained on a regular basis.
Tetra Pak has developed a planned maintenance system to keep pace with the
ongoing development of new and existing machines and equipment from
Tetra Pak, and to meet the demands set by customers for higher efficiency
and better economy.
Planned Maintenance Program
The Tetra Pak planned maintenance system reduces unplanned downtime
and maintenance time for complete production lines, as well as for individual
machines and equipment.
With the Tetra Pak planned maintenance system, preventive maintenance can
be performed before production is affected. The system is continually
updated based on experience with Tetra Pak machines and equipment
worldwide.
The Tetra Pak planned maintenance system maintains records of when
maintenance is performed, when parts are changed, whether alterations are
made, and so on. These records, combined with usage statistics, enable

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reliable predictions of the service life of all machine and equipment parts.
Checklists and Spare Parts Recommendations
Customers using the Tetra Pak planned maintenance system receive
checklists from their local Tetra Pak office whenever planned maintenance is
due. These checklists are individualised for each of Tetra Pak’s customer,
according to the type of machine, equipment usage, and maintenance
occasion. In addition, the system recommends spare parts, rotation units,
tools, and templates according to the statistics collected.
Tip! Contact the local Tetra Pak office for additional information about the
Tetra Pak Maintenance System and its planned maintenance program.

i - 16 (16) Doc. No. MM-3047612-0101

 ii Safety Precautions
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Doc. No. MM-3047612-0101 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. MM-3047612-0101

 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
Hotmelt Equipment . . . . . . . . . . . . . . . . . . . . . . . ii - 26
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 26

Doc. No. MM-3047612-0101 ii - 3 (30)

Table of Contents ii Safety Precautions

Hotmelt Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 27
Hotmelt Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 28

Equipment for Lifting and Moving Loads . . . . ii - 29

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ii - 4 (30) Doc. No. MM-3047612-0101

 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. MM-3047612-0101 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. MM-3047612-0101

 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. MM-3047612-0101 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. MM-3047612-0101

 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. MM-3047612-0101 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

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View of machine with magazine
unit on the RH side

(Cont'd)

ii - 10 (30) Doc. No. MM-3047612-0101

 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. MM-3047612-0101 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. MM-3047612-0101

 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
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Top view of machine with magazine unit

on the LH side

Doc. No. MM-3047612-0101 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. MM-3047612-0101

 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_0107 - sp01_3056455_01.fm

Top view of machine with magazine unit

on the LH side

(Cont'd)

Doc. No. MM-3047612-0101 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_0107 - sp01_3056455_01.fm
Top view of machine with magazine unit
on the LH side

(Cont'd)

ii - 16 (30) Doc. No. MM-3047612-0101

 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
TechPub_2614345_0107 - sp01_3056455_01.fm

Top view of machine with magazine unit

on the LH side

Doc. No. MM-3047612-0101 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.

TechPub_2614345_0107 - sp01_3056455_01.fm
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. MM-3047612-0101

 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
TechPub_2614345_0107 - sp01_3056455_01.fm

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. MM-3047612-0101 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.

TechPub_2614345_0107 - sp01_3056455_01.fm

ii - 20 (30) Doc. No. MM-3047612-0101

 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.
TechPub_2614345_0107 - sp01_3056455_01.fm

Doc. No. MM-3047612-0101 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.
‘

TechPub_2614345_0107 - sp01_3056455_01.fm
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. MM-3047612-0101

 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. MM-3047612-0101 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.

TechPub_2614345_0107 - sp01_3056455_01.fm

1 Socket outlet
2 Residual current device

1 2

ii - 24 (30) Doc. No. MM-3047612-0101

 ii Safety Precautions Supply Systems

Air Supply
WARNING
Compressed air and moving machinery.
Close the main air 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 main air valve (1), the lock (2), and their location.
.

1
Side view of machine with magazine unit
TechPub_2614345_0107 - sp01_3056455_01.fm

on the RH side

1 Main air valve

2 Lock

Doc. No. MM-3047612-0101 ii - 25 (30)

Supply Systems ii Safety Precautions

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

TechPub_2614345_0107 - sp01_3056455_01.fm
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.

ii - 26 (30) Doc. No. MM-3047612-0101

 ii Safety Precautions Supply Systems

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!
TechPub_2614345_0107 - sp01_3056455_01.fm

Doc. No. MM-3047612-0101 ii - 27 (30)

Supply Systems ii Safety Precautions

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!

TechPub_2614345_0107 - sp01_3056455_01.fm

ii - 28 (30) Doc. No. MM-3047612-0101

 Equipment for Lifting and Moving
ii Safety Precautions Loads

Equipment for Lifting and Moving Loads

WARNING
Risk of crushing injury.
Make sure that the capacity of the lifting equipment is adequate and that the
equipment itself is in proper working order.
If lifting tackle must be joined to make up the necessary lengths, make sure
that the joints are secure and have the same lifting capacity as the rest of the
lifting tackle.
Always engage safety clips fitted to lifting hooks to prevent the lifting tackle
from slipping off.
Use ropes or poles to steady and manoeuvre suspended loads. Do not use
hands or feet.
Make sure that the route and destination are free from obstacles before
moving a suspended load. It must always be possible to quickly and safely
lower the load to the floor in an emergency.
When depositing loads, keep lifting tackle in place until the stability of the
load has been substantiated.
TechPub_2614345_0107 - sp01_3056455_01.fm

Doc. No. MM-3047612-0101 ii - 29 (30)

Equipment for Lifting and Moving
Loads ii Safety Precautions

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ii - 30 (30) Doc. No. MM-3047612-0101

 1 Infeed Unit
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Doc. No. MM-3047612-0101 1 - 1 (134)

 1 Infeed Unit

Infeed Unit - Description

SPC Reference 663102-0200
Note! If not indicated in a different way, all the pictures used in the chapter
show the Infeed Unit for a machine with Magazine Unit on the RH side.

1.1

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1.2

1.3

1.1 Divider
1.2 Accumulation Unit
1.3 Infeed Conveyor

1 - 2 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit Table of Contents

1 Infeed Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
1-1 Infeed Unit - Functional Description . . . . . . . . . . 1 - 7
1-2 Infeed Unit - Setting Sequence, Type I . . . . . . . 1 - 10
1-3 Infeed Unit - Setting Sequence, Type II . . . . . . . 1 - 11
1-4 Infeed Unit - Setting Sequence, Type III . . . . . . 1 - 12

1.1 Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13
1.1-1 Divider - Set Belt Brakes Tension . . . . . . . . . . . 1 - 13
1.1-2 Divider - Check Parallelism . . . . . . . . . . . . . . . . 1 - 15
1.1-3 Divider - Set Width . . . . . . . . . . . . . . . . . . . . . . 1 - 16
1.1-4 Divider - Set Offset . . . . . . . . . . . . . . . . . . . . . . 1 - 19
1.1-5 Divider - Set Number of Units for Lane . . . . . . 1 - 21
1.1.1 Infeed Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 23
1.1.1-1 Infeed Brake - Set Photocells Position . . . . . . . . 1 - 23
1.1.1-2 Infeed Brake - Check . . . . . . . . . . . . . . . . . . . . . 1 - 25
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1.1.1-3 Infeed Brake - Change Timing Belts . . . . . . . . . 1 - 27

1.1.1-4 Infeed Brake - Overhaul . . . . . . . . . . . . . . . . . . . 1 - 28
1.1.1-5 Infeed Brake - Check Trolleys . . . . . . . . . . . . . . 1 - 32
1.1.2 Pivot Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 33
1.1.2-1 Pivot Arm - Check . . . . . . . . . . . . . . . . . . . . . . . 1 - 33
1.1.2-2 Pivot Arm - Overhaul . . . . . . . . . . . . . . . . . . . . . 1 - 34
1.1.3 Outfeed Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 38
1.1.3-1 Outfeed Brake - Set Timing Belts Tension . . . . 1 - 38
1.1.3-2 Outfeed Brake - Check . . . . . . . . . . . . . . . . . . . . 1 - 42
1.1.3-3 Outfeed Brake - Change Timing Belts . . . . . . . . 1 - 47
1.1.3-4 Outfeed Brake - Overhaul . . . . . . . . . . . . . . . . . 1 - 52
1.1.3-5 Outfeed Brake - Check Trolleys . . . . . . . . . . . . . 1 - 63
1.1.3-6 Outfeed Brake - Lubricate Trolleys . . . . . . . . . . 1 - 65

1.2 Accumulation Unit. . . . . . . . . . . . . . . . . . . . . . . 1 - 66

1.2-1 Accumulation Unit - Set Slide Rails . . . . . . . . . 1 - 66
1.2-2 Accumulation Unit - Set Conveyor Chains
Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 67
1.2-3 Accumulation Unit - Check Conveyor Chains . . 1 - 68

Doc. No. MM-3047612-0101 1 - 3 (134)

Table of Contents 1 Infeed Unit

1.2-4 Accumulation Unit - Check Guides . . . . . . . . . . 1 - 69

1.2.1 Grouping Conveyor. . . . . . . . . . . . . . . . . . . . . . . 1 - 70
1.2.1-1 Grouping Conveyor - Change Conveyor Chain 1 - 70
1.2.1-2 Grouping Conveyor - Check . . . . . . . . . . . . . . . 1 - 72
1.2.1-3 Grouping Conveyor - Overhaul . . . . . . . . . . . . . 1 - 74
1.2.1.1 Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 76
1.2.1.1-1 Drive Shaft - Check . . . . . . . . . . . . . . . . . . . . . . 1 - 76
1.2.1.1-2 Drive Shaft - Overhaul . . . . . . . . . . . . . . . . . . . 1 - 77
1.2.1.2 Chain Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 79
1.2.1.2-1 Chain Tensioner - Check Rollers . . . . . . . . . . . . 1 - 79
1.2.1.2-2 Chain Tensioner - Change Rollers . . . . . . . . . . . 1 - 80
1.2.2 Guide Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 82
1.2.2-1 Guide Rail - Set . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 82
1.2.3 Indexing Conveyor . . . . . . . . . . . . . . . . . . . . . . . 1 - 88
1.2.3-1 Indexing Conveyor - Change Conveyor Chain . 1 - 88

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1.2.3-2 Indexing Conveyor - Check . . . . . . . . . . . . . . . . 1 - 90
1.2.3-3 Indexing Conveyor - Overhaul . . . . . . . . . . . . . 1 - 92
1.2.3-4 Indexing Conveyor - Check Chain . . . . . . . . . . 1 - 94
1.2.3-5 Indexing Conveyor - Change Chain . . . . . . . . . 1 - 95
1.2.3-6 Indexing Conveyor - Set Chain Tension . . . . . . 1 - 96
1.2.3.1 Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 97
1.2.3.1-1 Drive Shaft - Check . . . . . . . . . . . . . . . . . . . . . . 1 - 97
1.2.3.1-2 Drive Shaft - Overhaul . . . . . . . . . . . . . . . . . . . 1 - 98
1.2.4 Accumulation Conveyor . . . . . . . . . . . . . . . . . . 1 - 100
1.2.4-1 Accumulation Conveyor - Change Conveyor
Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 100
1.2.4-2 Accumulation Conveyor - Check . . . . . . . . . . 1 - 102
1.2.4-3 Accumulation Conveyor - Overhaul . . . . . . . . 1 - 104
1.2.5 Divider Conveyor. . . . . . . . . . . . . . . . . . . . . . . . 1 - 106
1.2.5-1 Divider Conveyor - Change Conveyor Chains 1 - 106
1.2.5-2 Divider Conveyor - Check . . . . . . . . . . . . . . . . 1 - 108
1.2.5-3 Divider Conveyor - Overhaul . . . . . . . . . . . . . 1 - 110
1.2.6 Photocell Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 115
1.2.6-1 Photocell Unit - Set Position . . . . . . . . . . . . . . 1 - 115

1 - 4 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit Table of Contents

1.2.7 Conveyor Lubrication . . . . . . . . . . . . . . . . . . . . 1 - 129

1.2.7-1 Conveyor Lubrication - Set . . . . . . . . . . . . . . . 1 - 129
1.2.7-2 Conveyor Lubrication - Check . . . . . . . . . . . . . 1 - 130
1.2.7-3 Conveyor Lubrication - Clean Nozzles . . . . . . 1 - 131

1.3 Infeed Conveyor . . . . . . . . . . . . . . . . . . . . . . . 1 - 132

1.3-1 Infeed Conveyor - Set Speed . . . . . . . . . . . . . . 1 - 132
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Doc. No. MM-3047612-0101 1 - 5 (134)

 1 Infeed Unit

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1 - 6 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1 Infeed Unit

1 Infeed Unit
1-1 Infeed Unit - Functional Description
The packages are transported on the Infeed Conveyor (1) from the Filling
Machine to the Cardboard Packer, then the packages are transferred on the
Divider Conveyor (2) and feed into the machine by two belt brakes.
The first belt brake, called Infeed Brake (3) consists of two belts driven by
two separate drive motors controlled by a common frequency inverter. The
Infeed Brake (3) is running slower than the Divider Conveyor (2), due to the
different speeds, a gap between packages or units is created after the Infeed
Brake (3). The gap created is detected by a pair of photocells for two
purposes: count the packages for PLMS or measure the length of the unit
when running with film wrapped units.
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3 Infeed direction

1 Infeed conveyor
2 Divider conveyor
3 Infeed brake

(Cont'd)

Doc. No. MM-3047612-0101 1 - 7 (134)

1 Infeed Unit 1 Infeed Unit

(Cont'd)
The second belt brake, called Infeed Divider Brake (4) consists two servo
motors, one motor is controlling the sideways movement and one is
controlling the infeed of packages to the lanes true two belts.
The Infeed Divider Brake (4) is used to feed the packages into the different
lanes formed by a pair of slide rails (5), the amount of lines used is
depending by the packages pattern, (for example: 9 lanes are used when
running with the packing pattern 3x9).
The packages are then transported towards the Base Unit by the
Accumulation Conveyor (6).

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6

4
4 Infeed divider brake
5 Slide rail
6 Accumulation conveyor

(Cont'd)

1 - 8 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1 Infeed Unit

(Cont'd)
The packages are then transferred to the Indexing Conveyor (7) that will start
every time that the minimum queue photocells (9) are activated.
When the packages of all the lanes have reached the Stop Flight Bar and the
Minimum Queue Photocells (9) are activated, the Index Conveyor (7) will
run three cycles to compress the packages against the Stop Flight Bar.
The machine is also equipped with the Fallen Package Detector (8) and with
the Maximum Queue Photocells (10) that consists of a beam, with one
photocell for each lane, when a photocell is activated for a long time, the
Infeed Divider Brake (4) will stop to feed packages or units in that lane.

10
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4 Infeed divider brake

7 Indexing conveyor
8 Fallen package detector
9 Minimum queue photocell 4
10 Maximum queue photocell

Doc. No. MM-3047612-0101 1 - 9 (134)

1 Infeed Unit 1 Infeed Unit

1-2 Infeed Unit - Setting Sequence, Type I

Type I settings must be performed in sequence according to the flowchart
below. These settings are performed before the first start-up or
commissioning of the machine.

1.1-1 Divider - Set Belt Brakes Tension on 1.2.6-1 Photocell Unit - Set Position on page 1-115
page 1-13

1.1-2 Divider - Check Parallelism on page 1-15 1.2.7-1 Conveyor Lubrication - Set on page 1-129

1.1-3 Divider - Set Width on page 1-16 1.1-4 Divider - Set Offset on page 1-19

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1.1.1-1 Infeed Brake - Set Photocells Position on 1.1-5 Divider - Set Number of Units for Lane on
page 1-23 page 1-21

1.2.2-1 Guide Rail - Set on page 1-82 1.3-1 Infeed Conveyor - Set Speed on page 1-132

1 - 10 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1 Infeed Unit

1-3 Infeed Unit - Setting Sequence, Type II

Type II settings must be performed in sequence according to the flowchart
below. These settings are performed when the production change, in order to
adjust the Infeed Unit for the package unit in use and the packing pattern to
be produced.

1.1-3 Divider - Set Width on page 1-16

1.1.1-1 Infeed Brake - Set Photocells Position on

page 1-23

1.2.2-1 Guide Rail - Set on page 1-82

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1.2.6-1 Photocell Unit - Set Position on page 1-115

1.1-4 Divider - Set Offset on page 1-19

1.1-5 Divider - Set Number of Units for Lane on

page 1-21

Doc. No. MM-3047612-0101 1 - 11 (134)

1 Infeed Unit 1 Infeed Unit

1-4 Infeed Unit - Setting Sequence, Type III

Type III settings include all the remaining Infeed Unit setting procedures.
These settings can be performed independently and have no effect on any of
the other Infeed Unit settings.

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1 - 12 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

1.1 Divider
SPC Reference 2707845-0100

1.1-1 Divider - Set Belt Brakes Tension

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2707845-0100

For a good functioning of the machine, make sure that both belt brake
units (1) and (2) are tensioned correctly as follows on the next page.
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1
1 Belt brake (infeed)
infeed direction 2 Belt brake (outfeed)

(Cont'd)

Doc. No. MM-3047612-0101 1 - 13 (134)

1.1 Divider 1 Infeed Unit

(Cont'd)
Belt Brakes - Set Timing Belt Tension
Note! Check this setting on each belt brakes unit, before the first start up of
the machine and after any replacement of the timing belts (1).
Set the tension for each timing belt (1) as follows:
• loosen the four screws (2)
• make sure to remove the two screws (3)
• set the distance A using the two screws (4) then tighten the four
screws (2).

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4 1 4 1
2 2
Infeed brake Outfeed brake
A

A = 40 ±0.5 mm

4 3 2
1 Timing belt 1
2 Screw
Side view
3 Screw A
4 Screw

1 - 14 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

1.1-2 Divider - Check Parallelism

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2707845-0100
Note! Check the parallelism between the two timing belts (1) on both belt
brake units, before the first start up of the machine.
On both belt brake units, make sure that the timing belts (1) are parallel,
check using two packages placed at the ends of each belt brake. If required
fine adjust the parallelism with the three screws (3) and the four screws (4),
placed in the bottom of the plate (2).

3
2
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3
Infeed brake
1
1 4

1
Outfeed brake

// //
1 Timing belt
2 Plate
3 Screw
Top view
4 Screw
1

Doc. No. MM-3047612-0101 1 - 15 (134)

1.1 Divider 1 Infeed Unit

1.1-3 Divider - Set Width

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2707845-0100

Set the width of both belt brake units (1) and (2) according to the side of the
package unit coming into the machine, at the end of the setting also the width
of the pivot arm (3) will be set. Measure the distance A of the package unit
side (for package unit with straw applied, include also the diameter of the
straw when measuring the distance A), then perform the setting, as follows
on the next pages.

Single pack

A 3

TechPub_2614345_0107 - 0101_3057018_01.fm
2

Multi packs

1
Infeed direction
A (1X2)
A
(2X1)

1 Belt brake unit (infeed)

2 Belt brake unit (outfeed)
3 Pivot arm

(Cont'd)

1 - 16 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

(Cont'd)
Infeed Brake - Set Width
a) Loosen the locking lever (1).
Note! The following is only a basic setting, for some package units it may be
necessary to reduce the distance B.
b) Turn the handle (3) clockwise or counter clockwise until the correct
distance B between the two timing belts (2) is reached.
c) Tighten the locking lever (1).

1
TechPub_2614345_0107 - 0101_3057018_01.fm

3 1 3

2 Front view
A
B = A - 2 ±0.5 mm

B
1 Locking lever
2 Timing belt
3 Handle
2
(Cont'd)

Doc. No. MM-3047612-0101 1 - 17 (134)

1.1 Divider 1 Infeed Unit

(Cont'd)
Outfeed Brake - Set Width
a) Loosen the locking lever (1).
Note! The following is only a basic setting, for some package units it may be
necessary to reduce the distance B.
b) Turn the handle (3) clockwise or counter clockwise until the correct
distance B between the two timing belts (2) is reached.
c) Tighten the locking lever (1).

Note! Before starting the machine, make sure that the divider can be moved
freely in front of the lanes of the accumulation unit, by moving it sideways
with hands. During the PRODUCTION, check for the correct counting of the
packages, reduce the distance B if some errors happen.

TechPub_2614345_0107 - 0101_3057018_01.fm
3

2
Front view
A
B = A - 2 ±0.5 mm 1 3

B
1 Locking lever
2 Timing belt
3 Handle
2

1 - 18 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

1.1-4 Divider - Set Offset

Machine Status IDLE (STEP ZERO)
SPC Reference 2707845-0100
Note! Perform this setting in the following cases: at the first start up of the
machine, if the divider is not aligned with the first lane after have performed
the HOMING step or after every change of recipe.
a) On the TPOP, log on as: “tptechnician” or “supervisor” or “technician”,
see 6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) With the machine in IDLE, touch the MAINTENANCE button (1) and the
INFEED UNIT button (2), or touch the INFEED UNIT tab (3).
c) Touch the DIVIDER OFFSET icon (4) to display the dialogue window.

1 2 4
TechPub_2614345_0107 - 0101_3057018_01.fm

1 Maintenance button
2 Infeed unit button
3 Infeed unit tab
4 Divider offset icon

(Cont'd)

Doc. No. MM-3047612-0101 1 - 19 (134)

1.1 Divider 1 Infeed Unit

(Cont'd)
d) The offset value is displayed in the SETTING VALUE field (5). Set the
offset value to align the divider with the first lane, as follows:
• touch the FACTORY button (9) to display the factory value
• touch the DOUBLE-ARROW buttons (6) to increase or decrease the value
of 10 mm
• touch the SINGLE-ARROW buttons (7) to increase or decrease the value
of 1 mm
• touch the KEYBOARD button (8) to display the numeric keyboard, then
type the value
• touch the CONFIRMATION button (10) to confirm the value set
e) Touch the EXIT button (11).
f) Step up the machine to the HOMING step, in order to check if the divider
is aligned with the first lane, also if the first lane is not used to produce
the current recipe.

5 9 10 11

TechPub_2614345_0107 - 0101_3057018_01.fm
8

6 7 6

5 Setting value field 9 Factory button

6 Double-arrow button 10 Confirmation button
7 Single-arrow button 11 Exit button
8 Keyboard button

1 - 20 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

1.1-5 Divider - Set Number of Units for Lane

Machine Status Any STEP
SPC Reference 2707845-0100
Note! Perform this setting at the first start up of the machine and after every
change of recipe.
a) On the TPOP, log on as: “tptechnician” or “supervisor” or “technician”,
see 6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) Touch the MAINTENANCE button (1) and the INFEED UNIT
button (2), or touch the INFEED UNIT tab (3).
c) Touch the PACKAGE/UNITS FOR LANE icon (4) to display the
dialogue window.

1 2 4
TechPub_2614345_0107 - 0101_3057018_01.fm

1 Maintenance button
2 Infeed unit button
3 Infeed unit tab
4 Package/unit for lane icon

(Cont'd)

Doc. No. MM-3047612-0101 1 - 21 (134)

1.1 Divider 1 Infeed Unit

(Cont'd)
d) Set the number of packages (when running with single pack) or units
(when running with multi pack), released by the Divider for each lane, as
follows:
• the value set is displayed in the SETTING VALUE field (5)
• touch the FACTORY button (9) to display the factory value
• touch the DOUBLE-ARROW buttons (6) to increase or decrease the value
of 10 units
• touch the SINGLE-ARROW buttons (7) to increase or decrease the value
of 1 unit
• touch the KEYBOARD button (8) to display the numeric keyboard, then
type the value
• touch the CONFIRMATION button (10) to confirm the value set
e) Touch the EXIT button (11).
Note! Make sure that the photocells are set according to the new value set,
see Horizontal Setting for Photocells of Accumulation Unit on page 1-119.

5 9 10 11

TechPub_2614345_0107 - 0101_3057018_01.fm
8

6 7 6
5 Setting value field 9 Factory button
6 Double-arrow button 10 Confirmation button
7 Single-arrow button 11 Exit button
8 Keyboard button

1 - 22 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

1.1.1 Infeed Brake

1.1.1-1 Infeed Brake - Set Photocells Position
Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 2707844-0200

Photocells - Setting Position

Note! To set the sensitivity of the receiver photocell, see Transmitter/
Receiver Photocells (Through-Beam) - Set on page 6-296.
a) According to the package unit running on the machine, make sure that
both photocells (1) are positioned, so that:
• with single packs, the light barrier formed by the two photocells (1) pass
through the holes (2) existing on the brackets (3)
• with multi packs, the light barrier formed by the two photocells (1) pass
through the slots (4) existing on the brackets (3).
b) If required change the position of both photocells (1), see the next page.

1
TechPub_2614345_0107 - 0101_3057018_01.fm

Photocells position for Single packs

1

1 3 1

1 Photocell Side view

2 Hole
3 Bracket
4 Slot Photocells position for Multi packs

(Cont'd)

Doc. No. MM-3047612-0101 1 - 23 (134)

1.1 Divider 1 Infeed Unit

(Cont'd)
Photocells - Change Position
Change the position of both photocells (1) as follows.
a) Remove the two screws (2) to disconnect the support (3).
b) Remove the two screws (5) to disconnect the bracket (4) from the
support (3).
c) Assemble in the reverse order, making sure to install the support (3)
turned of 180°.

TechPub_2614345_0107 - 0101_3057018_01.fm
2

3
1
1 Photocell 4
2 Screw
3 Support
5
4 Bracket
5 Screw

1 - 24 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

1.1.1-2 Infeed Brake - Check

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2707844-0200

Check Timing Belts

Check that:
• both timing belts (1) are not worn or damaged, if required change them,
see 1.1.1-3 Infeed Brake - Change Timing Belts on page 1-27
• the tension of both timing belts (1) is set correctly, see 1.1-1 Divider -
Set Belt Brakes Tension on page 1-13.
TechPub_2614345_0107 - 0101_3057018_01.fm

1
1 Timing belt

(Cont'd)

Doc. No. MM-3047612-0101 1 - 25 (134)

1.1 Divider 1 Infeed Unit

(Cont'd)
Check Rollers and Drive Shafts
Note! The following instructions are valid for both belt brake units.
a) Remove the roller (1) and the timing belt (2), see 1.1.1-3 Infeed Brake -
Change Timing Belts on page 1-27.
b) Check that the roller (1) and the pulley (3) rotate freely without any play,
if not perform the 1.1.1-4 Infeed Brake - Overhaul on page 1-28.
c) Fit back the roller (1) and the timing belt (2).
d) Set the tension of the timing belt (2), see 1.1-1 Divider - Set Belt Brakes
Tension on page 1-13.

TechPub_2614345_0107 - 0101_3057018_01.fm
3

1 Roller 2
2 Timing belt
3 Pulley

1 - 26 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

1.1.1-3 Infeed Brake - Change Timing Belts

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2707844-0200
Note! The following instructions are valid for both belt brake units.
a) Remove the grub screws (1) and the screws (2).
b) Remove the screws (3), the brackets (4) and the roller (5).
c) Remove the screws (6) then turn and pull out the support (7).
Note! Make sure that the roller (5) and the pulley (9) rotate freely without
any play, if not see 1.1.1-4 Infeed Brake - Overhaul on page 1-28.
d) Replace the timing belt (8).
e) Assemble in the reverse order, making sure to push the support (7) in the
direction of the arrow before tightening the screws (6).
f) Set the tension of the timing belt (8), see 1.1-1 Divider - Set Belt Brakes
Tension on page 1-13.
TechPub_2614345_0107 - 0101_3057018_01.fm

7
9

1 Grub screw
2 Screw

8 5 3 Screw
4 Bracket
7 5 Roller
6 Screw
4 7 Support
1 8 Timing belt
3 2 9 Pulley

Doc. No. MM-3047612-0101 1 - 27 (134)

1.1 Divider 1 Infeed Unit

1.1.1-4 Infeed Brake - Overhaul

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2707844-0200
Note! The following instructions are valid for both belt brake units.
Change Ball Bearings on Roller
a) Remove the roller (1), see 1.1.1-3 Infeed Brake - Change Timing Belts
on page 1-27.
b) Remove the retaining ring (2) and take out the shaft (3).
c) Remove the two retaining rings (4).
d) Replace both ball bearings (5).
e) Reassemble the roller (1) in the reverse order.

TechPub_2614345_0107 - 0101_3057018_01.fm
3

5
1 Roller
2 Retaining ring
4
3 Shaft
4 Retaining ring
5 Ball bearing 1 2

(Cont'd)

1 - 28 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

(Cont'd)
Change Ball Bearings on Drive Shaft
a) Remove the screws (1) to disconnect the bracket (2) with the photocell.
b) Remove the screws (3) to disconnect the bracket (4).
c) Remove the screw (5) and the washer.
d) Remove the four screws (7) then pull out the motor (6), making sure to
not lose the key (8) of the drive shaft.

8
TechPub_2614345_0107 - 0101_3057018_01.fm

4
1
2
1 Screw 5 Screw
2 Bracket 6 Motor
3 Screw 7 Screw
4 Bracket 8 Key

(Cont'd)

Doc. No. MM-3047612-0101 1 - 29 (134)

1.1 Divider 1 Infeed Unit

(Cont'd)
e) Remove the three screws (9) and the flange (11).

CAUTION
Risk of minor or moderate injury.
Take care when removing the belt brake unit (13) due to the weight.
f) Remove the four screws (10) and the three screws (12), then disengage
and take out the belt brake unit (13).

11

TechPub_2614345_0107 - 0101_3057018_01.fm
10
12
9

13

9 Screw
10 Screw
11 Flange
12 Screw
13 Belt brake unit

(Cont'd)

1 - 30 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

(Cont'd)
g) Remove the parallel pin (14) and the pulley (15).
h) Remove the two retaining rings (16).
i) Replace both ball bearings (17).
j) Reassemble in the reverse order.
k) Set the tension of the timing belt, see 1.1-1 Divider - Set Belt Brakes
Tension on page 1-13.

16
17
TechPub_2614345_0107 - 0101_3057018_01.fm

17

16

14
15
14 Parallel pin
15 Pulley
16 Retaining ring
17 Ball bearings

Doc. No. MM-3047612-0101 1 - 31 (134)

1.1 Divider 1 Infeed Unit

1.1.1-5 Infeed Brake - Check Trolleys

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2707844-0200
Note! The trolleys (1) are life lubricated and due to the short run are almost
free of maintenance.
Check the trolleys (1) for any grease leakages. If required, clean the
trolleys (1) and the ends of the guide rail (2) from grease residues.

TechPub_2614345_0107 - 0101_3057018_01.fm
2

1 Trolley
2 Guide rail

1 - 32 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

1.1.2 Pivot Arm

1.1.2-1 Pivot Arm - Check
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2707843-0200

a) Check that:
• the guides (3) are not worn or damaged
• there is no an excessive play in the connections formed by the
brackets (1) and the plates (2).
b) If required change the parts damaged, see 1.1.2-2 Pivot Arm - Overhaul
on page 1-34.
TechPub_2614345_0107 - 0101_3057018_01.fm

2 1

1 2

1 Bracket
2 Plate
3 Guide

Doc. No. MM-3047612-0101 1 - 33 (134)

1.1 Divider 1 Infeed Unit

1.1.2-2 Pivot Arm - Overhaul

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2707843-0200

Pivot Arm - Disconnection

Remove the screws (1) and the washers to disconnect the pivot arms (2) from
the two belt brakes.

2
Outfeed belt brake

TechPub_2614345_0107 - 0101_3057018_01.fm
1

2
Infeed belt brake

1 Screw
2 Pivot arm 1

(Cont'd)

1 - 34 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

(Cont'd)
Pivot Arm - Parts Replacement
a) If necessary perform the following instructions for each pivot arm (1):
• separate the connection group (2) from the pivot arm (1)
• remove the screws (3) to replace the fingers (4)
• remove the screw (5) to replace the bushings (6) inside the connection
group (2)
• loosen the screws (8) and pull out the pin (7)
• loosen the screws (12) and pull out the guide group
• loosen the nuts (9) to separate the bar (10) from the guide (11)
• replace the guide (11) and assemble in the reverse order.

3 2
4
TechPub_2614345_0107 - 0101_3057018_01.fm

7
8

12 11 10 9
1 Pivot arm 5 Screw 9 Nut
2 Connection group 6 Bushing 10 Bar
3 Screw 7 Pin 11 Guide
4 Finger 8 Screw 12 Screw

(Cont'd)

Doc. No. MM-3047612-0101 1 - 35 (134)

1.1 Divider 1 Infeed Unit

(Cont'd)
b) Pull out the parallel pins (17) and the shafts (18) to disconnect the
brackets (15) from both ends of each pivot arm (1).
c) Replace the washers (19) and the bushings (20) then assemble in the
reverse order, making sure to fit back the brackets (15) with the hole for
the parallel pin (17) towards to the top and with the angled surface (16)
on the same side with the nuts (13) and the screws (14), as shown below.

Infeed direction

Top view

16
1 13 14 15 16

TechPub_2614345_0107 - 0101_3057018_01.fm
1
18
19 17
20

1 Pivot arm
13 Nut
14 Screw
15 Bracket
16 Angled surface
17 Parallel pin
18 Shaft 13 14 15 16
19 Washer
20 Bushing

(Cont'd)

1 - 36 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

(Cont'd)
Pivot Arm - Connection
Connect the pivot arms (1) to the two belt brakes with the screws (2) and the
washers, making sure that the screws (3) and the nuts (4) are placed on the
outer side, as shown below.

1
Outfeed belt brake
TechPub_2614345_0107 - 0101_3057018_01.fm

2
3 4

Infeed belt brake

2
1 Pivot arm
2 Screw
4 3
3 Screw
4 Nut

Doc. No. MM-3047612-0101 1 - 37 (134)

1.1 Divider 1 Infeed Unit

1.1.3 Outfeed Brake

1.1.3-1 Outfeed Brake - Set Timing Belts Tension
Machine Status Mains Power OFF
Air OFF
Water OFF
Special Equipment Dynamometer TP No. 74767-0102
SPC Reference 2707842-0200

Belt Brake Side Movement - Set Drive Belt Tension

a) Manually push the belt brake units fully towards the servo motors, until
they stop, then apply the dynamometer in the middle of the span of the
timing belt (1), with a force of 25 N the deflection must be 8 ± 1 mm. If
required adjust the tension as follows on the next page.

TechPub_2614345_0107 - 0101_3057018_01.fm

1 Timing belt

(Cont'd)

1 - 38 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

(Cont'd)
b) Fine adjust the tension of the timing belt (1) as follows:
• loosen the nuts (2) and (3) then fine adjust the tension of the timing
belt (1) with the setting screw (4)
• tighten the nut (2) then repeat the tension check, as described in the
previous page, until the correct value is reached
• at the end lock the setting screw (4) in position with the nut (3).

1
TechPub_2614345_0107 - 0101_3057018_01.fm

1 Timing belt
2 Nut
3 Nut
4 Setting screw

(Cont'd)

Doc. No. MM-3047612-0101 1 - 39 (134)

1.1 Divider 1 Infeed Unit

(Cont'd)
Belt Brake - Set Drive Belt Tension
Manually push the belt brake units fully towards the servo motors, until they
stop, then apply the dynamometer in the middle of the span of the timing
belt (1), with a force of 18 N the deflection must be 14 ± 1 mm. If required
adjust the tension of the timing belt (1) as follows:
• loosen the two screws (2) and the nut (3) then fine adjust the tension of
the timing belt (1) with the setting screw (4)
• tighten the screws (2) then repeat the tension check, as previously
described, until the correct value is reached
• at the end lock the setting screw (4) in position with the nut (3).

TechPub_2614345_0107 - 0101_3057018_01.fm
4

1
2
1 Timing belt
2 Screw 2
3 Nut 3
4 Setting screw

(Cont'd)

1 - 40 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

(Cont'd)
Belt Brake - Set Transmission Belt Tension
If required adjust the tension of the timing belt (1) as follows:
• loosen the three screws (2)
• move the flange group (3) to set the timing belt (1) tension
• tighten the three screws (2) then repeat the tension check, as previously
described, until the correct value is reached.

3
TechPub_2614345_0107 - 0101_3057018_01.fm

1 Timing belt
2 Screw
3 Flange group

Doc. No. MM-3047612-0101 1 - 41 (134)

1.1 Divider 1 Infeed Unit

1.1.3-2 Outfeed Brake - Check

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2707842-0200

Check Timing Belts

Check that:
• the timing belts (1), (2), (3) and (4) are not worn or damaged, if required
change them, see 1.1.3-3 Outfeed Brake - Change Timing Belts on
page 1-47
• the tension of both timing belts (1) is set correctly, see 1.1-1 Divider -
Set Belt Brakes Tension on page 1-13
• the tension of the timing belts (2), (3) and (4) is set correctly, see 1.1.3-1
Outfeed Brake - Set Timing Belts Tension on page 1-38.

TechPub_2614345_0107 - 0101_3057018_01.fm
3
2

1 Timing belt (belt brake)

2 Timing belt
(transmission belt for belt brake)
3 Timing belt
(drive belt for belt brake)
4 Timing belt
(drive belt for side movement)
1

(Cont'd)

1 - 42 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

(Cont'd)
Belt Brake - Check Rollers and Transmission Shafts
a) Remove the timing belt (1), see Belt Brake - Change Transmission Belt
on page 1-48.

1
TechPub_2614345_0107 - 0101_3057018_01.fm

1 Timing belt

(Cont'd)

Doc. No. MM-3047612-0101 1 - 43 (134)

1.1 Divider 1 Infeed Unit

(Cont'd)
b) Perform the following instructions on both belt brakes units:
• remove the roller (3) and the timing belt (5), see Belt Brake - Change
Timing Belts on page 1-47
• check that the roller (3) and the pulleys (2) and (4) rotate freely without
any play, if not see the 1.1.3-4 Outfeed Brake - Overhaul on page 1-52
• fit back the roller (3) and the timing belt (5)
• set the tension of the timing belt (5) see 1.1-1 Divider - Set Belt Brakes
Tension on page 1-13.
c) Fit back the timing belt (1), see Belt Brake - Change Transmission Belt
on page 1-48
d) Set the tension of the timing belt (1) see Belt Brake - Set Transmission
Belt Tension on page 1-41.

TechPub_2614345_0107 - 0101_3057018_01.fm
2

1 Timing belt
2 Pulley
3 4 3 Roller
4 Pulley
5 Timing belt
5

(Cont'd)

1 - 44 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

(Cont'd)
Drive Belt for Belt Brake - Check Pulleys
a) Remove the timing belt (1), see Belt Brake - Change Drive Belt on
page 1-49.
b) Check that the pulleys (2) rotate freely without any play, if not perform
the 1.1.3-4 Outfeed Brake - Overhaul on page 1-52.
c) Fit back the timing belt (1). Make pass the timing belt (1) round the
pulleys (2), as shown in the path below.
d) Set the tension of the timing belt (1), see Belt Brake - Set Drive Belt
Tension on page 1-40.

1 2
TechPub_2614345_0107 - 0101_3057018_01.fm

2 1 2

1 Timing belt
Timing belt path, top view 2 Pulley

(Cont'd)

Doc. No. MM-3047612-0101 1 - 45 (134)

1.1 Divider 1 Infeed Unit

(Cont'd)
Drive Belt for Side Movement - Check Wheel and Pulleys
a) Remove the timing belt (1), see Belt Brake Side Movement - Change
Drive Belt on page 1-50.
b) Check that the wheel (2) and the three pulleys (3) rotate freely without
any play, if not perform the 1.1.3-4 Outfeed Brake - Overhaul on
page 1-52.
c) Fit back the timing belt (1). Make pass the timing belt (1) round the
wheel (2) and the pulleys (3), as shown in the path below.
d) Set the tension of the timing belt (1), see Belt Brake Side Movement -
Set Drive Belt Tension on page 1-38.

TechPub_2614345_0107 - 0101_3057018_01.fm
1

2
3 3 1 Timing belt
2 Wheel
3 Pulley
Timing belt path, top view

1 - 46 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

1.1.3-3 Outfeed Brake - Change Timing Belts

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2707842-0200

Belt Brake - Change Timing Belts

Note! The following instructions are valid for both belt brake units.
a) Loosen the nut (1) and remove the setting screw (2).
b) Remove the two screws (3), the bracket (6) and the roller (4).
c) Remove and discard the timing belt (5).
Note! Make sure that the roller (4) and the pulley (7) rotate freely without
any play, if not see 1.1.3-4 Outfeed Brake - Overhaul on page 1-52.
d) Replace the timing belt (5) and assemble in the reverse order.
e) Set the tension of the timing belt (5), see 1.1-1 Divider - Set Belt Brakes
Tension on page 1-13.
TechPub_2614345_0107 - 0101_3057018_01.fm

1 7
1 Nut
3 2 Setting screw
2 3 Screw
3 6 4 Roller
4 5 Timing belt
6 Bracket
5 7 Pulley

(Cont'd)

Doc. No. MM-3047612-0101 1 - 47 (134)

1.1 Divider 1 Infeed Unit

(Cont'd)
Belt Brake - Change Transmission Belt
a) Remove the four screws (1) then remove and discard the timing belt (2).
Note! Make sure that both pulleys (4) rotate freely without any play, if not
see 1.1.3-4 Outfeed Brake - Overhaul on page 1-52.
b) Replace the timing belt (2) and assemble in the reverse order.
c) Check using a steel ruler (3) that the two pulleys (4) are aligned. If
required, loosen the four screws (5) and fine adjust the position of the
pulley until the alignment is reached, then tighten the four screws (5).

TechPub_2614345_0107 - 0101_3057018_01.fm
2 4

1 1

1 Screw
2 Timing belt
3 Steel ruler
4 Pulley
5 Screw
RH side view
4
(Cont'd)

1 - 48 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

(Cont'd)
Belt Brake - Change Drive Belt
a) Loosen the two screws (2) and the nut (3).
b) Release the tension of the timing belt (1) with the setting screws (4), then
remove and discard the timing belt (1).
Note! Make sure that the pulleys (5) rotate freely without any play, if not see
1.1.3-4 Outfeed Brake - Overhaul on page 1-52.
c) Replace the timing belt (1). Make pass the timing belt (1) round the
pulleys (5) and (6) as shown in the path below.
d) Set the tension of the timing belt (1), see Belt Brake - Set Drive Belt
Tension on page 1-40.
TechPub_2614345_0107 - 0101_3057018_01.fm

1
2
2
6 5 1 3 5
4
1 Timing belt
2 Screw
3 Nut
4 Setting screw
5 Pulley
Timing belt path, top view
6 Pulley

(Cont'd)

Doc. No. MM-3047612-0101 1 - 49 (134)

1.1 Divider 1 Infeed Unit

(Cont'd)
Belt Brake Side Movement - Change Drive Belt
a) Loosen the nuts (2) and (3).
b) Release the tension of the timing belt (1) with the setting screws (4).

TechPub_2614345_0107 - 0101_3057018_01.fm
2

1 4

1 Timing belt
2 Nut
3 Nut
4 Setting screw

(Cont'd)

1 - 50 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

(Cont'd)
c) Loosen the screws (5).
d) Separate the barriers (6) from the brackets (7), then remove and discard
the timing belt (1).
Note! Make sure that the wheel (8) and the pulleys (9) rotate freely without
any play, if not see 1.1.3-4 Outfeed Brake - Overhaul on page 1-52.
e) Replace the timing belt (1) and assemble in the reverse order. Make pass
the timing belt (1) round the wheel (8) and the pulleys (9) and (10), as
shown in the path below.
f) Set the tension of the timing belt (1), see Belt Brake Side Movement -
Set Drive Belt Tension on page 1-38.

1
TechPub_2614345_0107 - 0101_3057018_01.fm

1 10

7 6
1 Timing belt
8 5 Screw
6 Barrier
9
7 Bracket
8 Wheel
9 Pulley
Timing belt path, top view
10 Pulley

Doc. No. MM-3047612-0101 1 - 51 (134)

1.1 Divider 1 Infeed Unit

1.1.3-4 Outfeed Brake - Overhaul

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2707842-0200

Belt Brake - Change Ball Bearings on Rollers and on

Transmission Shafts
a) On both belt brake units, remove the roller (1) and the timing belt (2),
see Belt Brake - Change Timing Belts on page 1-47.
b) Replace the ball bearings (6) on both rollers (1), as follows:
• remove the ferrule (3)
• remove the retaining ring (4) and take out the shaft (7)
• remove the two retaining rings (5)
• replace both ball bearings (6)
• reassemble the roller (1) in the reverse order.

TechPub_2614345_0107 - 0101_3057018_01.fm
7

5
1 Roller
6 2 Timing belt
3 Ferrule
1 4 Retaining ring
5 5 Retaining ring

4 2 6 Ball bearing
7 Shaft
3
(Cont'd)

1 - 52 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

(Cont'd)
c) On both belt brake units, remove the screws (8) and the brackets (9).
d) Release the tension of the timing belt (10) with the setting screw (11).

10 11
TechPub_2614345_0107 - 0101_3057018_01.fm

8 Screw
9 Bracket
10 Timing belt
8 11 Setting screw
9

(Cont'd)

Doc. No. MM-3047612-0101 1 - 53 (134)

1.1 Divider 1 Infeed Unit

(Cont'd)

CAUTION
Risk of minor or moderate injury.
Take care when removing the belt brake units due to the weight.
e) Remove both belt brakes units as follows:
• remove the three screws (12) and the four screws (13)
• disengage and take out the belt brake unit.

TechPub_2614345_0107 - 0101_3057018_01.fm
12 13

12 Screw
13 Screw

(Cont'd)

1 - 54 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

(Cont'd)
f) Remove the four screws (21) to remove the timing belt (20).
g) On both belt brake units:
• remove the parallel pins (14) and the pulleys (15)
• loosen the fixing screws (22) of each clamping element (16) then
remove the clamping elements (16) and the pulleys (17)
• remove the retaining rings (18) and replace the six ball bearings (19).
h) Reassemble and fit back both belt brake units on the outfeed brake.

22 16 22 16
17 17
18 18
19 19

19
TechPub_2614345_0107 - 0101_3057018_01.fm

19 22 18
18 16
17 20
17
16 15 14
18 14 Parallel pin
22 19 19 15 Pulley
16 Clamping element
18 17 Pulley
18 Retaining ring
19 Ball bearing
20 Timing belt
21 Screw
22 Screw
21 21 15 14
(Cont'd)

Doc. No. MM-3047612-0101 1 - 55 (134)

1.1 Divider 1 Infeed Unit

(Cont'd)
i) Check using a steel ruler (23) that the two pulleys (17) are aligned. If
required, loosen the four screws (22) and fine adjust the position of the
pulley until the alignment is reached, then tighten the four screws (22).
j) Repeat on both belt brake units:
• fit back the roller (1) and the timing belt (2)
• set the tension of the timing belt (2), see 1.1-1 Divider - Set Belt Brakes
Tension on page 1-13
• fit back the bracket (9) with the screws (8).
k) Set the tension of the timing belt (10) with the setting screw (11), see
Belt Brake - Set Drive Belt Tension on page 1-40.

TechPub_2614345_0107 - 0101_3057018_01.fm
11

10 23 22

1
8
9 2

1 Roller 11 Setting screw

2 Timing belt 17 Pulley
8 Screw 22 Screw
9 Bracket 23 Steel ruler 17
10 Timing belt

(Cont'd)

1 - 56 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

(Cont'd)
Drive Belt for Belt Brake - Change Ball Bearings on Pulleys
a) Remove the setting screw (1) and the screws (3), then remove the
support (2).
b) Replace the ball bearing (6) on both pulleys (7), as follows:
• remove the retaining ring (4) and pull out the pulley (7)
• remove the retaining ring (5)
• replace the ball bearing (6)
• reassemble the pulley (7) on the support (2) in the reverse order.
Note! Do not fit back the support (2).
TechPub_2614345_0107 - 0101_3057018_01.fm

1 Setting screw
2 3
2 Support
3 Screw
3 7 4 Retaining ring
5 Retaining ring
6 6 Ball bearing
4 5 7 Pulley

(Cont'd)

Doc. No. MM-3047612-0101 1 - 57 (134)

1.1 Divider 1 Infeed Unit

(Cont'd)
c) Remove the three pulleys (10) by removing the nuts (8).
d) Replace the ball bearing (11) for each pulleys (10), as follows:
• remove the plug (15) and the gasket (14)
• remove the retaining ring (13) and take out the shaft (9)
• remove the retaining ring (12)
• replace the ball bearing (11)
• reassemble the pulley (10) in the reverse order.
e) Fit back the three pulleys (10) using the nuts (8).

15

TechPub_2614345_0107 - 0101_3057018_01.fm
14
13
12
11
10
9
8
8 Nut 12 Retaining ring
9 Shaft 13 Retaining ring
10 Pulley 14 Gasket
11 Ball bearing 15 Plug

(Cont'd)

1 - 58 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

(Cont'd)
f) Fit back the support (2) using the setting screw (1) and the screws (3).
g) Set the tension of the timing belt (16), see Belt Brake - Set Drive Belt
Tension on page 1-40.

16
1

3
TechPub_2614345_0107 - 0101_3057018_01.fm

2
1 Setting screw
2 Support
3 3 Screw
16 Timing belt

(Cont'd)

Doc. No. MM-3047612-0101 1 - 59 (134)

1.1 Divider 1 Infeed Unit

(Cont'd)
Drive Belt for Side Movement - Change Ball Bearings on Wheel
and Pulleys
a) Remove the nut (1), the setting screw (2) and the wheel (3).
b) Replace the ball bearings (5) of the wheel (3), as follows:
• remove the retaining ring (7) and take out the shaft (4)
• remove the retaining ring (6)
• replace both ball bearings (5)
• reassemble the wheel (3) in the reverse order.
Note! Do not fit back the wheel (3).

TechPub_2614345_0107 - 0101_3057018_01.fm
2

5
1 Nut 5 Ball bearing
2 Setting screw 6 Retaining ring
6 3 Wheel 7 Retaining ring
4 Shaft
7
(Cont'd)

1 - 60 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

(Cont'd)
c) Remove the three pulleys (9) by removing the nuts (8).
d) Replace the ball bearing (11) for each pulley (9), as follows:
• remove the retaining ring (13) and take out the shaft (10)
• remove the retaining ring (12)
• replace the ball bearing (11)
• reassemble the pulley (9) in the reverse order.
e) Fit back the three pulleys (9) using the nuts (8).

8
TechPub_2614345_0107 - 0101_3057018_01.fm

10

11
8 Nut 11 Ball bearing
12 9 Pulley 12 Retaining ring
10 Shaft 13 Retaining ring
13
(Cont'd)

Doc. No. MM-3047612-0101 1 - 61 (134)

1.1 Divider 1 Infeed Unit

(Cont'd)
f) Fit back the wheel (3) using the setting screw (2) and the nut (1).
g) Set the tension of the timing belt (14), see Belt Brake Side Movement -
Set Drive Belt Tension on page 1-38.

1
14

TechPub_2614345_0107 - 0101_3057018_01.fm
1 Nut
2 Setting screw
3 Wheel
14 Timing belt

1 - 62 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

1.1.3-5 Outfeed Brake - Check Trolleys

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2707842-0200
Note! The trolleys (1) are life lubricated and due to the short run are almost
free of maintenance.
a) Check the trolleys (1) for any grease leakages. If required, clean the
trolleys (1) and the ends of the guide rail (2) from grease residues.

1
TechPub_2614345_0107 - 0101_3057018_01.fm

1 Trolley
2 Guide rail

(Cont'd)

Doc. No. MM-3047612-0101 1 - 63 (134)

1.1 Divider 1 Infeed Unit

(Cont'd)
Note! The trolleys (3) are long life lubricated, but due to the long run, make
sure that they are always well lubricated.
b) Check the trolleys (3) for:
• any grease leakages, if required, clean the trolleys (3) and the ends of the
guide rail (4) from grease residues
• wear and damage, if required replace the trolleys (3)
• lubrication, if required lubricate the trolleys (3), see 1.1.3-6 Outfeed
Brake - Lubricate Trolleys on page 1-65.

3
4

TechPub_2614345_0107 - 0101_3057018_01.fm
3 4

3 Trolley
4 Guide rail
3

1 - 64 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.1 Divider

1.1.3-6 Outfeed Brake - Lubricate Trolleys

Machine Status Mains Power OFF
Air OFF
Water OFF
Special Equipment Pneumatic Grease Gun TP No. 1512559
Consumables Grease code F
SPC Reference 2707842-0200
Note! Lubricate the trolleys (1) every 4800 working hours or at least once a
year.
Lubricate the trolleys (1) through the nipple (2), with grease code F.

1
TechPub_2614345_0107 - 0101_3057018_01.fm

1 Trolley
1
2 Nipple

Doc. No. MM-3047612-0101 1 - 65 (134)

1.2 Accumulation Unit 1 Infeed Unit

1.2 Accumulation Unit

SPC Reference 2707834-0300

1.2-1 Accumulation Unit - Set Slide Rails

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2707834-0300
Note! Make sure that both slide rails (1) are installed with the rounded
corner opposite to the infeed direction, as shown below.
a) Repeat the following instructions on both sides of each slide rail (1):
• place a steel ruler on the top flat surface of the slide rail (1)
• check that the top flat surface is a bit lower than the conveyor chain (2)
and a bit higher than the conveyor chain (3), if required fine adjust the
position of the slide rail (1) with the screws (4).
b) During the PRODUCTION, check that the packages are transferred from
the conveyor chain (2) to the conveyor chain (3), without any trouble. If
required fine adjust the position of slide rails (1).

TechPub_2614345_0107 - 0101_3057019_01.fm
3 2
Infeed direction

1
4

1 Slide rail
2 Conveyor chain 1
3 Conveyor chain
4 Screw

1 - 66 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

1.2-2 Accumulation Unit - Set Conveyor Chains Tension

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2707834-0300

The tension of the conveyor chains (1), (2) and (3) can be set, with the chain
tensioner (4), until each conveyor chain is well driven by the sprockets (5) of
the drive shaft. Only for the conveyor chain (2), the chain tensioner (4) has to
be set in the upper position.
a) Set the chain tension, by modifying on both sides the vertical position of
the chain tensioner (4), as follows:
• fine adjust the position of the chain tensioner (4) with the screw (6),
make sure that the chain tensioner (4) is horizontal, by checking on both
sides if there is the same distance A, measured between the support (7)
and the top of the screw (6)
• tighten the nuts (8).
b) During the PRODUCTION, check if the conveyor chains (1), (2) and (3)
work correctly, if not repeat the setting.
TechPub_2614345_0107 - 0101_3057019_01.fm

6
2
7
1

1 4 8
1 Conveyor chain 4 Chain tensioner
(Grouping conveyor) 5 Sprocket
2 Conveyor chain 6 Screw
(Indexing conveyor) 7 Block
5 3 Conveyor chain 8 Nut
(Accumulation conveyor)

Doc. No. MM-3047612-0101 1 - 67 (134)

1.2 Accumulation Unit 1 Infeed Unit

1.2-3 Accumulation Unit - Check Conveyor Chains

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2707834-0300

Check the conveyor chains (1), (2), (3) and (4) for wear and damage, if
required change them, following the instructions listed below:
• for the conveyor chain (1) see 1.2.1-1 Grouping Conveyor - Change
Conveyor Chain on page 1-70
• for the conveyor chain (2) see 1.2.3-1 Indexing Conveyor - Change
Conveyor Chain on page 1-88
• for the conveyor chain (3) see 1.2.4-1 Accumulation Conveyor - Change
Conveyor Chain on page 1-100
• for the conveyor chains (4) see 1.2.5-1 Divider Conveyor - Change
Conveyor Chains on page 1-106.

TechPub_2614345_0107 - 0101_3057019_01.fm
3

1 Conveyor chain (Grouping conveyor)

2 Conveyor chain (Indexing Conveyor)
3 Conveyor chain (Accumulation conveyor)
4 Conveyor chain (Divider conveyor)

1 - 68 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

1.2-4 Accumulation Unit - Check Guides

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2707834-0300

Check all the guides (1), indicated with arrows, for wear and damage. If
required replace the guides (1) by removing the screws (2), then assemble in
the reverse order.
TechPub_2614345_0107 - 0101_3057019_01.fm

1 Guide
2 Screw
2

Doc. No. MM-3047612-0101 1 - 69 (134)

1.2 Accumulation Unit 1 Infeed Unit

1.2.1 Grouping Conveyor

1.2.1-1 Grouping Conveyor - Change Conveyor Chain
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2980535-0100
Note! Before starting, take note of the distance A, in order to reset the
conveyor chain tension, after the replacement.
a) Release the tension of the conveyor chain (1), see 1.2-2 Accumulation
Unit - Set Conveyor Chains Tension on page 1-67.
b) Lift and open the conveyor chain (1) by taking out a connection pin (2).
c) Remove and discard conveyor chain (1).

TechPub_2614345_0107 - 0101_3057019_01.fm
A
2 1

1 Conveyor chain
2 Connection pin

(Cont'd)

1 - 70 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

(Cont'd)
Note! Install a new conveyor chain (1) with the same length as the old.
d) Make pass the new conveyor chain (1) round the rollers (3), the
sprockets (4), the bars (5) and the chain tensioners (6), as shown below.
e) Lock the two parts of the conveyor chain (1) with a connection pin (2).
f) As a basic setting for the tension of the conveyor chain (1), reset the
distance A previously noted.

5 6 1 5

4 3 A
2 1
TechPub_2614345_0107 - 0101_3057019_01.fm

1 Conveyor chain
2 Connection pin
3 Roller
4 Sprocket
5 Bar
6 Chain tensioner

Doc. No. MM-3047612-0101 1 - 71 (134)

1.2 Accumulation Unit 1 Infeed Unit

1.2.1-2 Grouping Conveyor - Check

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2980535-0100

a) Open the conveyor chain (1), see 1.2.1-1 Grouping Conveyor - Change
Conveyor Chain on page 1-70.
b) Check that:
• the bars (2) and the slide rails (3) are not worn or damaged
• the rollers (4) are not worn or damaged and rotate freely without play.
c) If required change the parts damaged, see 1.2.1-3 Grouping Conveyor -
Overhaul on page 1-74.

4
2

1 4

TechPub_2614345_0107 - 0101_3057019_01.fm
2
3
2

1 Conveyor chain
2 Bar
3 Slide rail
4 Roller

(Cont'd)

1 - 72 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

(Cont'd)
d) Check the condition of the drive shaft (5), see 1.2.1.1-1 Drive Shaft -
Check on page 1-76 and of the chain tensioners (6) see 1.2.1.2-1 Chain
Tensioner - Check Rollers on page 1-79.
e) Lock the conveyor chain (1).

1 5 6
TechPub_2614345_0107 - 0101_3057019_01.fm

5
1 Conveyor chain
5 Drive shaft
6 Chain tensioner

Doc. No. MM-3047612-0101 1 - 73 (134)

1.2 Accumulation Unit 1 Infeed Unit

1.2.1-3 Grouping Conveyor - Overhaul

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2980535-0100

a) If not already done, remove the conveyor chain (1), see 1.2.1-1 Grouping
Conveyor - Change Conveyor Chain on page 1-70.
b) Replace both bars (3) as follows:
• on both sides remove the screws (2) to take out the bar (3)
• remove the screws (4) then separate the bar (3) from the support (5)
• fit a new bar (2) on the support (5) using a plastic hammer, then
assemble in the reverse order.
c) Replace the slide rails (6) by removing the screws (7).

7
3 6
3
1

TechPub_2614345_0107 - 0101_3057019_01.fm
2

4
2
1 Conveyor chain
2 Screw
3 Bar 5
4 Screw
5 Support
6 Slide rail
7 Screw

(Cont'd)

1 - 74 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

(Cont'd)
d) Replace the rollers (8) as follows:
• on both sides remove the screws (9) and take out the roller unit
• on one side, remove the retaining ring (10), then pull out the spacer (11)
and the rollers (8) from the shaft (12)
• replace the rollers (8) and assemble in the reverse order.
e) If required, perform the overhaul of the drive shaft (13), see 1.2.1.1-2
Drive Shaft - Overhaul on page 1-77.
f) If required, replace the rollers on the chain tensioners (14), see 1.2.1.2-2
Chain Tensioner - Change Rollers on page 1-79.
g) Fit back and lock the conveyor chain (1).
h) If required, tense the conveyor chain (1).

9
12

11 10
9
1 13 14 8 14
TechPub_2614345_0107 - 0101_3057019_01.fm

14
1 Conveyor chain
8 Roller
13
9 Screw
10 Retaining ring
11 Spacer
12 Shaft
13 Drive shaft
14 Chain tensioner

Doc. No. MM-3047612-0101 1 - 75 (134)

1.2 Accumulation Unit 1 Infeed Unit

1.2.1.1 Drive Shaft

1.2.1.1-1 Drive Shaft - Check
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2980522-0100
Note! Before starting, open and remove the conveyor chain that covers the
drive shaft (1).
Check that:
• the drive shaft (1) rotates freely without any play
• the sprockets (2) are not worn and damaged.
If required perform the 1.2.1.1-2 Drive Shaft - Overhaul on page 1-77.

TechPub_2614345_0107 - 0101_3057019_01.fm
2

1 Drive shaft
2 Sprocket

1 - 76 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

1.2.1.1-2 Drive Shaft - Overhaul

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2980522-0100

a) Remove the cover (1).

b) Remove the screw (2) and the washer, then remove the motor (3).
Note! Do not lose the key (4) of the drive shaft.
TechPub_2614345_0107 - 0101_3057019_01.fm

1 Cover 3
2 Screw
3 Motor
2
1
4 Key

(Cont'd)

Doc. No. MM-3047612-0101 1 - 77 (134)

1.2 Accumulation Unit 1 Infeed Unit

(Cont'd)
c) On both sides, remove the screws (5) and the two flange bearings (6).
d) Remove the drive shaft (7) from the conveyor.
e) Remove one of the screws (8) then pull out the sprockets (9).
f) Replace the two flange bearings (6) and the sprockets (9).
Note! During the assembly, place the sprockets (9) at the same distance
from each other on the drive shaft (7), making sure that a sprocket is placed
between the two screws (8) and the two outer sprockets are placed on the
edges of the conveyor chain.
g) Assemble and fit back the drive shaft (7) in the reverse order.

TechPub_2614345_0107 - 0101_3057019_01.fm
8
6
7

9 5
5 Screw
6 Flange bearing
7 Drive shaft
8 Screw
9 Sprocket

1 - 78 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

1.2.1.2 Chain Tensioner

1.2.1.2-1 Chain Tensioner - Check Rollers
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2707839-0100 (fixed)
2841329-0100 (movable)
Note! If required open and remove the conveyor chain that covers the chain
tensioner.
Check that the rollers (1) are not worn or damaged and rotate freely without
play, if required change them, see 1.2.1.2-2 Chain Tensioner - Change
Rollers on page 1-80.

Fixed chain tensioner

1
TechPub_2614345_0107 - 0101_3057019_01.fm

Movable chain tensioner

1

1 Roller

Doc. No. MM-3047612-0101 1 - 79 (134)

1.2 Accumulation Unit 1 Infeed Unit

1.2.1.2-2 Chain Tensioner - Change Rollers

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2707839-0100 (fixed)
2841329-0100 (movable)
Note! If required open and remove the conveyor chain that covers the chain
tensioner.
Fixed Chain Tensioner
a) Remove the two screws (1) and the washer, then take out the chain
tensioner from the conveyor.
b) Remove the retaining rings (2) and pull out the spacers (3) and the
rollers (4).
c) Replace the rollers (4) and assemble in the reverse order.
d) Fit back the chain tensioner using the screws (1).

TechPub_2614345_0107 - 0101_3057019_01.fm
1

2
3
4
3
2
1 1 Screw
2 Retaining ring
3 Spacer
4 Roller

(Cont'd)

1 - 80 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

(Cont'd)
Movable Chain Tensioner
a) Remove the two screws (1) and the flange (2), then take out the chain
tensioner from the conveyor.
b) Remove the bushing (3), the retaining rings (4) and pull out the
spacers (5) and the rollers (6).
c) Replace the rollers (6) and assemble in the reverse order.
d) Fit back the chain tensioner using the screws (1) and the flange (2).
TechPub_2614345_0107 - 0101_3057019_01.fm

4
5
6 1 Screw
5 2 Flange
3 Bushing
4
4 Retaining ring
3
5 Spacer
2 6 Roller
1

Doc. No. MM-3047612-0101 1 - 81 (134)

1.2 Accumulation Unit 1 Infeed Unit

1.2.2 Guide Rail

1.2.2-1 Guide Rail - Set
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2707836-0100

On the three shaft groups (2) are placed the guide rails (1) used to form the
lanes, where the packages are distributed in a certain number of queues,
necessary for the preparation of the packing pattern.
The machine is equipped with various blocks (3) to set the width of each
line, make sure to use the correct set of blocks according to the table below.

Package Type TP Part No. A (mm)

TBA 125S Multi Pack 2765894-0001 45
Portion Pack 2765894-0002 50
Family Pack 2765894-0004 78
TBA 125S Single Pack 2765894-0005 40

TechPub_2614345_0107 - 0101_3057019_01.fm
3
2

4 A

Setting for single portion pack, A

is shown

1 Guide rail
2 Shaft group
1
3 Block (portion pack)
4 Block (family pack)

(Cont'd)

1 - 82 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

(Cont'd)
Basic Setting
Make sure that each shaft (1) is centred, by checking on both sides, if there is
the same distance between the nut (2) and the end of the shaft (1). If required
centre each shaft (1) using the nuts (2) and (3).

1 = 1 1
TechPub_2614345_0107 - 0101_3057019_01.fm

Setting for single portion pack,

top view

= 1 Shaft
2 Nut
3 Nut
2
1
(Cont'd)

Doc. No. MM-3047612-0101 1 - 83 (134)

1.2 Accumulation Unit 1 Infeed Unit

(Cont'd)
Production Change
Note! Included with the machine there are two set of blocks, one to be used
for portion packs and one for family packs.
a) If the PRODUCTION changes, from portion pack to family pack and
vice versa, change the set of blocks, as follows:
• on one side of the shaft groups (1), loosen the nuts (3) and (4)
• change the blocks (2) on each shaft groups (1), making sure to set the
width for each lane, according to type of packages running on the
machine, see Lanes Width - Setting with Single Pack on page 1-86, or
see Lanes Width - Setting with Multi Pack on page 1-87
• tighten all the nuts (3) and (4), until the parts on the shaft groups (1) are
fully compacted.

TechPub_2614345_0107 - 0101_3057019_01.fm
2 1 2 1 2 1
Setting for single portion pack,
top view
1 Shaft group
2 Block
3 Nut
4 3
4 Nut

(Cont'd)

1 - 84 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

(Cont'd)
• tighten all the nuts (3) and (4), until the parts on the shaft groups (1) are
fully compacted.
b) Make sure that the guide rails are centred over the accumulation unit, on
both sides of the accumulation unit, check if there is the same distance
from the outer guide rails (5). If required centre using the nuts (4).

= =

= =

5 1 1 1
TechPub_2614345_0107 - 0101_3057019_01.fm

Setting for single portion pack,

top view
1 Shaft group
3 Nut
4 Nut
4 3
5 Outer guide rail

(Cont'd)

Doc. No. MM-3047612-0101 1 - 85 (134)

1.2 Accumulation Unit 1 Infeed Unit

(Cont'd)
Lanes Width - Setting with Single Pack
With single pack, use only one single block (1) to set the width between two
guide rails (2), so that there are as a result:
• maximum 10 lanes, when running with single portion packs
• maximum 6 lanes, when running with single family packs
Note! Only with single family packs, collect the guide rails (3) not used, in
the outer position and in equal number on both sides, as shown below.

Setting for single portion pack,

top view (10 lanes)
1 2

Setting for single family pack, 1 Block TechPub_2614345_0107 - 0101_3057019_01.fm

top view (6 lanes) 1 2 3 2 Guide rail
3 Outer guide rail

(Cont'd)

1 - 86 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

(Cont'd)
Lanes Width - Setting with Multi Pack
With multi pack, make sure to use the correct set of blocks when running
with TBA 125 S (see table on page 1-82), or use two or more blocks (1) to
set the width between two guide rails (2) for all the other packages,
according to the number of queue of packages forming the multi pack.
Note! Collect the guide rails (3) not used, in the outer position and if
possible in equal number on both sides, as shown below.

Example of setting with portion

multi pack
1 2 3
TechPub_2614345_0107 - 0101_3057019_01.fm

Example of setting with family 1 Block

multi pack 1 2 3 2 Guide rail
3 Outer guide rail

Doc. No. MM-3047612-0101 1 - 87 (134)

1.2 Accumulation Unit 1 Infeed Unit

1.2.3 Indexing Conveyor

1.2.3-1 Indexing Conveyor - Change Conveyor Chain
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2984735-0200
Note! Before starting, take note of the distance A, in order to reset the
conveyor chain tension, after the replacement.
a) Release the tension of the conveyor chain (1), see 1.2-2 Accumulation
Unit - Set Conveyor Chains Tension on page 1-67.
b) Lift and open the conveyor chain (1) by taking out a connection pin (2).
c) Remove and discard conveyor chain (1).

1
2

TechPub_2614345_0107 - 0101_3057019_01.fm
A
1 Conveyor chain
2 Connection pin

(Cont'd)

1 - 88 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

(Cont'd)
Note! Install a new conveyor chain (1) with the same length as the old.
d) Make pass the new conveyor chain (1) round the rollers (3), the
sprockets (4), the bars (5) and the chain tensioners (6), as shown below.
e) Lock the two parts of the conveyor chain (1) with a connection pin (2).
f) As a basic setting for the tension of the conveyor chain (1), reset the
distance A previously noted.

5 6 1 6 5

4 3 1 2
TechPub_2614345_0107 - 0101_3057019_01.fm

1 Conveyor chain
2 Connection pin
A
3 Roller
4 Sprocket
5 Bar
6 Chain tensioner

Doc. No. MM-3047612-0101 1 - 89 (134)

1.2 Accumulation Unit 1 Infeed Unit

1.2.3-2 Indexing Conveyor - Check

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2984735-0200

a) Open the conveyor chain (1), see 1.2.3-1 Indexing Conveyor - Change
Conveyor Chain on page 1-88.
b) Check that:
• the bars (2) and the slide rails (3) are not worn or damaged
• the rollers (4) are not worn or damaged and rotate freely without play
c) If required change the parts damaged, see 1.2.3-3 Indexing Conveyor -
Overhaul on page 1-92.

2
1 4

TechPub_2614345_0107 - 0101_3057019_01.fm
4 2

1 Conveyor chain
2 Bar
3 Slide rail
4 Roller

(Cont'd)

1 - 90 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

(Cont'd)
d) Check the condition of the drive shaft (5), see 1.2.3.1-1 Drive Shaft -
Check on page 1-97 and of the chain tensioners (6) see 1.2.1.2-1 Chain
Tensioner - Check Rollers on page 1-79.
e) Lock the conveyor chain (1).

5 6 6
TechPub_2614345_0107 - 0101_3057019_01.fm

5
1 Conveyor chain
5 Drive shaft
6 Chain tensioner

Doc. No. MM-3047612-0101 1 - 91 (134)

1.2 Accumulation Unit 1 Infeed Unit

1.2.3-3 Indexing Conveyor - Overhaul

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2984735-0200

a) If not already done, remove the conveyor chain (1), see 1.2.3-1 Indexing
Conveyor - Change Conveyor Chain on page 1-88.
b) Replace both bars (3) as follows:
• on both sides remove the screws (2) to take out the bar (3)
• remove the screws (4) then separate the bar (3) from the support (5)
• fit a new bar (3) on the support (5) using a plastic hammer, then
assemble in the reverse order.
c) Replace the slide rails (6) by removing the screws (7).

1
7 3

TechPub_2614345_0107 - 0101_3057019_01.fm
6

1 Conveyor chain
2 Screw
2 3 Bar
4 Screw
5 Support
6 Slide rail
4 5
7 Screw

(Cont'd)

1 - 92 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

(Cont'd)
d) Replace the rollers (8) as follows:
• on both sides remove the screws (9) and take out the roller unit
• on one side, remove the retaining ring (10), then pull out the spacer (11)
and the rollers (8) from the shaft (12)
• replace the rollers (8) and assemble in the reverse order.
e) If required, perform the overhaul of the drive shaft (13), see 1.2.3.1-2
Drive Shaft - Overhaul on page 1-98.
f) If required, replace the rollers on the chain tensioners (14), see 1.2.1.2-2
Chain Tensioner - Change Rollers on page 1-79.
g) Fit back and lock the conveyor chain (1).
h) If required, tense the conveyor chain (1).

13 14 1 8 14 12
TechPub_2614345_0107 - 0101_3057019_01.fm

11 10

8 9

1 Conveyor chain
8 Roller
9 Screw
10 Retaining ring
14 11 Spacer
13 12 Shaft
13 Drive shaft
14 Chain tensioner

Doc. No. MM-3047612-0101 1 - 93 (134)

1.2 Accumulation Unit 1 Infeed Unit

1.2.3-4 Indexing Conveyor - Check Chain

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2984735-0200

Check that:
• the chain (1) is not worn or damaged, if required change it, see 1.2.3-5
Indexing Conveyor - Change Chain on page 1-95
• the tension of the chain (1) is set correctly, see 1.2.3-6 Indexing
Conveyor - Set Chain Tension on page 1-96.

TechPub_2614345_0107 - 0101_3057019_01.fm
1

1 Chain

1 - 94 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

1.2.3-5 Indexing Conveyor - Change Chain

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2984735-0200

a) Remove the cover (1) with the two screws (2).

b) Manually push the sliding profile (3) inside the chain tensioner (4) then
block it in position by inserting a pin punch in the hole (5).
c) Remove and change the chain (6).
d) Remove the pin punch from the hole (5) to tense the chain (6).
e) Fit back the cover (1) with the two screws (2).

5
TechPub_2614345_0107 - 0101_3057019_01.fm

4 3

6 1 2
1 Cover
2 Screw
3 Sliding profile
4 Chain tensioner
5 Hole
6 Chain

Doc. No. MM-3047612-0101 1 - 95 (134)

1.2 Accumulation Unit 1 Infeed Unit

1.2.3-6 Indexing Conveyor - Set Chain Tension

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2984735-0100

Set the tension of the chain (1) as follows:

• loosen the two screws (2)
• set the chain tensioner (3) so that the sliding profile (4) is placed at the
distance A
• tighten the two screws (2).

3
A = 21 ±0.5 mm
A 2 1

TechPub_2614345_0107 - 0101_3057019_01.fm
4

1 Chain
2 Screw
3 Chain tensioner
4 Sliding profile

1 - 96 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

1.2.3.1 Drive Shaft

1.2.3.1-1 Drive Shaft - Check
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2707838-0100
Note! Before starting, open and remove the conveyor chain that covers the
drive shaft (1) then remove the drive chain.
Check that:
• the drive shaft (1) rotates freely without any play
• the sprockets (2) are not worn and damaged.
If required perform the 1.2.3.1-2 Drive Shaft - Overhaul on page 1-98.

2
TechPub_2614345_0107 - 0101_3057019_01.fm

1 Drive shaft
2 Sprocket

Doc. No. MM-3047612-0101 1 - 97 (134)

1.2 Accumulation Unit 1 Infeed Unit

1.2.3.1-2 Drive Shaft - Overhaul

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2707838-0100

a) Remove the cover (1).

b) Manually push the sliding profile (2) inside the chain tensioner (3) then
block it in position by inserting a pin punch in the hole (4).
c) Open and remove the chain (5).
d) Remove the sprocket (6), by removing the screw (7).
Note! Do not lose the key (8) of the drive shaft.

TechPub_2614345_0107 - 0101_3057019_01.fm
2

1
1 Cover
2 Sliding profile
3 Chain tensioner 8 5 6 7
4 Hole
5 Chain
6 Sprocket
7 Screw
8 Key

(Cont'd)

1 - 98 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

(Cont'd)
e) On both sides, remove the screws (9), the sealing rings (10) and the
bearing housings (11), then take out the drive shaft (15) from the
conveyor.
f) On both sides, remove the retaining rings (12), the ball bearings (13) and
the sealing rings (14).
g) Remove one of the screws (17) then pull out the sprockets (16).
h) Replace the parts (10), (13), (14) and (16).
Note! During the assembly, place the sprockets (16) at the same distance
from each other on the drive shaft (15), making sure that a sprocket is
placed between the two screws (17) and the two outer sprockets are placed
on the edges of the conveyor chain.
i) Assemble and fit back the drive shaft (15) in the reverse order.

16
TechPub_2614345_0107 - 0101_3057019_01.fm

15
14
13
12
11
10
9
17

9 Screw 14 Sealing ring

10 Sealing ring 15 Drive shaft
11 Bearing housing 16 Sprocket
12 Retaining ring 17 Screw
13 Ball bearing

Doc. No. MM-3047612-0101 1 - 99 (134)

1.2 Accumulation Unit 1 Infeed Unit

1.2.4 Accumulation Conveyor

1.2.4-1 Accumulation Conveyor - Change Conveyor Chain
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2980529-0200
Note! Before starting, take note of the distance A, in order to reset the
conveyor chain tension, after the replacement.
a) Release the tension of the conveyor chain (1), see 1.2-2 Accumulation
Unit - Set Conveyor Chains Tension on page 1-67.
b) Lift and open the conveyor chain (1) by taking out a connection pin (2).
c) Remove and discard conveyor chain (1).

TechPub_2614345_0107 - 0101_3057019_01.fm
A

1
2

1 Conveyor chain
2 Connection pin

(Cont'd)

1 - 100 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

(Cont'd)
Note! Install a new conveyor chain (1) with the same length as the old.
d) Make pass the new conveyor chain (1) round the rollers (3), the
sprockets (4), the bar (5) and the chain tensioners (6), as shown below.
e) Lock the two parts of the conveyor chain (1) with a connection pin (2).
f) As a basic setting for the tension of the conveyor chain (1), reset the
distance A previously noted.

5 6 1 6

4 3 3 A
TechPub_2614345_0107 - 0101_3057019_01.fm

1
2

1 Conveyor chain
2 Connection pin
3 Roller
4 Sprocket
5 Bar
6 Chain tensioner

Doc. No. MM-3047612-0101 1 - 101 (134)

1.2 Accumulation Unit 1 Infeed Unit

1.2.4-2 Accumulation Conveyor - Check

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2980529-0200

a) Open the conveyor chain (1), see 1.2.4-1 Accumulation Conveyor -

Change Conveyor Chain on page 1-100.
b) Check that:
• the bars (2) and the slide rails (3) are not worn or damaged
• the rollers (4) are not worn or damaged and rotate freely without play
c) If required change the parts damaged, see 1.2.4-3 Accumulation
Conveyor - Overhaul on page 1-104.

2 4
1

4 4

TechPub_2614345_0107 - 0101_3057019_01.fm
3
2

1 Conveyor chain
2 Bar
3 Slide rail
4 Roller

(Cont'd)

1 - 102 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

(Cont'd)
d) Check the condition of the drive shaft (5), see 1.2.1.1-1 Drive Shaft -
Check on page 1-76 and of the chain tensioners (6) see 1.2.1.2-1 Chain
Tensioner - Check Rollers on page 1-79.
e) Lock the conveyor chain (1).

6
5 6 1
TechPub_2614345_0107 - 0101_3057019_01.fm

1 Conveyor chain
5 5 Drive shaft
6 Chain tensioner

Doc. No. MM-3047612-0101 1 - 103 (134)

1.2 Accumulation Unit 1 Infeed Unit

1.2.4-3 Accumulation Conveyor - Overhaul

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2980529-0200

a) If not already done, remove the conveyor chain (1), see 1.2.4-1
Accumulation Conveyor - Change Conveyor Chain on page 1-100.
b) Replace the bar (3) as follows:
• on both sides remove the screws (2) to take out the bar (3)
• remove the screws (4) then separate the bar (3) from the support (5)
• fit a new bar (3) on the support (5) using a plastic hammer, then
assemble in the reverse order.
c) Replace the slide rails (6) by removing the screws (7).

TechPub_2614345_0107 - 0101_3057019_01.fm
7
6

1 Conveyor chain
2 Screw
3 Bar
4 Screw
2 5 Support
6 Slide rail
4 5 7 Screw

(Cont'd)

1 - 104 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

(Cont'd)
d) Replace the rollers (8) as follows:
• on both sides remove the screws (9) and take out the roller unit
• on one side, remove the retaining ring (10), then pull out the spacer (11)
and the rollers (8) from the shaft (12)
• replace the rollers (8) and assemble in the reverse order.
e) If required, perform the overhaul of the drive shaft (13), see 1.2.1.1-2
Drive Shaft - Overhaul on page 1-77.
f) If required, replace the rollers on the chain tensioners (14), see 1.2.1.2-2
Chain Tensioner - Change Rollers on page 1-79.
g) Fit back and lock the conveyor chain (1).
h) If required, tense the conveyor chain (1).

14

13 14 1 8 8 12
TechPub_2614345_0107 - 0101_3057019_01.fm

11 10

8 9

1 Conveyor chain 11 Spacer

14 13 8 Roller 12 Shaft
9 Screw 13 Drive shaft
10 Retaining ring 14 Chain tensioner

Doc. No. MM-3047612-0101 1 - 105 (134)

1.2 Accumulation Unit 1 Infeed Unit

1.2.5 Divider Conveyor

1.2.5-1 Divider Conveyor - Change Conveyor Chains
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2984730-0200

Outer Conveyor Chains

Note! The following instructions are valid for both outer conveyor chains (1).
a) Lift and open the conveyor chain (1) by taking out a connection pin (2).
b) Remove and discard conveyor chain (1).
Note! Install a new conveyor chain (1) with the same length as the old.
c) Make pass the new conveyor chain (1) round the rollers (3) and the
sprockets (4), as shown below.
d) Lock the two parts of the conveyor chain (1) with a connection pin (2).

TechPub_2614345_0107 - 0101_3057019_01.fm
4 3 1 3
1
2

1 Conveyor chain (outer)

2 Connection pin
3 Roller
4 Sprocket

(Cont'd)

1 - 106 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

(Cont'd)
Middle Conveyor Chain
a) Lift and open the conveyor chain (1) by taking out a connection pin (2).
b) Remove and discard conveyor chain (1).
Note! Install a new conveyor chain (1) with the same length as the old.
c) Make pass the new conveyor chain (1) round the rollers (3) and the
sprockets (4), as shown below.
d) Lock the two parts of the conveyor chain (1) with a connection pin (2).

4 3 1 3 2 1 3
TechPub_2614345_0107 - 0101_3057019_01.fm

1 Conveyor chain (middle)

2 Connection pin
3 Roller
4 Sprocket

Doc. No. MM-3047612-0101 1 - 107 (134)

1.2 Accumulation Unit 1 Infeed Unit

1.2.5-2 Divider Conveyor - Check

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2984730-0200

a) Open both outer conveyor chains (1) and the middle conveyor chain (2)
by removing the connection pins (3).

3 1 2

TechPub_2614345_0107 - 0101_3057019_01.fm
1 Conveyor chain (outer)
2 Conveyor chain (middle)
3 Connection pin

(Cont'd)

1 - 108 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

(Cont'd)
b) Check that:
• the slide rails (4) are not worn or damaged
• the rollers (5) are not worn or damaged and rotate freely without play
• the drive shaft (6) rotates freely without any play
• the sprockets (7) are not worn and damaged.
c) If required change the parts damaged, see 1.2.5-3 Divider Conveyor -
Overhaul on page 1-110.
d) Lock the conveyor chains.

5 4
TechPub_2614345_0107 - 0101_3057019_01.fm

7
6
4 Slide rail
5 Roller
6 Drive shaft
7 Sprocket

Doc. No. MM-3047612-0101 1 - 109 (134)

1.2 Accumulation Unit 1 Infeed Unit

1.2.5-3 Divider Conveyor - Overhaul

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2984730-0200
Note! If not already done remove the conveyor chains, then perform the
following instructions, at the end fit back and lock the conveyor chains, see
1.2.5-1 Divider Conveyor - Change Conveyor Chains on page 1-106.
Slide Rails - Replacement
Replace the slide rails (1) by removing the screws (2).

2 1

TechPub_2614345_0107 - 0101_3057019_01.fm

1 Slide rail
2 Screw

(Cont'd)

1 - 110 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

(Cont'd)
Drive Shaft - Overhaul
a) Remove the cover (1).
b) Remove the screw (2) and the washer, then remove the motor (3).
Note! Do not lose the key (4) of the drive shaft.

1
2
3
4
TechPub_2614345_0107 - 0101_3057019_01.fm

1 Cover
2 Screw
3 Motor
4 Key

(Cont'd)

Doc. No. MM-3047612-0101 1 - 111 (134)

1.2 Accumulation Unit 1 Infeed Unit

(Cont'd)
c) Remove the screws (5) on both sides.
d) Remove the bearing housing (6), then pull out the retaining ring (7), the
ball bearing (8) and the sealing ring (9) from the bearing housing (6).
e) Remove the sealing ring (11), the retaining rings (12), the ball
bearing (13), the bearing housing (10) and the sealing ring (14).
f) Take out the drive shaft (15), then remove the screws (16) and the
sprockets (17) from the drive shaft (15).
g) Replace the parts (8), (9), (13), (14) and (17).
Note! During the assembly, place the sprockets (17) at the same distance
from each other on the drive shaft (15), making sure that a sprocket is
placed between each couple of screws (16).
h) Assemble and fit back the drive shaft (15) in the reverse order.

5
6

TechPub_2614345_0107 - 0101_3057019_01.fm
5
13
7 8
9
15
16
17
14
10
12
11
5 Screw 10 Bearing housing 15 Drive shaft
6 Bearing housing 11 Sealing ring 16 Screw
7 Retaining ring 12 Retaining ring 17 Sprocket
8 Ball bearing 13 Ball bearing
9 Sealing ring 14 Sealing ring

(Cont'd)

1 - 112 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

(Cont'd)
Long Chain Tensioners - Change Rollers
Note! The following instructions are valid for the three chain tensioners
indicated with arrows.
a) Remove the two screws (1) and the washer, then take out the roller chain
tensioner from the conveyor.
b) Remove the retaining rings (2) and pull out the spacers (3) and the
rollers (4).
c) Replace the rollers (4) and assemble in the reverse order.
d) Fit back the chain tensioner using the screws (1).
TechPub_2614345_0107 - 0101_3057019_01.fm

4 3 2 1

1 Screw
2 Retaining ring
3 Spacer
4 Roller

(Cont'd)

Doc. No. MM-3047612-0101 1 - 113 (134)

1.2 Accumulation Unit 1 Infeed Unit

(Cont'd)
Short Chain Tensioners - Change Rollers
Note! The following instructions are valid for both chain tensioners indicated
with arrows.
a) Remove the slide rail (1) by removing the screws (2).
b) On the free side from the infeed conveyor, remove all the fixing screws
and the covering plate (3), in order to discover both chain tensioner.
c) Without taking out the chain tensioner, remove the retaining rings (4)
and pull out the spacers (5) and the rollers (6).
d) Replace the rollers (6) and assemble in the reverse order.

1
2

TechPub_2614345_0107 - 0101_3057019_01.fm
3

6
5
4

1 Slide rail
2 Screw
3 Covering plate
4 Retaining ring
5 Spacer
6 Roller

1 - 114 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

1.2.6 Photocell Unit

1.2.6-1 Photocell Unit - Set Position
Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 2724882-0200

Basic Setting for Photocells of Accumulation Unit

On both sides, make sure that the photocells (1), of the fallen package
detector (3) and of the min queue accumulation (4), are placed in the upper
position. If required fine adjust using the screws (2).
Note! Make sure that the sensitivity of the receiver photocells (1) is set
correctly, for more information seeTransmitter/Receiver Photocells
(Through-Beam) - Set on page 6-296.

3 4 Infeed direction
TechPub_2614345_0107 - 0101_3057019_01.fm

Side view

1 Photocell
2 2 Screw
1 3 Fallen package detector
4 Min queue accumulation

(Cont'd)

Doc. No. MM-3047612-0101 1 - 115 (134)

1.2 Accumulation Unit 1 Infeed Unit

(Cont'd)
Vertical Setting for Photocells of Accumulation Unit
a) On both sides, set the height of the max queue guard (1), using the
screws (3), so that the top side of the bracket (2) is at the distance A,
from the top side of the package.

Infeed direction

Side view

A
2

TechPub_2614345_0107 - 0101_3057019_01.fm
3
1

A = 100 ±0.5 mm

1 Max queue guard

2 Bracket
3 Screw

(Cont'd)

1 - 116 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

(Cont'd)
b) On both sides, set the height of the min queue accumulation (6), using
the screws (5), so that the top side of the bracket (4) is at the distance B,
from the top side of the package.

Infeed direction

Side view

B 4
6
5
TechPub_2614345_0107 - 0101_3057019_01.fm

B = 110 ±0.5 mm

4 Bracket
5 Screw
6 Min queue accumulation

(Cont'd)

Doc. No. MM-3047612-0101 1 - 117 (134)

1.2 Accumulation Unit 1 Infeed Unit

(Cont'd)
c) On both sides, set the height of the fallen package detector (12), using
the screws (11), so that the top side of the bracket (10) is at the
distance C, from the top side of the package.

Infeed direction

Side view

C 10
12

TechPub_2614345_0107 - 0101_3057019_01.fm
11

C = 105 ±0.5 mm

7 Bracket
8 Screw
9 Fallen package detector

(Cont'd)

1 - 118 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

(Cont'd)
Horizontal Setting for Photocells of Accumulation Unit
a) Measure the distance A, of the face of one single package.
Note! To obtain the distance B, multiply the distance A for the total number
of packages released for each lane by the divider, see the value set in
1.1-5 Divider - Set Number of Units for Lane on page 1-21.
b) On both sides, set the max queue guard (1) at the distance B, from the
plate (2), using the screws (3).

2
Infeed direction

B
TechPub_2614345_0107 - 0101_3057019_01.fm

Side view
3
B = A x (Total number of packages for each lane) ±0.5 mm

1 Max queue guard

2 Plate
A 3 Screw

(Cont'd)

Doc. No. MM-3047612-0101 1 - 119 (134)

1.2 Accumulation Unit 1 Infeed Unit

(Cont'd)
c) On both sides, set the min queue accumulation (4) using the screws (5),
at the distance C, from the covering plate (6).

Infeed direction

Side view

4
A

TechPub_2614345_0107 - 0101_3057019_01.fm
5 C = A + 45 ±0.5 mm

4 Min queue accumulation

5 Screw
6 Covering plate

(Cont'd)

1 - 120 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

(Cont'd)
d) On both sides, set the fallen package detector (7) using the screws (8), at
the distance D, from the support (9).

Infeed direction

Side view

D = 350 ±0.5 mm
D

7
TechPub_2614345_0107 - 0101_3057019_01.fm

7 Fallen package detector

9 8 Screw
9 Support

(Cont'd)

Doc. No. MM-3047612-0101 1 - 121 (134)

1.2 Accumulation Unit 1 Infeed Unit

(Cont'd)
Final Setting for Photocells of Accumulation Unit
Note! Before starting, make sure that the guide rails (4) are set correctly
according to the packing pattern to be produced, see 1.2.2-1 Guide Rail -
Set on page 1-82.
a) On the max queue guard (1), adjust the position of each reflection
photocell (2) with the screw (3), so that:
• starting from the magazine unit side, there is one single reflection
photocell (2) placed in the middle of each lane formed by two guide
rails (4)
• only when running with single family pack or with multi pack, the
photocells not in use, must be fully moved aside on the opposite side of
the magazine unit side.

3
Setting for single portion pack, front view
1
(10 lanes)

TechPub_2614345_0107 - 0101_3057019_01.fm
Infeed direction

4 ==

1 Max queue guard

Setting for single family pack, front view = = 2 Reflection photocell
(6 lanes) 3 Screw
4 Guide rail

(Cont'd)

1 - 122 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

(Cont'd)
Note! Make sure to set the sensitivity of each reflection photocells (2) so
that: the standing packages and the fallen packages are always detected,
whilst it is very important that the conveyor chain (5) is never detected. For
more information see Reflection Photocells - Set on page 6-293.

5 2

Infeed direction
TechPub_2614345_0107 - 0101_3057019_01.fm

Side view

2 Reflection photocell
5 Conveyor chain

(Cont'd)

Doc. No. MM-3047612-0101 1 - 123 (134)

1.2 Accumulation Unit 1 Infeed Unit

(Cont'd)
Note! Make sure that all the indicators (6) installed on the machine, are
placed in the correct direction, so that they can be lifted by the packages
passing below.
b) On the min queue accumulation (7), fit or remove the indicators (6) with
the screws (3), until the number of indicators (6) match the number of
lanes, then set the position of each indicator (6) in the middle of each
lane formed by two guide rails (4).

3
7
Setting for single portion pack, front view
(10 lanes)

Infeed direction

TechPub_2614345_0107 - 0101_3057019_01.fm
4 ==

3 Screw
Setting for single family pack, front view = = 4 Guide rail
(6 lanes) 6 Indicator
7 Min queue accumulation

(Cont'd)

1 - 124 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

(Cont'd)
c) On the fallen package detector (8), fit or remove the indicators (6) with
the screws (3), until the number of indicators (6) match the number of
lanes, then set the position of each indicator (6) in the middle of each
lane formed by two guide rails (4).

8
3
Setting for single portion pack, front view
(10 lanes)

Infeed direction

4 ==
TechPub_2614345_0107 - 0101_3057019_01.fm

3 Screw
4 Guide rail
Setting for single family pack, front view = = 6 Indicator
(6 lanes)
8 Fallen package detector

(Cont'd)

Doc. No. MM-3047612-0101 1 - 125 (134)

1.2 Accumulation Unit 1 Infeed Unit

(Cont'd)
Basic Setting for Photocells of Divider
Note! To set the sensitivity of the receiver photocells installed in the divider,
see Transmitter/Receiver Photocells (Through-Beam) - Set on page 6-296.
a) On both sides, make sure that the light barrier formed by the two lower
photocells (2), pass in the middle of the space existing between the
timing belts (4) of the outfeed belt brake and the conveyor chain (3).
If required fine adjust the position of each lower photocell (2) using the
two screws (1).

Infeed direction

TechPub_2614345_0107 - 0101_3057019_01.fm
Side view

1 2 3 4
1 Screw
2 Lower photocell (trailing counter)
3 Conveyor chain
4 Timing belt

(Cont'd)

1 - 126 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

(Cont'd)
b) On both sides, make sure that the light barrier formed by the two upper
photocells (5), pass at the distance A from the timing belts (4) of the
outfeed belt brake. If required fine adjust the position of each upper
photocell (5) using the four screws (6).

Infeed direction

Side view
6 5 6 4 4
TechPub_2614345_0107 - 0101_3057019_01.fm

A = 2 ÷ 3 mm

Top view
4 Timing belt
5 Upper photocell (leading counter)
6 Screw 5 6

(Cont'd)

Doc. No. MM-3047612-0101 1 - 127 (134)

1.2 Accumulation Unit 1 Infeed Unit

(Cont'd)
c) On both sides, make sure that the photocells (7) are placed fully towards
the base machine, as shown below. If required fine adjust the position of
each photocell (7) using the two screws (8).

7 Infeed direction

TechPub_2614345_0107 - 0101_3057019_01.fm
Side view

7 Photocell (divider congestion)

8 Screw

1 - 128 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

1.2.7 Conveyor Lubrication

1.2.7-1 Conveyor Lubrication - Set
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2787099-0100

The surface of the conveyor chain (1) must be evenly lubricated by the water
spray, if required loosen the valves (2) and fine adjust their position, as
shown below.
TechPub_2614345_0107 - 0101_3057019_01.fm

1
2

1 Conveyor chain
2 Valve

Doc. No. MM-3047612-0101 1 - 129 (134)

1.2 Accumulation Unit 1 Infeed Unit

1.2.7-2 Conveyor Lubrication - Check

Machine Status PRODUCTION
SPC Reference 2787099-0100

Check that:
• check that the water spray reach the conveyor chain (1) and that the
surface is evenly lubricated, if required fine adjust the valves (3), see
1.2.7-1 Conveyor Lubrication - Set on page 1-129.
• the nozzles (2) are not clogged for lime deposits, if required clean them,
see 1.2.7-3 Conveyor Lubrication - Clean Nozzles on page 1-131.
• the hoses and the connections for leakages, change them if required.

1 TechPub_2614345_0107 - 0101_3057019_01.fm
3 2

1 Conveyor chain
2 Nozzle
3 Valve

1 - 130 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.2 Accumulation Unit

1.2.7-3 Conveyor Lubrication - Clean Nozzles

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2787099-0100
Note! Do not lose the gasket (2) inside the nozzle (1).
a) Remove the nozzles (1) and clean them from lime deposits as follows:
• rinse with water
• blow with compressed air.
b) Fit back the nozzles (1).

2
TechPub_2614345_0107 - 0101_3057019_01.fm

1 Nozzle
2 Gasket

Doc. No. MM-3047612-0101 1 - 131 (134)

1.3 Infeed Conveyor 1 Infeed Unit

1.3 Infeed Conveyor

SPC Reference 2854211-0100

1.3-1 Infeed Conveyor - Set Speed

Machine Status PREHEATING
Special Equipment Tachometer TP No. 90243-105
SPC Reference 2854211-0100
Note! Perform this setting at the first start up of the machine.
a) On the TPOP, log on as: “tptechnician” or “supervisor” or “technician”,
see 6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) With the machine in PREHEATING, touch the MAINTENANCE
button (1) and the INFEED UNIT button (2), or touch the INFEED
UNIT tab (3).
c) Touch the INFEED CONVEYOR icon (4) to display the dialogue
window.
d) Touch the ON button (5) to select the infeed conveyor starting function.
e) Touch the CONFIRMATION button (6) to run the infeed conveyor, at the
same time using a tachometer, measure the speed in m/min.

TechPub_2614345_0107 - 0101_3057020_01.fm
1 2 4

3 5

1 Maintenance button
2 Infeed unit button
3 Infeed unit tab
4 Infeed conveyor icon 6
5 ON button
6 Confirmation button

(Cont'd)

1 - 132 (134) Doc. No. MM-3047612-0101

 1 Infeed Unit 1.3 Infeed Conveyor

(Cont'd)
f) According to the speed previously measured, if required touch the
NOMINAL SPEED icon (7), then set the new value for the speed, as
follows:
• the new speed value set, is displayed in the SETTING VALUE field (8)
• touch the FACTORY button (12) to display the factory value
• touch the DOUBLE-ARROW buttons (9) to increase or decrease the value
of 10 m/min
• touch the SINGLE-ARROW buttons (10) to increase or decrease the
value of 1 m/min
• touch the KEYBOARD button (11) to display the numeric keyboard, then
type the value
• touch the CONFIRMATION button (13) to confirm the speed value set
g) Touch the EXIT button (14).

12 13 14
7
TechPub_2614345_0107 - 0101_3057020_01.fm

11

9 10 9
7 Nominal speed icon 11 Keyboard button
8 Setting value field 12 Factory button
9 Double-arrow button 13 Confirmation button
10 Single-arrow button 14 Exit button

Doc. No. MM-3047612-0101 1 - 133 (134)

1.3 Infeed Conveyor 1 Infeed Unit

TechPub_2614345_0107 - 0101_3057020_01.fm
This page intentionally left blank

1 - 134 (134) Doc. No. MM-3047612-0101

 2 Magazine Unit
TechPub_2614345_0107 - 0201_3057021_01.fm

Doc. No. MM-3047612-0101 2 - 1 (80)

 2 Magazine Unit

Magazine Unit - Description

SPC Reference 663103-0300
Note! If not indicated in a different way, all the pictures used in the chapter
show the Magazine Unit for a machine with Magazine Unit on the RH side.

2.1

TechPub_2614345_0107 - 0201_3057021_01.fm
2.2

2.1 Magazine
2.2 Pneumatic Component

2 - 2 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit Table of Contents

2 Magazine Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
2-1 Magazine Unit - Functional Description . . . . . . . 2 - 5
2-2 Magazine Unit - Setting Sequence, Type I . . . . . . 2 - 9
2-3 Magazine Unit - Setting Sequence, Type II . . . . 2 - 10
2-4 Magazine Unit - Setting Sequence, Type III . . . 2 - 11

2.1 Magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 12
2.1-1 Magazine - Set Adjustment Bracket . . . . . . . . . 2 - 12
2.1-2 Magazine - Set Carton Magazine . . . . . . . . . . . . 2 - 23
2.1-3 Magazine - Set Top Frame . . . . . . . . . . . . . . . . . 2 - 28
2.1-4 Magazine - Set Feeder . . . . . . . . . . . . . . . . . . . . 2 - 30
2.1-5 Magazine - Set Indexing Unit . . . . . . . . . . . . . . 2 - 36
2.1-6 Magazine - Configure Magazine Side . . . . . . . . 2 - 42
2.1-7 Magazine - Referencing . . . . . . . . . . . . . . . . . . . 2 - 44
2.1-8 Magazine - Set Lever Pusher . . . . . . . . . . . . . . . 2 - 47
TechPub_2614345_0107 - 0201_3057021_01.fm

2.1.1 Carton Magazine . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 49

2.1.1-1 Carton Magazine - Set Proximity Switch . . . . . . 2 - 49
2.1.1-2 Carton Magazine - Set Timing Belts Tension . . 2 - 52
2.1.1-3 Carton Magazine - Check . . . . . . . . . . . . . . . . . . 2 - 53
2.1.2 Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 54
2.1.2.1 Carton Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 54
2.1.2.1-1 Carton Transfer - Set Timing Belt Tension . . . . 2 - 54
2.1.2.1-2 Carton Transfer - Check . . . . . . . . . . . . . . . . . . . 2 - 55
2.1.2.1-3 Carton Transfer - Overhaul . . . . . . . . . . . . . . . . 2 - 58
2.1.2.2 Pull Down Device. . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 62
2.1.2.2-1 Pull Down Device - Set Proximity Switch . . . . . 2 - 62
2.1.3 Indexing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 63
2.1.3.1 Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 63
2.1.3.1-1 Arm - Set Proximity Switch . . . . . . . . . . . . . . . . 2 - 63
2.1.3.2 Vacuum System . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 64
2.1.3.2-1 Vacuum System - Check . . . . . . . . . . . . . . . . . . 2 - 64

Doc. No. MM-3047612-0101 2 - 3 (80)

Table of Contents 2 Magazine Unit

2.2 Pneumatic Component . . . . . . . . . . . . . . . . . . . 2 - 65

2.2.1 Air Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 65
2.2.1-1 Air Equipment - Set Shut-Off Valve . . . . . . . . . 2 - 65
2.2.1-2 Air Equipment - Set Regulators . . . . . . . . . . . . . 2 - 66
2.2.1-3 Air Equipment - Set Pressure Switch . . . . . . . . 2 - 75
2.2.1-4 Air Equipment - Clean Regulator Filter . . . . . . 2 - 78

TechPub_2614345_0107 - 0201_3057021_01.fm

2 - 4 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2 Magazine Unit

2 Magazine Unit
2-1 Magazine Unit - Functional Description
Before starting the production, the Carton Magazine must be loaded by
placing the cardboard blanks over the two timing belts (1), slightly leaned
and with their outside downwards, the support (2) must be placed against the
last cardboard blank.
The Carton Magazine is equipped with two photocells which detect from the
position of the support (2), the level of cardboards in the Magazine Unit: the
photocell (3) indicates a low level of cardboard blanks and the photocell (4)
indicates when the Carton Magazine is empty. When the photocell (3) is
activated, a blue alarm appears on the control panel, the machine will
continue to run with the low level alarm, until the photocell (4) is activated,
then the machine stops and a yellow alarm is displayed on the control panel.
TechPub_2614345_0107 - 0201_3057021_01.fm

4
3
1 Timing belt
2 Support
3 Photocell
4 Photocell

(Cont'd)

Doc. No. MM-3047612-0101 2 - 5 (80)

2 Magazine Unit 2 Magazine Unit

(Cont'd)
The two stops (5) driven by pneumatic cylinders, keep the cardboard blanks
in position and release a single cardboard blank when it must be transferred
into the base unit. As the cardboard blanks are being consumed, a proximity
switch (7) detects when the pressure of the two stops (5) decrease and
controls the supply of new cardboard blanks by activating the pneumatic
cylinder (6) that drives the two timing belts (1).

TechPub_2614345_0107 - 0201_3057021_01.fm
5

1
7

1 Timing belt 6 Cylinder

5 Stop 7 Proximity switch

(Cont'd)

2 - 6 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2 Magazine Unit

(Cont'd)
A servo motor (8) drives the suction cups (9) to pick a cardboard blank, then
the cardboard blank is transferred in the position below the Carton Magazine,
and the photocell (10) is activated.
When the infeed of packages starts and the package pattern is in the correct
inlet position, the cylinder of the pull down device (11) push the cardboard
blank towards the carton transfer.

10

9 11
TechPub_2614345_0107 - 0201_3057021_01.fm

8 Servo motor
9 Suction cup
10 Photocell
11 Pull down device

(Cont'd)

Doc. No. MM-3047612-0101 2 - 7 (80)

2 Magazine Unit 2 Magazine Unit

(Cont'd)
The carton transfer mainly consists of a timing belt (12) and the pressure
rollers (12), they catch and transfer the cardboard blank into the Base Unit,
until the cardboard blank reaches the inlet position in front of the packing
pattern. A new blank is picked down from the Carton Magazine by the
suction cups (9).

13

12

TechPub_2614345_0107 - 0201_3057021_01.fm
9

9 Suction cup
12 Timing belt
13 Pressure roller

2 - 8 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2 Magazine Unit

2-2 Magazine Unit - Setting Sequence, Type I

Type I settings must be performed in sequence according to the flowchart
below. These settings are performed before the first start-up or
commissioning of the machine.

2.2.1-1 Air Equipment - Set Shut-Off Valve on 2.1-3 Magazine - Set Top Frame on page 2-28
page 2-65

2.2.1-2 Air Equipment - Set Regulators on 2.1-4 Magazine - Set Feeder on page 2-30
page 2-66

2.2.1-3 Air Equipment - Set Pressure Switch on 2.1-5 Magazine - Set Indexing Unit on page 2-36
page 2-75
TechPub_2614345_0107 - 0201_3057021_01.fm

2.1.1-1 Carton Magazine - Set Proximity Switch on 2.1-6 Magazine - Configure Magazine Side on
page 2-49 page 2-42

2.1-1 Magazine - Set Adjustment Bracket on 2.1-7 Magazine - Referencing on page 2-44
page 2-12

2.1-2 Magazine - Set Carton Magazine on

page 2-23

Doc. No. MM-3047612-0101 2 - 9 (80)

2 Magazine Unit 2 Magazine Unit

2-3 Magazine Unit - Setting Sequence, Type II

Type II settings must be performed in sequence according to the flowchart
below. These settings are performed when the production change, in order to
adjust the Magazine Unit for a new cardboard blank.

2.1-1 Magazine - Set Adjustment Bracket on

page 2-12

2.1-2 Magazine - Set Carton Magazine on

page 2-23

2.1-3 Magazine - Set Top Frame on page 2-28

TechPub_2614345_0107 - 0201_3057021_01.fm
Carton Transfer - Set Rollers on page 2-32

Carton Transfer - Set Guide on page 2-33

Pull Down Device - Set on page 2-35

Suction Cups - Set Position on page 2-39

2 - 10 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2 Magazine Unit

2-4 Magazine Unit - Setting Sequence, Type III

Type III settings include all the remaining Magazine Unit setting procedures.
These settings can be performed independently and have no effect on any of
the other Magazine Unit settings.
TechPub_2614345_0107 - 0201_3057021_01.fm

Doc. No. MM-3047612-0101 2 - 11 (80)

2.1 Magazine 2 Magazine Unit

2.1 Magazine
SPC Reference 2719046-0200

2.1-1 Magazine - Set Adjustment Bracket

Machine Status Mains Power OFF
Air OFF
Water OFF
Special Equipment Crank TP No. 318820-0105
Shaft TP No. 2728268
SPC Reference 2719041-0200
Note! Before starting, make sure to have already performed the following
instructions: 4-5 Feed Unit - Basic Setting on page 4-9 and 3.1-1 Flight Bar -
Set Dead Plate on page 3-9.
Preparation
a) Loosen the screw (1) then move the stop (2) aside.

TechPub_2614345_0107 - 0201_3057022_01.fm
2

1 Screw
2 Stop

(Cont'd)

2 - 12 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.1 Magazine

(Cont'd)
b) Unlock the shaft (4) with the locking lever (5).
c) Apply the crank (3) on the shaft (4) then move the stop (6) aside.

6
TechPub_2614345_0107 - 0201_3057022_01.fm

3 4
3 Crank
4 Shaft
5 Locking lever
6 Stop

(Cont'd)

Doc. No. MM-3047612-0101 2 - 13 (80)

2.1 Magazine 2 Magazine Unit

(Cont'd)
Bottom Steering - Set Height
a) Insert the cardboard blank (1) between the dead plate (2) and the support
rail (3) of the feed unit, until the bottom side of the cardboard blank (1)
is fully against the bottom steering (4), as shown below.

1 2

TechPub_2614345_0107 - 0201_3057022_01.fm
1 2
3

1 Cardboard blank
2 Dead plate
3 Support rail
4 Bottom steering

(Cont'd)

2 - 14 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.1 Magazine

(Cont'd)
b) Unlock the shaft (6) with the locking lever (7).
c) Apply the crank (5) on the shaft (6), then lift or lower the bottom
steering (4), until the correct setting is reached, see the next page.

4
TechPub_2614345_0107 - 0201_3057022_01.fm

6 5

4 Bottom steering
5 Crank
6 Shaft
7 Locking lever

(Cont'd)

Doc. No. MM-3047612-0101 2 - 15 (80)

2.1 Magazine 2 Magazine Unit

(Cont'd)
Note! Only when running with WAIF, WASF or Tray OF, make sure to align
the correct upper crease line (8), as shown below.
d) The bottom steering (4) is properly set, when the upper crease line (8) of
the cardboard blank (1) is a bit higher than the dead plate (2) and is
aligned with the bottom side of the packages (9).

8 2 8 9 2

TechPub_2614345_0107 - 0201_3057022_01.fm
1
8 8 8

WAIF

Tray OF Tray

8 1 Cardboard blank
2 Dead plate
WASF 4 Bottom steering
8 Upper crease line
9 Package

(Cont'd)

2 - 16 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.1 Magazine

(Cont'd)
e) Remove the crank (5) then lock the bottom steering (4) in position with
the locking lever (7).

4
TechPub_2614345_0107 - 0201_3057022_01.fm

4 Bottom steering
5 Crank
7 Locking lever

(Cont'd)

Doc. No. MM-3047612-0101 2 - 17 (80)

2.1 Magazine 2 Magazine Unit

(Cont'd)
Bottom Steering - Set Stop Position
a) Move the stop (1), until it touches the cardboard blank (2) and at the
same time, the side flap crease lines (3) are aligned with:
• the inner side of the chain frames (4), if the feed unit has been previously
set for cardboard blanks with the outside bottom A ≤ 400 mm, or
• the outer side of the chain frames (4), if the feed unit has been previously
set for cardboard blanks with the outside bottom A > 400 mm.
b) Lock the stop (1) in position with the screw (5).

Setting for A > 400 mm Setting for A ≤ 400 mm

4 4

TechPub_2614345_0107 - 0201_3057022_01.fm
1 1

2 3 2 3

1 Stop
2 Cardboard blank
3 Side flap crease line
4 Chain frame
A 5 Screw
5
(Cont'd)

2 - 18 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.1 Magazine

(Cont'd)
c) Unlock the shaft (7) with the locking lever (6).
d) Apply the crank (8) on the shaft (7), then with the cardboard blank (2)
against the stop (1), set the position of the stop (9), until it is placed at
the distance B from the cardboard blank (2).
e) Remove the crank (8) then lock the shaft (7) with the locking lever (6).

B = 3 ÷ 3.5 mm

9
TechPub_2614345_0107 - 0201_3057022_01.fm

2
1

8 7 6

1 Stop
2 Cardboard blank
6 Locking lever
1 7 Shaft
8 Crank
9 Stop
2 B 9
(Cont'd)

Doc. No. MM-3047612-0101 2 - 19 (80)

2.1 Magazine 2 Magazine Unit

(Cont'd)
Top Steering - Set Height
a) Unlock the shaft (2) with the locking lever (1).
b) Apply the crank (3) on the shaft (2), then lift or lower the top
steering (4), until the correct setting is reached, see the next page.

1 2
3

TechPub_2614345_0107 - 0201_3057022_01.fm
4

1 Locking lever
2 Shaft
3 Crank
4 Top steering

(Cont'd)

2 - 20 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.1 Magazine

(Cont'd)
c) With the cardboard blank (5) fully against the bottom steering (6) as
shown below, set the top steering (4) so that the cardboard blank (5) lays
on the top steering (4) for at least the distance A.

A = 30 ±1 mm

A
4
TechPub_2614345_0107 - 0201_3057022_01.fm

5
6

4 Top steering
5 Cardboard blank
6 Bottom Steering

(Cont'd)

Doc. No. MM-3047612-0101 2 - 21 (80)

2.1 Magazine 2 Magazine Unit

(Cont'd)
d) Remove the crank (3) then lock the top steering (4) in position with the
locking lever (1).

1
3

TechPub_2614345_0107 - 0201_3057022_01.fm
4

1 Locking lever
3 Crank
4 Top steering

2 - 22 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.1 Magazine

2.1-2 Magazine - Set Carton Magazine

Machine Status Mains Power OFF
Air OFF
Water OFF
Special Equipment Crank TP No. 318820-0105
Shaft TP No. 2728268
SPC Reference 2719045-0100

Carton Magazine - Set Height

Note! Only when running with WAIF, WASF or Tray OF, make sure to align
the correct upper crease line (1), as shown below.
a) Measure the distance A, between the upper crease line (1) and the
bottom side of the cardboard blank (2).
TechPub_2614345_0107 - 0201_3057022_01.fm

A A
1 A
1 1

2 Tray OF 2 WAIF 2 WASF

1
A

1 Upper crease line

2 Cardboard blank 2
Tray

(Cont'd)

Doc. No. MM-3047612-0101 2 - 23 (80)

2.1 Magazine 2 Magazine Unit

(Cont'd)
Note! Only when the carton magazine (4) has to be lifted, check if there is
space enough from the top frame (3), if required lift it, see Top Frame - Basic
Setting on page 2-28.
b) Unlock the carton magazine (4) with the locking lever (7).
c) Using the setting scale (6) as reference, turn the hand wheel (8) to lift or
lower the carton magazine (4), until the top side of the guide block (5), is
aligned to the measure B.
d) Lock the carton magazine (4) in position with the locking lever (7).

3
4

TechPub_2614345_0107 - 0201_3057022_01.fm
B=A

5 7
6 8

Front view
3 Top frame 6 Setting scale
4 Carton magazine 7 Locking lever
5 Guide block 8 Hand wheel

(Cont'd)

2 - 24 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.1 Magazine

(Cont'd)
Carton Magazine - Set Width
Note! The fixed guide (2) is always placed on the base unit side.
a) Measure the width A of the cardboard blank (3), or place the cardboard
blank (3) in the carton magazine, making sure that is fully against the
fixed guide (2).
b) Apply the crank (5) on the shaft (4) then move the adjustable guide (1),
until the distance B from the fixed guide (2) is reached.

B
A B = A + 3 ±0.5 mm

2 1
TechPub_2614345_0107 - 0201_3057022_01.fm

3
1
4 5

Front view

1 Adjustable guide
2 Fixed guide
3 Cardboard blank
4 Shaft
5 Crank

(Cont'd)

Doc. No. MM-3047612-0101 2 - 25 (80)

2.1 Magazine 2 Magazine Unit

(Cont'd)
Note! For a good working of the magazine, make sure that the bottom side
of the cardboard blank (3) is placed on both timing belts (6) and (8).
c) With the cardboard blank (3) fully against the fixed guide (2), check if
there is the same distance, between the side flap crease lines (7) and the
timing belts (6) and (8), if not apply the crank (5) on the shaft (9) then
move the structure of the timing belt (6).

6
3
= =

TechPub_2614345_0107 - 0201_3057022_01.fm
6 8
9 5
Front view 2 Fixed guide
3 Cardboard blank
5 Crank
6 Timing belt
7 Side flap crease line
8 Timing belt
9 Shaft

(Cont'd)

2 - 26 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.1 Magazine

(Cont'd)
Carton Magazine - Set Brackets
Note! If necessary, before set the top frame, see 2.1-3 Magazine - Set Top
Frame on page 2-28. The fixed guide (4) is always placed on the base unit
side.
Place a cardboard blank (1) in the carton magazine, then set both brackets (2)
with the locking levers (3), so that the outer side of each bracket (2) is
aligned to the side of the cardboard blank (1). At the end make sure that the
cardboard blank (1) is supported by both brackets (2), even if it is placed
fully against the fixed guide (4) or the adjustable guide (5), if not fine adjust
the brackets (2).

1
TechPub_2614345_0107 - 0201_3057022_01.fm

3
3

Back view

5
1 Cardboard blank 4 Fixed guide
2 Bracket 5 Adjustable guide
3 Locking lever

Doc. No. MM-3047612-0101 2 - 27 (80)

2.1 Magazine 2 Magazine Unit

2.1-3 Magazine - Set Top Frame

Machine Status Mains Power OFF
Air OFF
Water OFF
Special Equipment Crank TP No. 318820-0105
Shaft TP No. 2728268
SPC Reference 2719050-0100

Top Frame - Basic Setting

Make sure that the plate (1) is set in the lower position, if not adjust using the
three screws (2).

TechPub_2614345_0107 - 0201_3057022_01.fm

1 Plate 2
2 Screw
1
(Cont'd)

2 - 28 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.1 Magazine

(Cont'd)
Top Frame - Set Height
a) Unlock the top frame (1) with the locking lever (3).
b) Turn the hand wheel (2) to lift or lower the top frame (1), so that the
plate (4) supports the top side of the cardboard blank (5) for the
distance A, when the cardboard blank (5) is placed slightly leaned
against both brackets (6) and both stops (7),as shown below.
c) Lock the top frame (1) in position with the locking lever (3).

A = 10 ±0.5 mm
2
3

A
1
5
TechPub_2614345_0107 - 0201_3057022_01.fm

Side view
7

1 Top frame 5 Cardboard blank

2 Hand wheel 6 Bracket
3 Locking lever 7 Stop
4 Plate

Doc. No. MM-3047612-0101 2 - 29 (80)

2.1 Magazine 2 Magazine Unit

2.1-4 Magazine - Set Feeder

Machine Status Mains Power ON
Air ON
Water OFF
SPC Reference 2719037-0200

Carton Transfer - Basic Setting of Slide Plate

Note! Perform this setting only once, before the first start up of the machine,
making sure to have already performed the instructions: Bottom Steering -
Set Height on page 2-14 and Top Steering - Set Height on page 2-20.
a) Place the cardboard blank (1) below the slide plate (2).
Note! Only when running with WAIF, WASF or Tray OF, make sure to align
the correct upper crease line (3), as shown below.
b) Set the slide plate (2) aligned to the upper crease line (3) of the
cardboard blank (1), using the two screws (4).

4 3 3

TechPub_2614345_0107 - 0201_3057022_01.fm
Tray Tray OF

2
2
3

3 3

1
WAIF WASF

1 Cardboard blank
2 Slide plate
3 Upper crease line
4 Screw

(Cont'd)

2 - 30 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.1 Magazine

(Cont'd)
c) Set the slide plate (2) parallel to the support rail (5) of the feed unit,
using the two screws (6).

2
6

//

5
TechPub_2614345_0107 - 0201_3057022_01.fm

2 Slide plate
5 Support rail
6 Screw

(Cont'd)

Doc. No. MM-3047612-0101 2 - 31 (80)

2.1 Magazine 2 Magazine Unit

(Cont'd)
Carton Transfer - Set Rollers
With the cardboard blank (2) fully against the stop (1), set the rollers (3) with
the screw (4), until they are at the distance A from the side of the cardboard
blank (2).

TechPub_2614345_0107 - 0201_3057022_01.fm
1

A = 3.5 ÷ 4 mm

3 4 1 Stop
1 2 Cardboard blank
3 Roller
4 Screw
2 A
(Cont'd)

2 - 32 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.1 Magazine

(Cont'd)
Carton Transfer - Set Guide
Note! Only when running with WAIF, WASF or Tray OF, make sure that they
are folded in the correct upper crease line (4) by the guide (1), as shown
below.
Set the guide (1) with the two locking levers (2), so that when the cardboard
blanks (3) are transported into the base unit, they are already folded in the
upper crease line (4), as shown below.

4 Tray

1
4

Tray OF
3
2
TechPub_2614345_0107 - 0201_3057022_01.fm

4
WAIF

Example of setting with tray

4
WASF

1 Guide
2 Locking lever
3 Cardboard blank
4 Upper crease line

(Cont'd)

Doc. No. MM-3047612-0101 2 - 33 (80)

2.1 Magazine 2 Magazine Unit

(Cont'd)
Pull Down Device - Change Pusher
The machine is equipped with two type of pushers: the pusher (1) must be
used for wide cardboard blanks and the pusher (2) must be used for narrow
cardboard blanks. According to the cardboard blanks used, fit the correct
pusher to the plate (3) using the four screws (4). Keep the pusher not used in
a safe place.

TechPub_2614345_0107 - 0201_3057022_01.fm
3

4
1 Pusher (for wide cardboard blank)
2 Pusher (for narrow cardboard blank) 3
3 Plate 2
4 Screw

(Cont'd)

2 - 34 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.1 Magazine

(Cont'd)
Pull Down Device - Set
a) Make sure that the width of the carton magazine has been already set and
the adjustable guide (1) is in correct position, then if necessary manually
push out the pistons from the cylinder, until the pusher (2) is in position
to be detected by the proximity switch (3).
b) Unlock the locking lever (4) on the backside of the pull down device (5).
c) As a basic setting, move the pull down device (5) so that the pusher (2) is
placed at the distance A, outer than the adjustable guide (1).
d) Lock the pull down device (5) in position with the locking lever (4).
Note! During PRODUCTION, check if the cardboard blanks are well moved
into the carton transfer, if required fine adjust the position of the pull down
device (5).

3
TechPub_2614345_0107 - 0201_3057022_01.fm

5 2

A = 3 ÷ 4 mm
A
Top view of Pull Down Device with 1
Pusher for wide cardboard blanks

1 Adjustable guide
2 Pusher
3 Proximity switch
4 Locking lever
5 Pull down device

Doc. No. MM-3047612-0101 2 - 35 (80)

2.1 Magazine 2 Magazine Unit

2.1-5 Magazine - Set Indexing Unit

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2719042-0200

Indexing Unit- Basic Settings

Note! Check these settings before the first start up of the machine.
a) Check the length A of the arm (1), if required fine adjust as follows:
• loosen the nuts (2)
• screw or unscrew the rod (3) until the length A is reached
• tighten the nuts (2).

A = 479 ±0.2 mm

TechPub_2614345_0107 - 0201_3057022_01.fm
1 3 2

Side view

1 Arm
2 Nut
3 Rod

(Cont'd)

2 - 36 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.1 Magazine

(Cont'd)
b) At the beginning of the setting, as a basic setting make sure that the
threaded part (4) of the spring holder is aligned to the nut (5) for all the
suction cups (7), if required fine adjust using the nuts (5) and (6).

7
4
5

B
TechPub_2614345_0107 - 0201_3057022_01.fm

Side view
B = 0 ±0.1 mm B

4 Threaded part
5 Nut
6 Nut
7 Suction cup

(Cont'd)

Doc. No. MM-3047612-0101 2 - 37 (80)

2.1 Magazine 2 Magazine Unit

(Cont'd)
c) Manually lift the arm (10) towards the carton magazine as to pick up the
first cardboard blank, then holding the arm (10) in position use a steel
ruler (8) to check that all the suction cups (7) touch it at the same time
and with the spring holders (9) compressed of about half stroke C. If not
fine adjust the position of the suction cups with the nuts (5) and (6).
d) At the end manually move down the arm (10).

C = 10 ±2 mm

C
8
9
7
5
6

TechPub_2614345_0107 - 0201_3057022_01.fm
Side view

10

5 Nut 8 Steel ruler

6 Nut 9 Spring holder
7 Suction cup 10 Arm

(Cont'd)

2 - 38 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.1 Magazine

(Cont'd)
Suction Cups - Set Position
Note! The suction cup (5) is used only when the machine runs with WAIF
and WASF blanks, remove and disconnect the suction cup (5) when the
machine runs with tray.
a) Place the cardboard blank (1) in position as shown below, then making
sure that the suction cups (5), (6) and (7) do not overlap the flap crease
lines (2) and the crease lines (3) and (4), set their positions so that:
• the suction cup (5) is placed close to the crease line (4)
• the suction cups (6) and (7) are positioned close to the four corners
formed by the flap crease lines (2) and the crease lines (3) and (4).

5 5
4
1
TechPub_2614345_0107 - 0201_3057022_01.fm

WAIF WASF Tray OF

4 1 1
6

1 Cardboard blank
2 Flap crease line
7 3 Crease line
2 4 Crease line
5 Suction cup (only for WA Unit)
6 Suction cup
3 Tray 1 7 Suction cup

(Cont'd)

Doc. No. MM-3047612-0101 2 - 39 (80)

2.1 Magazine 2 Magazine Unit

(Cont'd)
b) If required, set the position of the suction cups (5), (6) and (7) as
follows:
• use the nuts (8) to fine adjust the position of each suction cups (6)
and (7) in the slots
• use the screws (9) and the nuts, to change the vertical position of the
suction cups (7) on the plate (10)
• use the screws (11) and the nuts:
– to fit the supports (12) or (13), only when the machine has to run with
WAIF and WASF blanks, then use the nuts (8) to fine adjust the
position of the suction cup (5) in the slot, or
– to remove the support installed when the machine has to run with tray,
then disconnect the suction cup (5).

5
13 12
8
11

TechPub_2614345_0107 - 0201_3057022_01.fm
6
7 6
7

5 Suction cup (only for WA Unit) 8

6 Suction cup
7 Suction cup 8
8 Nut 9
9 Screw
10 Plate
11 Screw
12 Support (long)
13 Support (short)
10

(Cont'd)

2 - 40 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.1 Magazine

(Cont'd)
Note! During PRODUCTION when the arm turns (14), check that the
cardboard blanks (1) in the carton magazine are picked up correctly by all
the suction cups (6), (7) and when installed also by the suction cup (5). If
required fine adjust the positions of the suction cups (5), (6) and (7).

7
TechPub_2614345_0107 - 0201_3057022_01.fm

Side view

14

1 Cardboard blank 7 Suction cup

5 Suction cup (only for WA Unit) 14 Arm
6 Suction cup

Doc. No. MM-3047612-0101 2 - 41 (80)

2.1 Magazine 2 Magazine Unit

2.1-6 Magazine - Configure Magazine Side

Machine Status AIR ON
SPC Reference 663103-0300

Note! Configure the magazine side at the first start up of the machine.
a) On the TPOP, log on as “tptechnician”, see 6.7.1-2 HMI User
Management - Log On as a User on page 6-237.
b) With the machine in AIR ON, touch the MACHINE CONFIGURATION
button (1).
Note! The icon (2), means that the magazine side has not been
configurated.
c) In the MACHINE CONFIGURATION window, touch the icon (2).

1 2

TechPub_2614345_0107 - 0201_3057022_01.fm
1 Machine configuration button
2 Icon (magazine side not configured)

(Cont'd)

2 - 42 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.1 Magazine

(Cont'd)
d) In the SETTING window (3), proceed as follows:
• touch the SINGLE-ARROW buttons (4) to change the magazine side
• at the end touch the CONFIRMATION button (7), to confirm the
magazine side displayed in the window (6), or touch the CLEAR
button (5) to abort the selection.
Note! In the CONFIGURATION window will appear the icons (9) or (10),
according to the magazine side previously configurated.
e) Touch the EXIT button (8).

6 7 8 9 10

3
TechPub_2614345_0107 - 0201_3057022_01.fm

4 5
3 Setting window
4 Single-arrow button
5 Clear button
6 Magazine side window
7 Confirmation button
8 Exit button
9 Icon (Magazine on RH side)
10 Icon (Magazine on LH side)

Doc. No. MM-3047612-0101 2 - 43 (80)

2.1 Magazine 2 Magazine Unit

2.1-7 Magazine - Referencing

Machine Status AIR ON
SPC Reference 2719042-0200

Magazine - Set Homing Position

Note! Perform this setting at the first start up of the machine or after the
replacement of the servo motor, making sure to have already performed the
instruction Indexing Unit- Basic Settings on page 2-36.
a) On the TPOP, log on as: “tptechnician” or “supervisor” or “technician”,
see 6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) With the machine in a program step before AIR ON, touch the
MAINTENANCE button (1) and the MAGAZINE UNIT button (2), or
touch the MAGAZINE UNIT tab (3).
c) Touch the HOME POSITION icon (4) to display the dialogue window.

1 2 4

TechPub_2614345_0107 - 0201_3057022_01.fm
3

1 Maintenance button
2 Magazine unit button
3 Magazine unit tab
4 Home position icon

(Cont'd)

2 - 44 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.1 Magazine

(Cont'd)
d) Touch the ON button (5) to select the homing position function.
e) Press the STEP UP button (6) to step up the machine to HOMING.
f) Touch the CONFIRMATION button (7) to turn the arm (8) towards the
lower position. The arm (8) will move until the proximity switch detects
the lever (9) then it will move of the offset value.
g) If the lever (9) and the tie rod (10) are aligned, use the reference
mark (13) existing on the lever (9) to check the correct alignment, then
touch the EXIT button (11) to set the homing position, otherwise set a
different offset value until the alignment is reached, as follows on the
next page.

10
9
6 7 11

5
TechPub_2614345_0107 - 0201_3057022_01.fm

12 = 13
10

= 9

Side view

5 ON button 8 Arm 11 Exit button

6 Step up button 9 Lever 12 Proximity switch
7 Confirmation button 10 Tie rod 13 Reference mark

(Cont'd)

Doc. No. MM-3047612-0101 2 - 45 (80)

2.1 Magazine 2 Magazine Unit

(Cont'd)
h) If required touch the OFFSET VALUE icon (14), then set the new angle
of rotation, as follows:
• the new angle of rotation, is displayed in the SETTING VALUE
field (15)
• touch the FACTORY button (19) to display the factory value
• touch the DOUBLE-ARROW buttons (16) to increase or decrease the
value of 10 degrees
• touch the SINGLE-ARROW buttons (17) to increase or decrease the
value of 1 degree
• touch the KEYBOARD button (18) to display the numeric keyboard, then
type the value
• touch the CONFIRMATION button (20) to confirm the angle of rotation
set
i) Repeat the setting of the homing position from item f) on page 2-45 until
the correct alignment is reached.

19 20
14

TechPub_2614345_0107 - 0201_3057022_01.fm
15

18

16 17 16
14 Offset value icon 18 Keyboard button
15 Setting value field 19 Factory button
16 Double-arrow button 20 Confirmation button
17 Single-arrow button

2 - 46 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.1 Magazine

2.1-8 Magazine - Set Lever Pusher

Machine Status Before EMPTYING
SPC Reference 2719041-0200

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

see 6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) With the machine in a program step before EMPTYING, touch the
MAINTENANCE button (1) and the MAGAZINE UNIT button (2), or
touch the MAGAZINE UNIT tab (3).
c) Touch the LEVER PUSHER icon (4) to display the dialogue window.

1 2 4

3
TechPub_2614345_0107 - 0201_3057022_01.fm

1 Maintenance button
2 Magazine unit button
3 Magazine unit tab
4 Lever pusher icon

(Cont'd)

Doc. No. MM-3047612-0101 2 - 47 (80)

2.1 Magazine 2 Magazine Unit

(Cont'd)
d) Touch the LEVER PUSHER ON ANGLE SECTOR icon (5) or the
LEVER PUSHER OFF ANGLE SECTOR icon (6), then set the new
value as follows:
• the new angle set, is displayed in the SETTING VALUE field (7)
• touch the FACTORY button (11) to display the factory value
• touch the DOUBLE-ARROW buttons (8) to increase or decrease the value
of 10 degrees
• touch the SINGLE-ARROW buttons (9) to increase or decrease the value
of 1 degree
• touch the KEYBOARD button (10) to display the numeric keyboard, then
type the value
• touch the CONFIRMATION button (12) to confirm the new value set
e) Touch the EXIT button (13).

TechPub_2614345_0107 - 0201_3057022_01.fm
11 12 13
6

10

8 9 8
5 Lever pusher on angle sector icon 10 Keyboard button
6 Lever pusher off angle sector icon 11 Factory button
7 Setting value field 12 Confirmation button
8 Double-arrow button 13 Exit button
9 Single-arrow button

2 - 48 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.1 Magazine

2.1.1 Carton Magazine

2.1.1-1 Carton Magazine - Set Proximity Switch
Machine Status Mains Power ON
Air ON
Water OFF
SPC Reference 2719045-0100
Note! Before starting, make sure that the carton magazine is empty.
(Cont'd)
TechPub_2614345_0107 - 0201_3057022_01.fm

Doc. No. MM-3047612-0101 2 - 49 (80)

2.1 Magazine 2 Magazine Unit

(Cont'd)

CAUTION
Risk of damage to the equipment.
Loosen the proximity switch (4) until it is far as much as possible from the
plate (5).
a) Make sure that the pressure regulator (2) has been properly set, see Set
Pressure Regulator for Cylinder Blank Releasing on page 2-67, then
activate the cylinders (3) with the pressurizing valve (1).

Side view

TechPub_2614345_0107 - 0201_3057022_01.fm
3 5

Front view

4 5 1 2

1 Pressurizing valve
2 Pressure regulator; cylinder blank releasing
3 Cylinder
4 Proximity switch
5 Plate

(Cont'd)

2 - 50 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.1 Magazine

(Cont'd)
b) On both sides of the carton magazine, check that both stops (7) are
parallel to each other and turned within the range of angle A. If required
fine adjust the length of the piston (6) until the angle A is reached.
c) Due to the transversal play of the stop (7) and to make sure that the
plate (5) is well detected by the proximity switch (4), set as follows:
• manually push and hold the stop (7) towards the proximity switch (4),
then set the proximity switch (4) at the distance B from the plate (5)
• if required set the position of the plate (9) towards the plate (5) with the
two screws (8). With a correct setting, the LED (10) must be lit when the
plate (5) is detected.

7
A = 90 ÷ 85° 6
B = 0.2 mm

A
8
TechPub_2614345_0107 - 0201_3057022_01.fm

7 Side view

4
5
Front view

4 Proximity switch 8 Screw

5 Plate 9 Plate
6 Piston 10 LED
7 Stop
10 4 B 5

Doc. No. MM-3047612-0101 2 - 51 (80)

2.1 Magazine 2 Magazine Unit

2.1.1-2 Carton Magazine - Set Timing Belts Tension

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2719045-0100

Set the tension of both timing belts (1) with the nuts (2), so that the timing
belts (1) do not touch the bottom side of the guides (3).

Side view

3 1

TechPub_2614345_0107 - 0201_3057022_01.fm
1

3 3 1 Timing belt
2 Nut
2 3 Guide

2 - 52 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.1 Magazine

2.1.1-3 Carton Magazine - Check

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2719045-0100

Check that:
• both timing belts (1) are not worn or damaged, if required change them.
• the tension of both timing belts (1) is set correctly, see 2.1.1-2 Carton
Magazine - Set Timing Belts Tension on page 2-52.
TechPub_2614345_0107 - 0201_3057022_01.fm

1 Timing belt

Doc. No. MM-3047612-0101 2 - 53 (80)

2.1 Magazine 2 Magazine Unit

2.1.2 Feeder
2.1.2.1 Carton Transfer
2.1.2.1-1 Carton Transfer - Set Timing Belt Tension
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2969055-0100

a) Loosen the four screws (2) and the nuts.

b) Manually move the carton transfer until the conveyor belt (1) is well
tensioned by the two springs (3).
c) Tighten the four screws (2).

2 3

TechPub_2614345_0107 - 0201_3057022_01.fm
2 3

1 Conveyor belt
2 Screw
3 Spring

2 - 54 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.1 Magazine

2.1.2.1-2 Carton Transfer - Check

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2969055-0100

Conveyor Belt - Check

Check that:
• the conveyor belt (1) is not worn or damaged, if required replace it
• the tension of the conveyor belt (1) is set correctly, see 2.1.2.1-1 Carton
Transfer - Set Timing Belt Tension on page 2-54.
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1 Conveyor belt

(Cont'd)

Doc. No. MM-3047612-0101 2 - 55 (80)

2.1 Magazine 2 Magazine Unit

(Cont'd)
Rubber Rollers - Check
a) Check that:
• the rubber rings (1) are not worn or damaged
• the rollers (2) rotate freely without play.
b) If required change the parts damaged, see Rubber Rollers - Change on
page 2-60.

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2

1 Rubber ring
2 Roller
1
(Cont'd)

2 - 56 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.1 Magazine

(Cont'd)
Plastic Rollers - Check
Check that the plastic rollers (1) are not worn or damaged and rotate freely
without play. If required change the parts damaged, see Plastic Rollers -
Change on page 2-61.
TechPub_2614345_0107 - 0201_3057022_01.fm

1 Plastic roller

Doc. No. MM-3047612-0101 2 - 57 (80)

2.1 Magazine 2 Magazine Unit

2.1.2.1-3 Carton Transfer - Overhaul

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2969055-0100

Conveyor Belt - Overhaul

a) Loosen the grub screw (1).
b) Unblock the retaining ring (2) and manually push the shaft (3) in the
direction of the arrow.
Note! Make sure to not lose the parallel key (4).

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3

1 Grub screw
2 Retaining ring
1 3 Shaft
4 Parallel key

(Cont'd)

2 - 58 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.1 Magazine

(Cont'd)
c) Loosen the four screws (5).
d) Manually push the feeder (6) in the direction of the arrow to remove the
conveyor belt (7).
e) Change the conveyor belt (7) and assemble in the reverse order.

6 5

7
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5
5 Screw
6 Feeder
7 Conveyor belt

(Cont'd)

Doc. No. MM-3047612-0101 2 - 59 (80)

2.1 Magazine 2 Magazine Unit

(Cont'd)
Rubber Rollers - Change
a) If required, remove and replace the rubber rings (1) on the rollers (2).
b) Change the ball bearing (3) for each rollers (2), as follows:
• remove the screw (5) and the roller (2)
• remove a retaining ring (4)
• take out and replace the ball bearing (3) on the roller (2)
• assemble in the reverse order.

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1 2 3 4 5

1 Rubber ring
2 Roller
3 Ball bearing
4 Retaining ring
5 Screw

(Cont'd)

2 - 60 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.1 Magazine

(Cont'd)
Plastic Rollers - Change
a) Loosen the screw (1) and remove the retaining ring (2).
b) Remove and replace the roller (3) then assemble in the reverse order.
TechPub_2614345_0107 - 0201_3057022_01.fm

1 3
1 Screw
2 Retaining ring
3 Roller

Doc. No. MM-3047612-0101 2 - 61 (80)

2.1 Magazine 2 Magazine Unit

2.1.2.2 Pull Down Device

2.1.2.2-1 Pull Down Device - Set Proximity Switch
Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 2986426-0100

If necessary manually push out the pistons from the cylinder (1), then make
sure that the proximity switch (3) is set at the distance A from the plate (2).
Note! Only for the machines equipped with the automatic homing
procedure, with a correct setting the LED (4) must be lit when the pate (2) is
detected during PRODUCTION.

4
Front view of Pull Down Device
with pusher for wide cardboard
blanks 3

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A

2
1
A = 1 ÷ 2 mm
4
Front view of Pull Down Device
with pusher for narrow cardboard
blanks 3

1 Cylinder A
2 Plate
3 Proximity switch 2
4 Led
1

2 - 62 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.1 Magazine

2.1.3 Indexing Unit

2.1.3.1 Arm
2.1.3.1-1 Arm - Set Proximity Switch
Machine Status Mains Power ON
Air OFF
Water ON
SPC Reference 2997501-0100

Make sure that the proximity switch (1) is set at the distance A from the
lever (2).
Note! Only for the machines equipped with the automatic homing
procedure, with a correct setting the LED (3) must be lit when the lever (2) is
detected during PRODUCTION.

2
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1
Top view

A
A = 1 ÷ 2 mm

1 Proximity switch
2 Lever 1 2
3 Led

Doc. No. MM-3047612-0101 2 - 63 (80)

2.1 Magazine 2 Magazine Unit

2.1.3.2 Vacuum System

2.1.3.2-1 Vacuum System - Check
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2984691-0100

Check that:
• the suction cups (1) are not worn or damaged, if required replace them
• the suction cups (1) are clean, if required clean them with a damp cloth
• the air hoses (2) do not leak, if required replace them.

1 2

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2
1

1 Suction cup
2 Air hose

2 - 64 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.2 Pneumatic Component

2.2 Pneumatic Component

SPC Reference 2734093-0100

2.2.1 Air Equipment

2.2.1-1 Air Equipment - Set Shut-Off Valve
Machine Status Mains Power ON
Air ON
Water ON
SPC Reference 2791737-0200

The shut-off valve can be set in two positions as follows:

• the shut-off valve (1) is open when the top handle is in the position B as
shown below
• the shut-off valve (1) is closed when the top handle is in the position A
as shown below. The shut-off valve (1) can be locked with a padlock (2)
in this position.
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2
A B

1 Shut-off valve 1
2 Padlock

Doc. No. MM-3047612-0101 2 - 65 (80)

2.2 Pneumatic Component 2 Magazine Unit

2.2.1-2 Air Equipment - Set Regulators

Machine Status Mains Power ON
Air ON
Water ON
SPC Reference 2791737-0200

Turn the pressure regulators from (1) to (7) to adjust the air pressure and
verify on the pressure gauges (8) that the pressure values are correct.
Pressure Regulators - Basic Setting
Note! Do not set the pressure regulator (1) over 0.6 MPa (6.0 bar),
otherwise the main air valve does not function correctly and there is no air
distribution in the pneumatic circuit. Set the pressure regulator (2) as
described from page 2-67 and set the pressure regulator (6) as described
from page 2-71.
According to the table below, set the pressure regulators indicated at the
correct pressure.

Pressure regulator Function Pressure setting

(1) Main air supply (during Production) 0.55 MPa (5.5 bar)
(3) Ejector suction cups 0.50 MPa (5.0 bar)
(4) Hotmelt applicator RH side 0.40 MPa (4.0 bar)

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(5) Hotmelt applicator LH side 0.40 MPa (4.0 bar)
(7) Clutch and brake 0.40 MPa (4.0 bar)

1 2 3 4 5 6 7

8
1 Pressure regulator; main air supply 6 Pressure regulator; pressure rollers of carton
2 Pressure regulator; cylinder blank releasing transfer
3 Pressure regulator; ejector suction cups 7 Pressure regulator; clutch and brake
4 Pressure regulator; hotmelt applicator RH side 8 Pressure gauge
5 Pressure regulator; hotmelt applicator LH side

(Cont'd)

2 - 66 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.2 Pneumatic Component

(Cont'd)
Set Pressure Regulator for Cylinder Blank Releasing
a) Make sure that the pressure value indicated on the pressure gauge (1) is
0 bar, if required turn the pressure regulator (2) to reduce the pressure
value.

CAUTION
Risk of personal injury.
Moving parts can crush.
b) Remove the cover (4) from the pressurizing valve (3) then pull down the
button (5).

3 2

3
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1 Pressure gauge
2 Pressure regulator; cylinder blank releasing
3 Pressurizing valve
4 Cover
1
5 Button

(Cont'd)

Doc. No. MM-3047612-0101 2 - 67 (80)

2.2 Pneumatic Component 2 Magazine Unit

(Cont'd)
Note! Make sure that the carton magazine is empty.
CAUTION
Risk of damage to the equipment.
According to the type of support installed on the machine, loosen the
proximity switch (6) until it is far as much as possible from the plate (7).

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6 7

6 Proximity switch
7 Plate

(Cont'd)

2 - 68 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.2 Pneumatic Component

(Cont'd)
c) With no air pressure, the pistons (9) are fully inside the cylinders (8) and
the stops (10) are in the outer position for the blank releasing. Slowly
increase the pressure by turning the pressure regulator (2), the pistons (9)
start to move and the stops (10) turn, the correct pressure value is
reached when the pistons (9) are fully out from the cylinders (8) and the
stops (10) are in the position for the blank holding, as shown below.
d) According to the type of support installed on the machine, set the
position of the proximity switch (6) to detect the plate (7), see 2.1.1-1
Carton Magazine - Set Proximity Switch on page 2-49.

9 10 2
8
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Side view - Stops are shown

in position for the blank 7 6
holding
2 Pressure regulator; cylinder blank releasing
6 Proximity switch
7 Plate
8 Cylinder
9 Piston
10 Stop

(Cont'd)

Doc. No. MM-3047612-0101 2 - 69 (80)

2.2 Pneumatic Component 2 Magazine Unit

(Cont'd)

CAUTION
Risk of personal injury.
Moving parts can crush.
e) Deactivate the cylinders for blank releasing, by lifting up the button (5),
then fit back the cover (4) on the pressurizing valve (3).

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3 Pressurizing valve
4 Cover
5 Button

(Cont'd)

2 - 70 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.2 Pneumatic Component

(Cont'd)
Set Pressure Regulator for Pressure Rollers of Carton Transfer
Note! Perform this setting only once, at the first start up of the machine.
a) Make sure that the pressure value indicated on the pressure gauge (1) is
0 bar, if required turn the pressure regulator (2) to reduce the pressure
value.

CAUTION
Risk of personal injury.
Moving parts can crush.
b) Remove the cover (4) from the pressurizing valve (3) then pull down the
button (5).

3 2

3
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1 Pressure gauge
2 Pressure regulator; pressure rollers of carton transfer
3 Pressurizing valve
4 Cover
5 Button
1

(Cont'd)

Doc. No. MM-3047612-0101 2 - 71 (80)

2.2 Pneumatic Component 2 Magazine Unit

(Cont'd)
c) With no air pressure the piston is fully inside the cylinder (6) and the
pressure rollers (7) are far from conveyor belt (8). Make sure that the
pressure rollers (7) are parallel to the conveyor belt (8), if required
loosen the four screws (9) to adjust the parallelism, then tighten the four
screws (9).
d) Fully loosen two setting screws (10) and the two nuts (11) until they are
far from the cylinder (6).
e) Loosen the four screws (12).

10 9 10

11 11
9
12 12

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6

7
8

8
//

6 Cylinder
7 Pressure roller
8 Conveyor belt
9 Screw
10 Setting screw
11 Nut
12 Screw

(Cont'd)

2 - 72 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.2 Pneumatic Component

(Cont'd)
Note! Make sure that there is no cardboard blank between the pressure
rollers (7) and the conveyor belt (8).
CAUTION
Risk of damage to the equipment.
Do not set the pressure regulator (2) over 0.2 MPa (2.0 bar).
f) Set the pressure regulator (2) at 0.2 MPa (2.0 bar), so that the pressure
rollers (7) start to move towards the conveyor belt (8) until the piston is
fully out from the cylinder (6).
g) Tighten the four screws (12) to lock the cylinder (6) in position.
h) Tighten the two setting screws (10) until they are in contact with the
cylinder (6), then tighten the two nuts (11).

2
10
11
12

7
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2 Pressure regulator; pressure rollers

of carton transfer
6 Cylinder
7 Pressure roller
8 Conveyor belt
10 Setting screw
11 Nut
12 Screw

(Cont'd)

Doc. No. MM-3047612-0101 2 - 73 (80)

2.2 Pneumatic Component 2 Magazine Unit

(Cont'd)

CAUTION
Risk of personal injury.
Moving parts can crush.
i) Deactivate the pressure rollers, by lifting up the button (5), then fit back
the cover (4) on the pressurizing valve (3).

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3 Pressurizing valve
4 Cover
5 Button

2 - 74 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.2 Pneumatic Component

2.2.1-3 Air Equipment - Set Pressure Switch

Machine Status Mains Power ON
Air ON
Water ON
SPC Reference 2791737-0200

Basic Setting
Press up-key (2) and down-key (3), at the same time once, and the setting for
min value is shown.
Press up-key (2) and down-key (3), at the same time twice, and the setting
for max value is shown.
Press up-key (2) to view the current settings on the pressure switch.
Unit Definition
a) Press the EDIT button (1) with a pointed object.
b) Press up-key (2) or down-key (3) to find the unit definition and confirm
the choice by pressing the EDIT button (1).
c) Press up-key (2) to select between: Bar, Pascal or PSI.
Tip! The default value is always Bar!
d) Confirm with the EDIT button (1).
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2 3
Edit

A B

1 Edit button
2 Up-key
3 Down-key
1
(Cont'd)

Doc. No. MM-3047612-0101 2 - 75 (80)

2.2 Pneumatic Component 2 Magazine Unit

(Cont'd)
Password Definition
a) Press up-key (2) or down-key (3) to find the password definition and
confirm the choice by pressing the EDIT button (1).
b) Select either:
• 0 = No password
• 1 = Password

Tip! The default value is 0!

c) Confirm the setting by pressing the EDIT button (1).
d) If password protection is chosen, choose the password with up-key (2)
or/and down-key (3) and confirm the setting with the EDIT button (1).
e) Press the EDIT button (1) once more to return to the main menu.
Remove a Password
a) Turn off the power supply disconnecting device.
b) Press EDIT button (1), up-key (2) and down-key (3), simultaneously,
while turning on the power supply disconnecting device.

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2 3
Edit

A B

1 Edit button
2 Up-key
3 Down-key
1
(Cont'd)

2 - 76 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.2 Pneumatic Component

(Cont'd)
Parameter Settings
a) Press the EDIT button (1) twice with a pointed object.
b) Press up-key (2) or down-key (3) to select between threshold or window
comparator. Choose window comparator (4). The selected value starts
flashing.
c) Confirm the setting by pressing the EDIT button (1).
d) Press up-key (2) or down-key (3) to set air pressure 3.8 bar (0.38 MPa).
e) Confirm the setting by pressing the EDIT button (1).
f) Press up-key (2) or down-key (3) to set shut off pressure to 6 bar
(0.60 MPa).
g) Confirm the setting by pressing the EDIT button (1).
h) Press up-key (2) or down-key (3) to select hysteresis value [HY].
i) Press up-key (2) or down-key (3) to set hysteresis value to 0.2 bar
(0.02 MPa).
j) Confirm the setting by pressing the EDIT button (1).
k) Press up-key (2) or down-key (3) to select between normally open or
normally closed. Choose normally closed [NC].
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l) Confirm the choice by pressing the EDIT button (1).

2 3
Edit

1 Edit button
A B
2 Up-key
3 Down-key
4 Symbol for window comparator
1

Doc. No. MM-3047612-0101 2 - 77 (80)

2.2 Pneumatic Component 2 Magazine Unit

2.2.1-4 Air Equipment - Clean Regulator Filter

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2791737-0200

WARNING
Risk of injuries.
The system must be depressurised before cleaning!
Clean the filter regulator, as follows:
a) Shut off the air supply by turning the shut-off valve (1) to the left.
b) Press the button (2) downwards.
c) Turn the filter holder (3) to the left. Jerk it and pull gently downwards.

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2

3
1 Shut-off valve
2 Button
3 Filter holder

(Cont'd)

2 - 78 (80) Doc. No. MM-3047612-0101

 2 Magazine Unit 2.2 Pneumatic Component

(Cont'd)
d) Turn the filter plate (4) to the left.
e) Remove the filter plate (4) and the filter (5).
f) Change the filter (5) or clean it with water (max. + 60°C), soap suds or
petroleum ether (free of compounds).
Note! Only hold the clean filter in the lower end!
g) Attach the filter plate (4) and turn it to the right.

WARNING
Risk of injuries.
The filter bowl must be turned fully to the right into the body before
pressurising the unit.
h) Attach the filter bowl (6). Make sure that the locking pin (7) points
towards the large recess (8) in the housing.
i) Turn the filter bowl (6) to the right until you hear a clicking sound. To
get it in place it might be necessary to jerk it a bit!
TechPub_2614345_0107 - 0201_3057023_01.fm

4 5

4 Filter plate
5 Filter
6 Filter bowl
8 7 Locking pin
7 8 Large recess
6

Doc. No. MM-3047612-0101 2 - 79 (80)

2.2 Pneumatic Component 2 Magazine Unit

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This page intentionally left blank

2 - 80 (80) Doc. No. MM-3047612-0101

 3 Grouping Unit
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Doc. No. MM-3047612-0101 3 - 1 (72)

 3 Grouping Unit

Grouping Unit - Description

SPC Reference 663104-0200
Note! If not indicated in a different way, all the pictures used in the chapter
show the Grouping Unit for a machine with Magazine Unit on the RH side.

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1

2
3.1 Flight Bar
3.2 Stop Unit

3 - 2 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit Table of Contents

3 Grouping Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5
3-1 Grouping Unit - Functional Description . . . . . . . 3 - 5
3-2 Grouping Unit - Setting Sequence, Type I . . . . . . 3 - 7
3-3 Grouping Unit - Setting Sequence, Type II . . . . . 3 - 8
3-4 Grouping Unit - Setting Sequence, Type III . . . . 3 - 8

3.1 Flight Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9

3.1-1 Flight Bar - Set Dead Plate . . . . . . . . . . . . . . . . . . 3 - 9
3.1-2 Flight Bar - Set Side Guides . . . . . . . . . . . . . . . . 3 - 12
3.1-3 Flight Bar - Referencing . . . . . . . . . . . . . . . . . . . 3 - 18
3.1.1 Positioning Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 29
3.1.1-1 Positioning Unit - Check . . . . . . . . . . . . . . . . . . 3 - 29
3.1.1-2 Positioning Unit - Change Sliding Strips . . . . . . 3 - 30
3.1.2 Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 31
TechPub_2614345_0107 - 0301_3057024_01.fm

3.1.2-1 Sprocket - Check . . . . . . . . . . . . . . . . . . . . . . . . 3 - 31

3.1.2-2 Sprocket - Change Ball Bearings . . . . . . . . . . . . 3 - 32
3.1.3 Chain Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 33
3.1.3-1 Chain Unit - Set Tension . . . . . . . . . . . . . . . . . . 3 - 33
3.1.3-2 Chain Unit - Check . . . . . . . . . . . . . . . . . . . . . . . 3 - 35
3.1.3-3 Chain Unit - Overhaul . . . . . . . . . . . . . . . . . . . . 3 - 37
3.1.4 Chain Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 43
3.1.4-1 Chain Tensioner - Set Spring Force . . . . . . . . . . 3 - 43
3.1.4-2 Chain Tensioner - Check . . . . . . . . . . . . . . . . . . 3 - 44
3.1.4-3 Chain Tensioner - Change Sliding Profile . . . . . 3 - 45
3.1.5 Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 46
3.1.5-1 Drive Shaft - Check . . . . . . . . . . . . . . . . . . . . . . 3 - 46
3.1.5-2 Drive Shaft - Change Ball Bearings . . . . . . . . . . 3 - 48
3.1.6 Servo Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 51
3.1.6-1 Servo Motor - Check . . . . . . . . . . . . . . . . . . . . . 3 - 51
3.1.6-2 Servo Motor - Set Chains Tension . . . . . . . . . . . 3 - 52
3.1.6-3 Servo Motor - Change Chains . . . . . . . . . . . . . . 3 - 53

Doc. No. MM-3047612-0101 3 - 3 (72)

Table of Contents 3 Grouping Unit

3.2 Stop Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 54

3.2-1 Stop Unit - Set . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 54
3.2-2 Stop Unit - Referencing . . . . . . . . . . . . . . . . . . . 3 - 60
3.2-3 Stop Unit - Set Timing Belt Tension . . . . . . . . . 3 - 64
3.2-4 Stop Unit - Check . . . . . . . . . . . . . . . . . . . . . . . 3 - 65
3.2-5 Stop Unit - Change Timing Belt . . . . . . . . . . . . 3 - 66
3.2-6 Stop Unit - Change Ball Bearings . . . . . . . . . . . 3 - 69
3.2.1 Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 71
3.2.1-1 Arm - Change Rubber Strip . . . . . . . . . . . . . . . . 3 - 71

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3 - 4 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3 Grouping Unit

3 Grouping Unit
3-1 Grouping Unit - Functional Description
The grouping area consists of: a Stop Unit (1), two Flight Bars (3) and (4)
with different functions and the Side Guides (5).
The two Flight Bars (3) and (4) are controlled by one servo motor each, the
Push Flight Bars (3) run synchronized with the main motor of the machine,
whilst the Stop Flight Bars (4) run with different speed. When the Minimum
Queue Photocell has been activated, after a certain time the arms (2) of the
Stop Unit (1) will move down and squeeze the top of the packages standing
on the Accumulation Conveyor, at the same time the Stop Flight Bars (4)
will start to move.
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5
1 Stop unit
2 Arm
3 Push flight bar Infeed direction
4 Stop flight bar
5 Side guide 1 2
(Cont'd)

Doc. No. MM-3047612-0101 3 - 5 (72)

3 Grouping Unit 3 Grouping Unit

(Cont'd)
When the machine is ready for the production, the arms (2) of the Stop
Unit (1), will move up and release a group of packages necessary to form the
packing pattern, then the arms (2) will move down again, the packing pattern
is then transported forward by the Grouping Conveyor against the Stop
Flight Bars (4). The Grouping Conveyor runs with constant speed, driven by
a motor that is controlled with a frequency inverter. The Stop Flight Bars (4)
will increase in speed and move away from the packing pattern, at the same
time the Push Flight Bar (3) is coming down behind the packing pattern and
gently push it forward, during their movement the packages are slightly
compacted together by the side guides (5).

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4

5
1 Stop unit
2 Arm
3 Push flight bar Infeed direction
4 Stop flight bar
5 Side guide 1 2

3 - 6 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3 Grouping Unit

3-2 Grouping Unit - Setting Sequence, Type I

Type I settings must be performed in sequence according to the flowchart
below. These settings are performed before the first start-up or
commissioning of the machine.

3.1-1 Flight Bar - Set Dead Plate on page 3-9

3.1-2 Flight Bar - Set Side Guides on page 3-12

3.1-3 Flight Bar - Referencing on page 3-18

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3.2-1 Stop Unit - Set on page 3-54

3.2-2 Stop Unit - Referencing on page 3-60

Doc. No. MM-3047612-0101 3 - 7 (72)

3 Grouping Unit 3 Grouping Unit

3-3 Grouping Unit - Setting Sequence, Type II

Type II settings must be performed in sequence according to the flowchart
below. These settings are performed when the production change, in order to
adjust the Grouping Unit for the package unit in use and the packing pattern
to be produced.

3.1-2 Flight Bar - Set Side Guides on page 3-12

3.2-1 Stop Unit - Set on page 3-54

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3-4 Grouping Unit - Setting Sequence, Type III
Type III settings include all the remaining Grouping Unit setting procedures.
These settings can be performed independently and have no effect on any of
the other Grouping Unit settings.

3 - 8 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.1 Flight Bar

3.1 Flight Bar

SPC Reference 2812930-0200

3.1-1 Flight Bar - Set Dead Plate

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2812910-0100

Dead Plate - Check

The machine is equipped with two type of dead plates: the short dead
plate (1) must be used only to produce a particular box according to the table
below, while the long dead plate (2) must be used in all the other cases.
Check the dead plate installed on the machine and if necessary change it
using the four screws (3).

Type of Dead Plate A (mm) Box to Produce

Packing Pattern Type of Blank
Dead plate (1) 328 ±1 3X4 TBA 1000Sq with WAIF with
TP No. 3037956-0000 StreamCap 1000 Close End Flap
Dead plate (2) 338 ±1 All the others All the others
TechPub_2614345_0107 - 0301_3057025_01.fm

TP No. 2741941-0000

3 2 3

1 Dead plate (short)

2 Dead plate (long) A
3 Screw

(Cont'd)

Doc. No. MM-3047612-0101 3 - 9 (72)

3.1 Flight Bar 3 Grouping Unit

(Cont'd)
Dead Plate - Setting
a) Set the dead plate (3) at the distance A, lower than the conveyor
chain (1) and distance B upper than the support rail (4) of the feed unit.
If required, fine adjust the height of the dead plate (3), on both sides,
using the nuts (2) of the spring loaded screws, as follows:
• tighten the nuts (2) to lift of the dead plate (3), or
• loosen the nuts (2) to lower the dead plate (3).

3 2 1
Infeed direction
B A

A = 0.5 ±0.1 mm

4 B = 3 ÷ 4 mm

TechPub_2614345_0107 - 0301_3057025_01.fm
Side view
Infeed direction

3
1 Conveyor chain
2 Nut
3 Dead plate
4 Support rail
2
(Cont'd)

3 - 10 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.1 Flight Bar

(Cont'd)
b) Set the dead plate (3) at the distance C from the conveyor chain (1), with
the screws (5), making sure to measure the distance C from the edge of
the conveyor chain (1) and not from the flat surface, in order to avoid
that the conveyor chain (1) touches the dead plate (3) during the
PRODUCTION.

3 5 5 1
Infeed direction C

C = 1 ÷ 1.5 mm

Side view
TechPub_2614345_0107 - 0301_3057025_01.fm

Infeed direction

1 Conveyor chain
3 Dead plate
5 Screw

5 5

Doc. No. MM-3047612-0101 3 - 11 (72)

3.1 Flight Bar 3 Grouping Unit

3.1-2 Flight Bar - Set Side Guides

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2882250-0200

Side Guides - Basic Setting

a) Before starting make sure that the spacers (1) are installed between the
beams (2) and (3), if not use the screws (4) to fit the spacers (1).

3 2

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1
1
2

1 Spacer
2 Beam
3 Beam
4 Screw

(Cont'd)

3 - 12 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.1 Flight Bar

(Cont'd)
b) Make sure that both side guides (5) are set fully low, by checking if there
is the distance A from the top side of the beams (3). If required adjust
each side guide (5) with the screws (6).

3 3 3
A = 160 ± 0.5 mm

6 6

A A A
5

Side view
TechPub_2614345_0107 - 0301_3057025_01.fm

3
Infeed direction

3 Beam
5 Side guide
6 Screw

5
(Cont'd)

Doc. No. MM-3047612-0101 3 - 13 (72)

3.1 Flight Bar 3 Grouping Unit

(Cont'd)

CAUTION
Risk of damage to the equipment.
Make sure that the push flight bars (8) and the stop flight bars (11), run free
without touching the side guides (5).
c) For both side guides (5) make sure that: the front side is placed at the
distance B from the shaft (7) and that there is the distance C between the
two parts forming each side guide (5). If required, fine adjust
longitudinally each side guide (5) with the nuts (9) and the screw (10).

B = 80 ± 0.5 mm
7 C = 10± 1 mm

B C

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Side view
8 9 5 10 9 11

Infeed direction

5 Side guide
7 Shaft
7 8 Push flight bar
9 Nut
10 Screw
11 Stop flight bar

5
(Cont'd)

3 - 14 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.1 Flight Bar

(Cont'd)
Side Guides - Preparation
CAUTION
Risk of damage to the equipment.
Make sure that both side guides (1) and (2) can be moved freely during the
settings.
Before starting with the settings described on the next pages, it is necessary
to slightly loosen the nut (3) and the screws (4) and (5) so that the side
guides (1) and (2) can be moved freely, at the end of the setting tighten the
nuts and the screws.

1
Infeed direction

5
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2
3

4
1 Side guide (0-line)
2 Side guide
3 Nut
4 Screw
5 Screw

(Cont'd)

Doc. No. MM-3047612-0101 3 - 15 (72)

3.1 Flight Bar 3 Grouping Unit

(Cont'd)
Side Guides - Set 0-Line Side (Magazine Unit Side)
Note! According to the configuration of the machine, the side guide (1) on
the magazine unit side corresponds always to 0-line side.
Only if the machine has to produce the combination: family packs and
cardboard box of width A > 400 mm, set the side guide (1) at the distance
B = 164 mm, then make sure to set the feed unit by following the procedure
Feed Unit - Set Width for Wide Cardboard Boxes on page 4-20.
Measure the width A of the outside bottom of the cardboard box to produce,
then adjust the position of the side guide (1) on the 0-line side using the four
locking levers (2), as follows:
• according to the table below, set the side guide (1) parallel and at the
distance B from the plate (3), check the parallelism using the setting
scales (4) as reference
• set the side guide (1) at the distance C wider than the outer guide rail (5)
actually in use for the packing pattern to produce.

3 2 Magazine unit side

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C
B
A
B
A ≤ 400 mm A > 400 mm
Infeed direction 1 5
B 195 ±0.5 mm 164 ±0.5 mm

C = 10 ÷ 20 mm

1 Side guide (0-line) 4 Setting scale Top view

2 Locking lever 5 Guide rail
3 Plate

(Cont'd)

3 - 16 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.1 Flight Bar

(Cont'd)
Side Guides - Set Width
Note! Before starting, make sure that the side guide (1) has been already
set, see previous page. The width A is referred to a packing pattern with the
packages not squeezed together.
According to the width A of the packing pattern, adjust the position of the
side guide (2) using the four locking levers (4), as follows:
• set the side guide (2) parallel and at the distance B from the side
guide (1), check the parallelism using the setting scales (3) as reference
• set the side guide (2) at the distance C wider than the outer guide rail (5)
actually in use for the packing pattern to produce.
Magazine unit side
1

B=A

Infeed direction
B B 5 C = 10 ÷ 20 mm
TechPub_2614345_0107 - 0301_3057025_01.fm

2 C
3

Top view
4 A

1 Side guide (0-line)

2 Side guide
3 Setting scale
4 Locking lever
5 Guide rail

Doc. No. MM-3047612-0101 3 - 17 (72)

3.1 Flight Bar 3 Grouping Unit

3.1-3 Flight Bar - Referencing

Machine Status AIR ON
SPC Reference 663104-0200
Note! Perform this setting at the first start up of the machine or after the
replacement of a servo motor.
Note! Before starting make sure to perform the 4-11 Feed Unit - Referencing
on page 4-36.
Preparation
a) On the TPOP, log on as: “tptechnician” or “supervisor” or “technician”,
see 6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) Step up the machine to AIR ON, then continue by following the
instructions Push Flight Bars - Set Homing Position on page 3-20, if the
ABSOLUTE HOMING POSITION LOST alarm (1) appears continue
by following the instructions Absolute Homing Position Lost Alarm -
Reset on page 3-19.

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1 Absolute homing position lost alarm

(Cont'd)

3 - 18 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.1 Flight Bar

(Cont'd)
Absolute Homing Position Lost Alarm - Reset
a) Press the STEP UP button (1) to step up the machine to PREHEATING.
b) Touch the ALARM AKNOWLEDGE button (2), the alarm does not
disappear.
c) Touch the MAINTENANCE button (3) and the GROUPING UNIT
button (4), or touch the GROUPING UNIT tab (5).
d) Touch the OFFSET icons (6) or the HOME POSITION icons (7).
e) Touch the ON button (8) to select the function.
f) Press the STEP UP button (1) to step up the machine to AIR ON.
g) Continue by following the instructions Push Flight Bars - Set Homing
Position on page 3-20.

1 2 3 4

5
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6 7 8
1 Step up button 5 Grouping unit tab
2 Alarm aknowledge button 6 Offset icon
3 Maintenance button 7 Home position icon
4 Grouping unit button 8 ON button

(Cont'd)

Doc. No. MM-3047612-0101 3 - 19 (72)

3.1 Flight Bar 3 Grouping Unit

(Cont'd)
Push Flight Bars - Set Homing Position
a) With the machine in AIR ON, touch the MAINTENANCE button (1) and
the GROUPING UNIT button (2), or touch the GROUPING UNIT
tab (3).
b) Touch the PUSH FLIGHT BAR OFFSET icon (4), in order to display
the dialogue window.
c) Touch the ON button (5) to select the movement function.
d) Touch the OFFSET VALUE icon (6) to display the dialogue window.

1 2 3 4

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1 Maintenance button 6
2 Grouping unit button
3 Grouping unit tab
4 Push flight bar offset icon
5 ON button
6 Offset value icon

(Cont'd)

3 - 20 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.1 Flight Bar

(Cont'd)
e) The offset value is displayed in the SETTING VALUE field (7). Set the
offset value to move the push flight bars in the homing position (see the
next pages), as follows:
• touch the FACTORY button (10) to display the factory value
• touch the DOUBLE-ARROW buttons (8) to increase or decrease the value
of 10 mm
• touch the SINGLE-ARROW buttons (9) to increase or decrease the value
of 1 mm
• touch the KEYBOARD button (11) to display the numeric keyboard, then
type the value.
f) When the new value is displayed in the OFFSET VALUE field (12),
touch the CONFIRMATION button (13) to move the push flight bars.

7
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8 9 8 10 11

7 Setting value field

8 Double-arrow button
9 Single-arrow button
12 13
10 Factory button
11 Keyboard button
12 Offset value field
13 Confirmation button

(Cont'd)

Doc. No. MM-3047612-0101 3 - 21 (72)

3.1 Flight Bar 3 Grouping Unit

(Cont'd)
g) On both sides, make sure that the pushers (14), are aligned to the
reference marks (15) existing on the frames, see 4-11 Feed Unit -
Referencing on page 4-36.
h) Open the door and place a steel ruler (16) against both pushers (14).

16

14

15

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14

15

14 Pusher
15 Reference mark
16 Steel ruler

(Cont'd)

3 - 22 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.1 Flight Bar

(Cont'd)
i) The home position is reached when a push flight bar (17) is positioned at
the distance A from the steel ruler (16) placed behind the pushers (14).
j) Remove the steel ruler (16) and close the door.
Note! In case that the ABSOLUTE HOMING POSITION LOST alarm (18)
has been activated, after opening the door in order to check the distance A,
then continue from item b) on page 3-19.
k) If necessary repeat the instructions from item e) on page 3-21, using a
different offset value until the home position is reached, otherwise
confirm the home position as follows on the next page.

18

A = 635 ±0.2 mm
16 14
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17
14 Pusher
16 Steel ruler
17 Push flight bar
Top view
18 Absolute homing position lost alarm

(Cont'd)

Doc. No. MM-3047612-0101 3 - 23 (72)

3.1 Flight Bar 3 Grouping Unit

(Cont'd)
l) Confirm the home position as follows:
• touch the OFF button (19) to deselect the movement function
• touch the PUSH FLIGHT BAR ABSOLUTE HOMING icon (20)
• touch the ON button (21) to select the homing function
• touch the CONFIRMATION button (22) to confirm the home position
• touch the EXIT button (23).

19 20

21 22 23
19 OFF button

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20 Push flight bar absolute homing icon
21 ON button
22 Confirmation button
23 Exit button

(Cont'd)

3 - 24 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.1 Flight Bar

(Cont'd)
Stop Flight Bars - Set Homing Position
a) If not already done, with the machine in AIR ON, touch the
MAINTENANCE button (1) and the GROUPING UNIT button (2), or
touch the GROUPING UNIT tab (3).
b) Touch the STOP FLIGHT BAR OFFSET icon (4), in order to display
the dialogue window.
c) Touch the ON button (5) to select the movement function.
d) Touch the OFFSET VALUE icon (6) to display the dialogue window.

1 2 3 4

5
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1 Maintenance button 6
2 Grouping unit button
3 Grouping unit tab
4 Stop flight bar offset icon
5 ON button
6 Offset value icon

(Cont'd)

Doc. No. MM-3047612-0101 3 - 25 (72)

3.1 Flight Bar 3 Grouping Unit

(Cont'd)
e) The offset value is displayed in the SETTING VALUE field (7). Set the
offset value to move the stop flight bars in the homing position (see the
next page), as follows:
• touch the FACTORY button (10) to display the factory value
• touch the DOUBLE-ARROW buttons (8) to increase or decrease the value
of 10 mm
• touch the SINGLE-ARROW buttons (9) to increase or decrease the value
of 1 mm
• touch the KEYBOARD button (11) to display the numeric keyboard, then
type the value.
f) When the new value is displayed in the OFFSET VALUE field (12),
touch the CONFIRMATION button (13) to move the stop flight bars.

TechPub_2614345_0107 - 0301_3057025_01.fm
8 9 8 10 11

7 Setting value field

8 Double-arrow button
9 Single-arrow button
10 Factory button
12 13
11 Keyboard button
12 Offset value field
13 Confirmation button

(Cont'd)

3 - 26 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.1 Flight Bar

(Cont'd)
g) The home position is reached when a stop flight bar (14), is positioned at
the distance A from the slide rail (15), existing between the indexing
conveyor (16) and the grouping conveyor (17).
Note! In case that the ABSOLUTE HOMING POSITION LOST alarm (18)
has been activated, after opening the door in order to check the distance A,
then continue from item b) on page 3-19.
h) If necessary repeat the instructions from item e) on page 3-26, using a
different offset value until the home position is reached, otherwise
confirm the home position as follows on the next page.

18
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A = 140 ±0.2 mm

17 14
A 15
16
14 Stop flight bar
15 15 Slide rail
16 Indexing conveyor
16 17 Grouping conveyor
18 Absolute homing position lost
alarm
Top view

(Cont'd)

Doc. No. MM-3047612-0101 3 - 27 (72)

3.1 Flight Bar 3 Grouping Unit

(Cont'd)
i) Confirm the home position as follows:
• touch the OFF button (19) to deselect the movement function
• touch the STOP FLIGHT BAR ABSOLUTE HOMING icon (20)
• touch the ON button (21) to select the homing function
• touch the CONFIRMATION button (22) to confirm the home position
• touch the EXIT button (23).

19 20

21 22 23
19 OFF button

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20 Stop flight bar absolute homing icon
21 ON button
22 Confirmation button
23 Exit button

3 - 28 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.1 Flight Bar

3.1.1 Positioning Unit

3.1.1-1 Positioning Unit - Check
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2812910-0100

a) Open and pull out the chains (1), see 3.1.3-3 Chain Unit - Overhaul on
page 3-37.
b) On both sides, check that the sliding strips (2) are not worn or damaged,
if required change them, see 3.1.1-2 Positioning Unit - Change Sliding
Strips on page 3-30.
c) At the end fit back and lock the chains (1), see 3.1.3-3 Chain Unit -
Overhaul on page 3-37.
TechPub_2614345_0107 - 0301_3057025_01.fm

1
2
1 Chain
2 Sliding strip

Doc. No. MM-3047612-0101 3 - 29 (72)

3.1 Flight Bar 3 Grouping Unit

3.1.1-2 Positioning Unit - Change Sliding Strips

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2812910-0100

a) Open and pull out the chains (1) and (2), see 3.1.3-3 Chain Unit -
Overhaul on page 3-37.
b) On both sides, replace the sliding strips (6) as follows:
• remove the screws (3) and the slide rail (4)
• remove the screws (5) and take out the sliding strip (6)
• replace the sliding strip (6) and assemble in the reverse order.
c) At the end fit back and lock the chains (1) and (2), see 3.1.3-3 Chain
Unit - Overhaul on page 3-37.

TechPub_2614345_0107 - 0301_3057025_01.fm
1

1 Chain
3
2 Chain
3 Screw
4 Slide rail 4
5 Screw
6 Sliding strip
5

3 - 30 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.1 Flight Bar

3.1.2 Sprocket
3.1.2-1 Sprocket - Check
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2812920-0100

a) Open and pull out the chains (1), see 3.1.3-3 Chain Unit - Overhaul on
page 3-37.
b) On both sides, check that the four sprocket units (2) rotate freely and
without play, if required replace the ball bearings, see 3.1.2-2 Sprocket -
Change Ball Bearings on page 3-32.
c) At the end fit back and lock the chains (1), see 3.1.3-3 Chain Unit -
Overhaul on page 3-37.
TechPub_2614345_0107 - 0301_3057025_01.fm

2
1

1 Chain
2 Sprocket
2

Doc. No. MM-3047612-0101 3 - 31 (72)

3.1 Flight Bar 3 Grouping Unit

3.1.2-2 Sprocket - Change Ball Bearings

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2812920-0100
Note! The following instructions are valid for all the four sprockets groups,
indicated with arrows.
a) Remove the plate (1) by removing the two screws (2).
b) Remove the retaining ring (4), the sprockets (3) and the spacer (6).
c) Take out the ball bearings (5) from the sprockets (3). Discard the ball
bearings (5).
d) Replace the ball bearings (5) and assemble in the reverse order.

TechPub_2614345_0107 - 0301_3057025_01.fm
2
3

3
1 4
5

6 1 Plate 4 Retaining ring

2 Screw 5 Ball bearing
5 3 Sprocket 6 Spacer

3 - 32 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.1 Flight Bar

3.1.3 Chain Unit

3.1.3-1 Chain Unit - Set Tension
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2812940-0100

a) On both sides, as a basic setting, place the plate (1) using the screws (2)
at the distance A from the side of the plate (3).

A
3

2
A
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1
A = 30 ±0.5 mm

1 Plate
2 Screw
3 Plate

(Cont'd)

Doc. No. MM-3047612-0101 3 - 33 (72)

3.1 Flight Bar 3 Grouping Unit

(Cont'd)
Note! Make sure that the four chain tensioners (4) are well set, see 3.1.4-1
Chain Tensioner - Set Spring Force on page 3-43.
b) Check the tension of the four chains (5) by measuring the distance B. If
required adjust the chain tension on both sides with the screws (6).

4
6

TechPub_2614345_0107 - 0301_3057025_01.fm
5
B

B = 15 ±0.5 mm 5

4 Chain tensioner
5 Chain
6 Screw

3 - 34 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.1 Flight Bar

3.1.3-2 Chain Unit - Check

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2812940-0100

a) Check that:
• the four chains (1) and the rollers (2) are not worn or damaged, if
required change them see 3.1.3-3 Chain Unit - Overhaul on page 3-37
• the tension of the four chains (1) is set correctly, see 3.1.3-1 Chain Unit -
Set Tension on page 3-33.
b) Open and pull out the chains (1), see 3.1.3-3 Chain Unit - Overhaul on
page 3-37, to perform the next checks.

2
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1 Chain
2 Roller
1
(Cont'd)

Doc. No. MM-3047612-0101 3 - 35 (72)

3.1 Flight Bar 3 Grouping Unit

(Cont'd)
c) On both sides, check that the sliding strips (3) and (4) are not worn or
damaged, if required change them, see Sliding Strips Replacement on
page 3-41.
d) At the end fit back and lock the chains, see 3.1.3-3 Chain Unit -
Overhaul on page 3-37.

TechPub_2614345_0107 - 0301_3057025_01.fm
3

3 Sliding strip
4 Sliding strip

3 - 36 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.1 Flight Bar

3.1.3-3 Chain Unit - Overhaul

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2812940-0100

Chains Replacement
a) Open the chains (1) and (2) by removing the chain lock (3).
b) Pull out the chains (1) and (2) from the grouping unit.
TechPub_2614345_0107 - 0301_3057025_01.fm

1
3

1 Chain
2 Chain
3 Chain lock

(Cont'd)

Doc. No. MM-3047612-0101 3 - 37 (72)

3.1 Flight Bar 3 Grouping Unit

(Cont'd)
c) Separate all the push flight bar (4) from the chains (1) and all the stop
flight bar (5) from the chains (2), by removing the screws (6) and the
blocks (7).
d) Replace the chains (1) and (2) then assemble in the reverse order,
making sure to place the blocks (7) on the Magazine Unit Side.

6
7

TechPub_2614345_0107 - 0301_3057025_01.fm
6 6

1 7
5

6
1 Chain
2 Chain 2
4 Push flight bar
5 Stop flight bar
6 Screw
7 Block

(Cont'd)

3 - 38 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.1 Flight Bar

(Cont'd)
Note! According to the motion direction of the chains (1) and (2), make sure
to fit the chain lock (3) as shown below.
e) Fit back the chains (1) and (2) then lock each chain using the chain
lock (3).

Motion direction
TechPub_2614345_0107 - 0301_3057025_01.fm

1
3

1 Chain
2 Chain
3 Chain lock

(Cont'd)

Doc. No. MM-3047612-0101 3 - 39 (72)

3.1 Flight Bar 3 Grouping Unit

(Cont'd)
Rollers Replacement
a) On each push flight bar (1), remove the screws (2), the rollers (3) and the
spacers (4).
b) Replace the rollers (3) and assemble in the reverse order.

TechPub_2614345_0107 - 0301_3057025_01.fm
2
3
4

4
3 1 Push flight bar
2 Screw
2 3 Roller
1 4 Spacer

(Cont'd)

3 - 40 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.1 Flight Bar

(Cont'd)
Sliding Strips Replacement
a) On both sides, replace the sliding strips (6) as follows:
• remove the two screws (1), the plate (2) and the spacer (4)
• remove the screws (5) and the sliding strips (6)
• replace the sliding strips (6) and assemble in the reverse order.
b) Reset the position of plates (2), see 3.1.3-1 Chain Unit - Set Tension on
page 3-33.

3
2
1
4
TechPub_2614345_0107 - 0301_3057025_01.fm

1 Screw
2 Plate
3 Nut
4 Spacer
5 Screw
6 Sliding strip

(Cont'd)

Doc. No. MM-3047612-0101 3 - 41 (72)

3.1 Flight Bar 3 Grouping Unit

(Cont'd)
c) On both sides, replace the sliding strips (9) as follows:
• remove the screws (7) and the plate (8)
• remove the screws (10), the nuts and the sliding strips (9)
• replace the sliding strips (9) and assemble in the reverse order.

10
9

TechPub_2614345_0107 - 0301_3057025_01.fm
8

7 Screw
8 Plate
9 Sliding strip
10 Screw

3 - 42 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.1 Flight Bar

3.1.4 Chain Tensioner

3.1.4-1 Chain Tensioner - Set Spring Force
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2812950-0200

The chain tensioners (1) are equipped with three screws (2) reachable
through the holes on the plates (3), each screw (2) controls a spring inside the
chain tensioner (1). The final spring force for each chain tensioner (1),
depends by the number of springs unlocked, if required tighten a screw (2) to
lock the spring, or loosen a screw (2) to unlock the spring.
Note! As a basic setting, make sure that on each chain tensioner (1), the
middle screw is tightened and the other two screws are loosened.

3
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1 Chain tensioner
2 Screw
3 Plate

Doc. No. MM-3047612-0101 3 - 43 (72)

3.1 Flight Bar 3 Grouping Unit

3.1.4-2 Chain Tensioner - Check

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2812950-0200

Check that:
• the spring force of the four chain tensioners (1) is set correctly,
see 3.1.4-1 Chain Tensioner - Set Spring Force on page 3-43
• the sliding profiles (2) are not worn or damaged, if required change
them, see 3.1.4-3 Chain Tensioner - Change Sliding Profile on
page 3-45.

TechPub_2614345_0107 - 0301_3057025_01.fm

1 Chain tensioner
2 1 2 Sliding profile

3 - 44 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.1 Flight Bar

3.1.4-3 Chain Tensioner - Change Sliding Profile

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2812950-0200

Change the slide profile (3), on each chain tensioner (1) as follows:
• on both sides, remove the couple of chain tensioners (1) by removing the
two screws (4)
• remove the two screws (2) then change the sliding profiles (3) and
assemble in the reverse order
• reset the chains tension, see 3.1.3-1 Chain Unit - Set Tension on
page 3-33.
TechPub_2614345_0107 - 0301_3057025_01.fm

2
1

1 Chain tensioner 3 Sliding profile

2 Screw 4 Screw

Doc. No. MM-3047612-0101 3 - 45 (72)

3.1 Flight Bar 3 Grouping Unit

3.1.5 Drive Shaft

3.1.5-1 Drive Shaft - Check
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2812960-0200
2813030-0200

a) Open and pull out the chains (1) and (2), see 3.1.3-3 Chain Unit -
Overhaul on page 3-37, to perform the next checks.

TechPub_2614345_0107 - 0301_3057025_01.fm
1

1 Chain
2 Chain

(Cont'd)

3 - 46 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.1 Flight Bar

(Cont'd)
b) Check that both drive shafts (3) and the sprockets (4) rotate freely and
without any play, if required replace the ball bearings, see 3.1.5-2 Drive
Shaft - Change Ball Bearings on page 3-48.
c) At the end fit back and lock the chains, see 3.1.3-3 Chain Unit -
Overhaul on page 3-37.

3
4

4
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3 Drive shaft
4 Sprocket

Doc. No. MM-3047612-0101 3 - 47 (72)

3.1 Flight Bar 3 Grouping Unit

3.1.5-2 Drive Shaft - Change Ball Bearings

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2812960-0200
2813030-0200

a) Open and remove the chains (4), (5) and (6).

b) Remove the screws (3) to disconnect the drive shafts (1) and (2).
c) Continue following the instructions described for the Drive Shaft (1) on
page 3-49 and for the Drive Shaft (2) on page 3-50.
Note! For a good functioning of the machine, make sure to install the drive
shafts (1) and (2) in the correct positions inside the grouping unit.
d) At the end fit back the drive shafts (1) and (2) in the reverse order and
lock the chains (4), (5) and (6).

1 3 2
3

TechPub_2614345_0107 - 0301_3057025_01.fm
4 3
3

5
1 Drive shaft
2 Drive shaft
3 Screw
6 4 Chain
5 Chain
6 Chain

(Cont'd)

3 - 48 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.1 Flight Bar

(Cont'd)
Drive Shaft (1)
Perform the following instructions, on both sides of the drive shaft (1):
• remove the plate (2) from the drive shaft (1)
• remove one of the retaining rings (3) then pull out the ball bearing (4)
from the plate (2)
• remove the two retaining rings (5), the ball bearings (6) and the
sprocket (7)
• replace the ball bearings (4) and (6) then assemble and fit back the drive
shaft (1) in the reverse order.

6
7
6
5 1
3
TechPub_2614345_0107 - 0301_3057025_01.fm

4
3
1 Drive shaft
2 Plate
3 Retaining ring
4 Ball bearing
5 Retaining ring
6 Ball bearing
7 Sprocket
2
(Cont'd)

Doc. No. MM-3047612-0101 3 - 49 (72)

3.1 Flight Bar 3 Grouping Unit

(Cont'd)
Drive Shaft (2)
Perform the following instructions, on both sides of the drive shaft (2):
• remove the plate (3) from the drive shaft (2)
• remove one of the retaining rings (4) then pull out the ball bearing (5)
from the plate (3)
• remove the two retaining rings (6) and the sprocket (7) making sure to
not lose the key (1)
• remove the two retaining rings (8), the ball bearings (9) and the
sprocket (10)
• replace the ball bearings (5) and (9) then assemble and fit back the drive
shaft (2) in the reverse order.

9
10

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9
8 2
7
6
4 1 Key
5 2 Drive shaft
4 1 3 Plate
4 Retaining ring
5 Ball bearing
6 Retaining ring
7 Sprocket
8 Retaining ring
9 Ball bearing
10 Sprocket
3

3 - 50 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.1 Flight Bar

3.1.6 Servo Motor

3.1.6-1 Servo Motor - Check
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2812990-0300
2813040-0300

Check that:
• the two chains (1) are well tensioned, see 3.1.6-2 Servo Motor - Set
Chains Tension on page 3-52
• the two chains (1) are not worn or damaged, if required change them see
3.1.6-3 Servo Motor - Change Chains on page 3-53.

1
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1 Chain

Doc. No. MM-3047612-0101 3 - 51 (72)

3.1 Flight Bar 3 Grouping Unit

3.1.6-2 Servo Motor - Set Chains Tension

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2812990-0300
2813040-0300

Set the tension of both chains (1) as follows:

• make sure that the screw (4) has been removed, then if necessary
manually move the servo motor (5) until the chain (1) is well tensioned
by the two springs (6)
• block the servo motor (5) in position with the screw (2) and the nut (3).

5 1
4 6 3 2

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1

1 Chain
2 Screw
3 Nut
4 Screw
5 Servo motor
6 Spring

3 - 52 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.1 Flight Bar

3.1.6-3 Servo Motor - Change Chains

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2812990-0300
2813040-0300

a) Release the tension of the chain (1) with the screw (2) and the nut (3).
b) Open the chain (1) by removing the chain lock (4).
Note! According to the motion direction of the chains (1), make sure to fit the
chain lock (4) as shown below.
c) Fit the new chain (1) and then lock it with the chain lock (4).
d) Loosen the screw (2) and the nut (3), then manually move the servo
motor (5) until the chain (1) is well tensioned by the two springs (6).
e) Lock the servo motor (5) in position with the screw (2) and the nut (3).

4 1 5 1
Motion direction
TechPub_2614345_0107 - 0301_3057025_01.fm

6 3

1 2

1 Chain 4 Chain lock

2 Screw 5 Servo motor
3 Nut 6 Spring

Doc. No. MM-3047612-0101 3 - 53 (72)

3.2 Stop Unit 3 Grouping Unit

3.2 Stop Unit

SPC Reference 2813110-0200

3.2-1 Stop Unit - Set

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2813110-0200

Stop Unit - Basic Settings

a) Make sure that the shaft (1) is centred and blocked in position, by
checking on both sides if there is the same distance A, measured
between the ends of the shaft (1) and the side of the plates (2) and (3).
If required adjust as follows:
• loosen all the grub screws (4) on both retaining rings (5) then centre the
shaft (1)
• move both retaining rings (5) until they touch the ball bearings (6), then
tighten the grub screws (4) on both sides to lock the shaft (1) in position.

5 3 5 2

TechPub_2614345_0107 - 0301_3057026_01.fm
4 4

A A

1 1

1 Shaft
2 Plate
3 Plate
4 Grub screw
5 Retaining ring 6 1 2
6 Ball bearing
3 6

(Cont'd)

3 - 54 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.2 Stop Unit

(Cont'd)
b) Make sure that the pulleys (7) and (8) are aligned, so that the timing
belt (9) runs straight as much as possible. If required adjust as follows:
• loosen the clamping element (10)
• adjust the position of the pulley (8) until it is aligned to the pulley (7)
• tighten the clamping element (10).

7
9
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8
7 Pulley
8 Pulley
9 Timing belt
10 Clamping element

10 9

(Cont'd)

Doc. No. MM-3047612-0101 3 - 55 (72)

3.2 Stop Unit 3 Grouping Unit

(Cont'd)
c) For each arm (11), make sure that the top side of the support (12) is
always aligned to the bar (13) as shown below. If necessary loosen the
two screws (14) and push the support (12) against the bar (13), then
tighten the two screws (14).

13 12

14

13 12
11

Side view

TechPub_2614345_0107 - 0301_3057026_01.fm
11 Arm 11
12 Support
13 Bar
14 Screw

(Cont'd)

3 - 56 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.2 Stop Unit

(Cont'd)
Stop Unit - Set Height
Set the height of the stop unit, so that the bottom side of the shaft (1) is at the
distance A, from the top side of the package. If required adjust as follows:
• loosen the four screws (2) and the screw (3)
• on both sides, set the vertical position of the stop unit, using the two
setting screws (4) until the distance A is reached
• tighten the screws (2) and (3).

4 1 4

A A
TechPub_2614345_0107 - 0301_3057026_01.fm

A = 90 ±0.5 mm

2 2

1 Shaft
2 Screw
3 Screw
4 Setting screw

(Cont'd)

Doc. No. MM-3047612-0101 3 - 57 (72)

3.2 Stop Unit 3 Grouping Unit

(Cont'd)
Stop Unit - Set Arms
Note! The machines running with portion packs are equipped with ten
arms (1) and the machines running with family packs are equipped with six
arms (1). When using packages equipped with caps, make sure that the
arms (1),do not press on the caps but only on the packaging material, in
order to avoid any damage to the packages.
Set the position of the arms (1) so that they push the top side of the incoming
packages. If required loosen the two grub screws (2) and the two screws (3)
to move the arm (1) in the correct position, make sure that the top side of the
support (4) is always aligned to the bar (5), then tighten the grub screws (2)
and the screws (3).

Setting for Single Portion Packs

5 4 3
2

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1 Setting for Single Family Packs

1 Arm
2 Grub screw
3 Screw
4 Support
5 Bar

(Cont'd)

3 - 58 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.2 Stop Unit

(Cont'd)
Note! The picture below shows some examples of setting for Multi Packs.

Setting for Multi Portion Packs

Setting for Multi Family Packs

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Doc. No. MM-3047612-0101 3 - 59 (72)

3.2 Stop Unit 3 Grouping Unit

3.2-2 Stop Unit - Referencing

Machine Status AIR ON
SPC Reference 2813110-0200
Note! Perform this setting at the first start up of the machine or after the
replacement of the servo motor. Make sure to have already performed the
instruction 3.2-1 Stop Unit - Set on page 3-54.
Preparation
a) On the TPOP, log on as: “tptechnician” or “supervisor” or “technician”,
see 6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) Step up the machine to AIR ON, then continue by following the
instructions Stop Unit - Set Homing Position on page 3-62, if the
ABSOLUTE HOMING POSITION LOST alarm (1) appears continue
by following the instructions Absolute Homing Position Lost Alarm -
Reset on page 3-61.

TechPub_2614345_0107 - 0301_3057026_01.fm
1 Absolute homing position lost alarm

(Cont'd)

3 - 60 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.2 Stop Unit

(Cont'd)
Absolute Homing Position Lost Alarm - Reset
a) Press the STEP UP button (1) to step up the machine to PREHEATING.
b) Touch the ALARM AKNOWLEDGE button (2), the alarm does not
disappear.
c) Touch the MAINTENANCE button (3) and the GROUPING UNIT
button (4), or touch the GROUPING UNIT tab (5).
d) Touch the HOME POSITION icons (6).
e) Touch the ON button (7) to select the function.
f) Press the STEP UP button (1) to step up the machine to AIR ON.
g) Continue by following the instructions Stop Unit - Set Homing Position
on page 3-62.

1 2 3 4

5
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1 Step up button
2 Alarm aknowledge button
3 Maintenance button
4 Grouping unit button
5 Grouping unit tab 6 7
6 Home position icon
7 ON button

(Cont'd)

Doc. No. MM-3047612-0101 3 - 61 (72)

3.2 Stop Unit 3 Grouping Unit

(Cont'd)
Stop Unit - Set Homing Position
a) With the machine in AIR ON, touch the MAINTENANCE button (1) and
the GROUPING UNIT button (2), or touch the GROUPING UNIT
tab (3).
b) Touch the HOME POSITION icon (4) for the stopper, in order to display
the dialogue window.

1 2 4

1 Maintenance button
2 Grouping unit button

TechPub_2614345_0107 - 0301_3057026_01.fm
3 Grouping unit tab
4 Home position icon

(Cont'd)

3 - 62 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.2 Stop Unit

(Cont'd)
Note! For each arm (5), make sure that the top side of the support (6) is
always aligned to the bar (7) as shown below
c) Touch the ON button (8) to select the homing position function.
d) Touch the CONFIRMATION button (9), the arms (5) of the stopper will
start to move upwards until they have reached the top position and then
will move downwards a bit.
e) When the ON button (8) becomes green, touch the EXIT button (10).

7 6

8 9 10
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5 Arm
6 Support
7 Bar
8 ON button
9 Confirmation button
10 Exit button

Doc. No. MM-3047612-0101 3 - 63 (72)

3.2 Stop Unit 3 Grouping Unit

3.2-3 Stop Unit - Set Timing Belt Tension

Machine Status Mains Power OFF
Air OFF
Water OFF
Special Equipment Force Gauge TP No. 90459-1467
SPC Reference 2813110-0200

Apply the force gauge in the middle of the span of the timing belt (1), with a
force of 5 N the deflection must be 2.5 ± 0.5 mm. If required adjust the
tension of the timing belt (1) as follows:
• loosen the four screws (2) then fine adjust the tension of the timing
belt (1) with the setting screw (3)
• repeat the tension check, as previously described, until the correct value
is reached, at the end tighten the four screw (2).

TechPub_2614345_0107 - 0301_3057026_01.fm
2

1 Timing belt
2 Screw
3 Setting screw 1

3 - 64 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.2 Stop Unit

3.2-4 Stop Unit - Check

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2813110-0200

Check that:
• the timing belt (1) is not worn and damaged, if required change it, see
3.2-5 Stop Unit - Change Timing Belt on page 3-66
• the shaft (2) rotates freely and without play, if required change the ball
bearings (3) see 3.2-6 Stop Unit - Change Ball Bearings on page 3-69
• the rubber strips (4) are not worn and damaged, if required change them,
see 3.2.1-1 Arm - Change Rubber Strip on page 3-71.
TechPub_2614345_0107 - 0301_3057026_01.fm

4 2 1 3

1 Timing belt
2 Shaft
3 Ball bearing
4 Rubber strip

Doc. No. MM-3047612-0101 3 - 65 (72)

3.2 Stop Unit 3 Grouping Unit

3.2-5 Stop Unit - Change Timing Belt

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2813110-0200

a) Loosen the four screws (1).

b) Release the tension of the timing belt (2) with the setting screw (3).
c) Remove the clamping element (5) and the pulley (4).

3
1 4 5

TechPub_2614345_0107 - 0301_3057026_01.fm
2

1 Screw
2 Timing belt
3 Setting screw
4 Pulley
5 Clamping element

(Cont'd)

3 - 66 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.2 Stop Unit

(Cont'd)
d) Remove the four screws (6) and (7) on both sides, then turn the
beam (8).

7 8

6
7 6
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6 Screw
7 Screw
8 Beam

(Cont'd)

Doc. No. MM-3047612-0101 3 - 67 (72)

3.2 Stop Unit 3 Grouping Unit

(Cont'd)
e) Remove the two screws (9).

CAUTION
Risk of minor or moderate injury.
Take care when removing the timing belt (2) due to the weight of the
shaft (10).
f) Pull out the shaft (10) in the direction indicated with the arrow, until
there is space enough to remove the timing belt (2).
g) Replace the timing belt (2) and assemble in the reverse order.
h) Reset the tension of the timing belt (2), see 3.2-3 Stop Unit - Set Timing
Belt Tension on page 3-64.

TechPub_2614345_0107 - 0301_3057026_01.fm
2

9 10

2 Timing belt
9 Screw
10 Shaft

3 - 68 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.2 Stop Unit

3.2-6 Stop Unit - Change Ball Bearings

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2813110-0200

a) Loosen the four screws (1).

b) Release the tension of the timing belt (3) with the setting screw (2).
c) Remove the four screws (4) and (5) on both sides, then turn the
beam (6).

3 2

5 6
1

1
TechPub_2614345_0107 - 0301_3057026_01.fm

4
5 4

1 Screw
2 Setting screw
3 Timing belt
4 Screw
5 Screw
6 Beam

(Cont'd)

Doc. No. MM-3047612-0101 3 - 69 (72)

3.2 Stop Unit 3 Grouping Unit

(Cont'd)
d) Remove the two screws (7).

CAUTION
Risk of minor or moderate injury.
Take care when pulling out the shaft (8) due to the weight.
e) Pull out the shaft (8) in the direction indicated with the arrow.
f) Replace the two ball bearings (9) and assemble in the reverse order.
g) Reset the tension of the timing belt (3), see 3.2-3 Stop Unit - Set Timing
Belt Tension on page 3-64.

TechPub_2614345_0107 - 0301_3057026_01.fm
3

7 8

3 Timing belt
7 Screw
8 Shaft
9 Ball bearing

3 - 70 (72) Doc. No. MM-3047612-0101

 3 Grouping Unit 3.2 Stop Unit

3.2.1 Arm
3.2.1-1 Arm - Change Rubber Strip
Machine Status Mains Power OFF
Air OFF
Water OFF
Special Equipment Adhesive TP No. 90153-0023
SPC Reference 3033734-0100

If necessary replace the rubber strip (5), as follows:

• remove the two screws (1)
• remove the screw (2) and the bracket (3)
• remove the old rubber strip (5) from the plate (4)
• clean the bottom of the plate (4) and glue a new rubber strip (5) using the
adhesive indicated, then assemble in the reverse order.
TechPub_2614345_0107 - 0301_3057026_01.fm

3
1 Screw
2 Screw 4
3 Bracket
4 Plate 5
5 Rubber strip

Doc. No. MM-3047612-0101 3 - 71 (72)

3.2 Stop Unit 3 Grouping Unit

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This page intentionally left blank

3 - 72 (72) Doc. No. MM-3047612-0101

 4 Feed Unit
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Doc. No. MM-3047612-0101 4 - 1 (80)

 4 Feed Unit

Feed Unit - Description

SPC Reference 663105-0100
Note! If not indicated in a different way, all the pictures used in the chapter
show the Feed Unit for a machine with Magazine Unit on the RH side.

4.9

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4.3 4.8
4.7

4.2 4.4
4.1
4.6
4.1 Rear Flap Folder
4.2 Front Flap Folder
4.3 Frame
4.4 Drive Shaft (for Inner Chains)
4.5 Drive Unit
4.5
4.6 Adjustment Bracket
4.7 Side Adjuster
4.8 Drive Shaft (for Outer Chains)
4.9 Chain Tensioner

4 - 2 (80) Doc. No. MM-3047612-0101

 4 Feed Unit Table of Contents

4 Feed Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5
4-1 Feed Unit - Functional Description . . . . . . . . . . . 4 - 5
4-2 Feed Unit - Setting Sequence, Type I . . . . . . . . . . 4 - 7
4-3 Feed Unit - Setting Sequence, Type II . . . . . . . . . 4 - 8
4-4 Feed Unit - Setting Sequence, Type III . . . . . . . . 4 - 8
4-5 Feed Unit - Basic Setting . . . . . . . . . . . . . . . . . . . 4 - 9
4-6 Feed Unit - Set Width . . . . . . . . . . . . . . . . . . . . . 4 - 14
4-7 Feed Unit - Set Rear Flap Folder . . . . . . . . . . . . 4 - 28
4-8 Feed Unit - Set Front Flap Folder . . . . . . . . . . . 4 - 29
4-9 Feed Unit - Set Gun Holder . . . . . . . . . . . . . . . . 4 - 33
4-10 Feed Unit - Set Guide Unit . . . . . . . . . . . . . . . . . 4 - 35
4-11 Feed Unit - Referencing . . . . . . . . . . . . . . . . . . . 4 - 36
4-12 Feed Unit - Synchronize Rear Flap Folder . . . . 4 - 42
4-13 Feed Unit - Rephase Feed Motor . . . . . . . . . . . . 4 - 45
4-14 Feed Unit - Set Chains Tension . . . . . . . . . . . . . 4 - 46
TechPub_2614345_0107 - 0401_3057027_01.fm

4-15 Feed Unit - Set Chains Offset . . . . . . . . . . . . . . 4 - 49

4-16 Feed Unit - Check Chains . . . . . . . . . . . . . . . . . 4 - 51
4-17 Feed Unit - Change Chains . . . . . . . . . . . . . . . . 4 - 52
4-18 Feed Unit - By-pass Down Stream Equipment . 4 - 54

4.1 Rear Flap Folder . . . . . . . . . . . . . . . . . . . . . . . . 4 - 55

4.1-1 Rear Flap Folder - Basic Settings . . . . . . . . . . . . 4 - 55
4.1-2 Rear Flap Folder - Disable Alarm . . . . . . . . . . . 4 - 60

4.2 Front Flap Folder . . . . . . . . . . . . . . . . . . . . . . . . 4 - 61

4.2-1 Front Flap Folder - Check Guides . . . . . . . . . . . 4 - 61

4.3 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 62
4.3-1 Frame - Check . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 62

4.4 Drive Shaft (for Inner Chains). . . . . . . . . . . . . . 4 - 65

4.4-1 Drive Shaft (for Inner Chains) - Check . . . . . . . 4 - 65
4.4-2 Drive Shaft (for Inner Chains) - Change Chain . 4 - 66

Doc. No. MM-3047612-0101 4 - 3 (80)

Table of Contents 4 Feed Unit

4.5 Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 67

4.5-1 Drive Unit - Check . . . . . . . . . . . . . . . . . . . . . . 4 - 67
4.5-2 Drive Unit - Change Chains . . . . . . . . . . . . . . . 4 - 70
4.5.1 Bevel Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 72
4.5.1-1 Bevel Gear - Check . . . . . . . . . . . . . . . . . . . . . . 4 - 72
4.5.1-2 Bevel Gear - Change Chains . . . . . . . . . . . . . . . 4 - 73

4.6 Adjustment Bracket . . . . . . . . . . . . . . . . . . . . . . 4 - 74

4.6-1 Adjustment Bracket - Set Timing Belt Tension . 4 - 74

4.7 Side Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 75

4.7-1 Side Adjuster - Check Timing Belt . . . . . . . . . . 4 - 75

4.8 Drive Shaft (for Outer Chains) . . . . . . . . . . . . . 4 - 76

4.8-1 Drive Shaft (for Outer Chains) - Check . . . . . . . 4 - 76
4.8-2 Drive Shaft (for Outer Chains) -
Change Chain . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 77

TechPub_2614345_0107 - 0401_3057027_01.fm
4.9 Chain Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 78
4.9-1 Chain Tensioner - Check . . . . . . . . . . . . . . . . . . 4 - 78
4.9-2 Chain Tensioner - Overhaul . . . . . . . . . . . . . . . . 4 - 79

4 - 4 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4 Feed Unit

4 Feed Unit
4-1 Feed Unit - Functional Description
The Feed Unit mainly consists of a main motor (1), that drives two pairs of
chains: the inner chains with the counter fingers (2) and the outer chains with
the pushers (3).
When the packages reach the front long side of the cardboard blank, the
Flight Bar pushes the packages and the cardboard blank, against the pair of
counter fingers (2). The Flight Bar is then lifted and moved back towards the
Grouping Unit again.
As the Flight Bar leaves the packages, the rear long side of the cardboard
blank, is folded up to 90° by the pair of pushers (3). Thus both long sides of
the tray are raised against the packages.

2
3
TechPub_2614345_0107 - 0401_3057027_01.fm

1
1 Main motor
2 Counter finger
3 Pusher

(Cont'd)

Doc. No. MM-3047612-0101 4 - 5 (80)

4 Feed Unit 4 Feed Unit

(Cont'd)
The Feed Unit is equipped on both sides with: the front flap folders (4), the
rear flap folders (5), the hotmelt guns (7) and (8), the bottom rails (9) and the
guide units (10). The hotmelt guns (7) are used only when running with WA.
The rear flap folders (5) are driven by the main motor (1) through a cam (6).
While the tray with the packages if transported on the Feed Unit, the four
side flaps, two on each side are folded as follows: the front side flaps are
folded by the front flap folders (4), the rear side flaps are folded by the rear
flap folders (5), then all the side flaps are held in place by the rail of the front
flap folders (4).
When the box pass through the hotmelt guns (8), the glue is applied on the
four side flaps, then the bottom flaps are lifted up by the bottom rails (9) and
are kept pressed against the side flaps by the guide units (10), until the box
leaves the Feed Unit.

10
7
8
4

TechPub_2614345_0107 - 0401_3057027_01.fm
5

9
8
1 Main motor
4 Front flap folder
1
5 Rear flap folder 4
6 Cam
7 Hotmelt gun (only with WA) 6
8 Hotmelt gun
9 Bottom rail
10 Guide unit

4 - 6 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4 Feed Unit

4-2 Feed Unit - Setting Sequence, Type I

Type I settings must be performed in sequence according to the flowchart
below. These settings are performed before the first start-up or
commissioning of the machine.

4-5 Feed Unit - Basic Setting on page 4-9 4-11 Feed Unit - Referencing on page 4-36

4-6 Feed Unit - Set Width on page 4-14 4-12 Feed Unit - Synchronize Rear Flap Folder on
page 4-42

4-7 Feed Unit - Set Rear Flap Folder on page 4-28

TechPub_2614345_0107 - 0401_3057027_01.fm

4-8 Feed Unit - Set Front Flap Folder on page 4-29

4-9 Feed Unit - Set Gun Holder on page 4-33

4-10 Feed Unit - Set Guide Unit on page 4-35

Doc. No. MM-3047612-0101 4 - 7 (80)

4 Feed Unit 4 Feed Unit

4-3 Feed Unit - Setting Sequence, Type II

Type II settings must be performed in sequence according to the flowchart
below. These settings are performed when the production change, in order to
adjust the Feed Unit for the cardboard blank in use.

4-6 Feed Unit - Set Width on page 4-14

4-7 Feed Unit - Set Rear Flap Folder on page 4-28

4-8 Feed Unit - Set Front Flap Folder on page 4-29

TechPub_2614345_0107 - 0401_3057027_01.fm
4-9 Feed Unit - Set Gun Holder on page 4-33

4-10 Feed Unit - Set Guide Unit on page 4-35

4-4 Feed Unit - Setting Sequence, Type III

Type III settings include all the remaining Feed Unit setting procedures.
These settings can be performed independently and have no effect on any of
the other magazine unit settings.

4 - 8 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4 Feed Unit

4-5 Feed Unit - Basic Setting

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 663105-0100

Check 0-Line Side (Magazine Unit Side)

Note! According to the configuration of your machine, chain frame (1)
placed on the magazine unit side corresponds always to 0-line side.
Set the position of the chain frame (1) on the 0-line side only once, before
the first start up of the machine.
a) Check the distance A between the chain frame (1) and both supports (2),
to make sure that they are parallel. If required adjust the position of the
chain frame (1), as described on the next page.

Top view of Magazine Unit side

1 2 1 2
TechPub_2614345_0107 - 0401_3057027_01.fm

A A

A = 185 ±0.5 mm

1 Chain frame (0 line side)

Infeed direction 2 Support

(Cont'd)

Doc. No. MM-3047612-0101 4 - 9 (80)

4 Feed Unit 4 Feed Unit

(Cont'd)
b) Loosen the stop screw (3).

TechPub_2614345_0107 - 0401_3057027_01.fm
3 Stop screw

(Cont'd)

4 - 10 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4 Feed Unit

(Cont'd)

c) Set the position of the chain frame (1), as follows:

• loosen the stop screws (4) of the two bearing housings (5)
Note! Measure the distance A between the chain frame (1) and both
supports (2), to make sure that they are parallel.
• pull or push the chain frame (1), until the measure A is reached
• tighten the stop screws (4).

2 2
A = 185 ±0.5 mm

5
A A
4

Top view of Magazine Unit side

1 4 5
TechPub_2614345_0107 - 0401_3057027_01.fm

Infeed direction

1 Chain frame (0 line side)

2 Support
4 Stop screw
5 Bearing housing

(Cont'd)

Doc. No. MM-3047612-0101 4 - 11 (80)

4 Feed Unit 4 Feed Unit

(Cont'd)
Check Parallelism
Measure the distance between the two chain frames (1) and (2), at least in
two different points, to make sure that they are parallel. If required adjust the
position of the chain frame (2), as follows:
• loosen the stop screw (3) then remove the three screws (4) and move the
bearing housing (5)
• remove the two screws (6) from the inside of the chain frame (2)
• turn the ring (7) to fine adjust the position of the chain frame (2), until it
is parallel to the chain frame (1)
• lock the chain frame (2) in position with the two screws (6) then
assemble in the reverse order.

Infeed direction //

TechPub_2614345_0107 - 0401_3057027_01.fm
3 2 Top view

6 1 Chain frame (0 line side)

5
2 Chain frame
3 Stop screw
4 Screw
7 5 Bearing housing
6 Screw
7 Ring

(Cont'd)

4 - 12 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4 Feed Unit

(Cont'd)
Check Bottom Rails
The machine is equipped with two type of bottom rails: the short bottom
rails (1) must be used only to produce a particular packing pattern according
to the table below, while the long bottom rails (2) must be used in all the
other cases.
Check the bottom rails installed on both sides of the feed unit and if
necessary change them using the four spacers (3) and the four screws (4).

Type of Bottom Rails Packing Pattern

Bottom rails (1) 8X6 TBA 125S
TP No. 3044783-0000
TP No. 3044784-0000
Bottom rails (2) All the others
TP No. 2721631-0000
TP No. 2721632-0000

3
2 4
1
3
TechPub_2614345_0107 - 0401_3057027_01.fm

1
2

3 1 Bottom rail (short) 3 Spacer

2 Bottom rail (long) 4 Screw
4

Doc. No. MM-3047612-0101 4 - 13 (80)

4 Feed Unit 4 Feed Unit

4-6 Feed Unit - Set Width

Machine Status Mains Power OFF
Air OFF
Water OFF
Special Equipment Crank TP No. 318820-0105
Shaft TP No. 2728268
SPC Reference 663105-0100
Note! Before starting, make sure to have already performed the instruction
4-5 Feed Unit - Basic Setting on page 4-9.
Measure the distance A of the outside bottom of the cardboard box, then set
the width of the feed unit, as follows:
• with a distance A ≤ 400 mm, see the procedure Feed Unit - Set Width for
Narrow Cardboard Boxes on page 4-15
• with a distance A > 400 mm, see the procedure Feed Unit - Set Width for
Wide Cardboard Boxes on page 4-20.
Note! Only when running with the combination: family packs and cardboard
boxes with a distance A > 350 mm; follow the procedure Feed Unit - Set
Width for Wide Cardboard Boxes on page 4-20, so that the chain frames (1)
and (2) are set more closed, in order to better support the bottom of the
boxes, in this case make sure that the side guides of the grouping unit are

TechPub_2614345_0107 - 0401_3057027_01.fm
set correctly, see 3.1-2 Flight Bar - Set Side Guides on page 3-12.

Infeed direction

Top view
2

1 Chain frame (0-line side)

2 Chain frame
A
(Cont'd)

4 - 14 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4 Feed Unit

(Cont'd)
Feed Unit - Set Width for Narrow Cardboard Boxes
Note! Perform this setting only when running with cardboard boxes with a
distance A ≤ 400 mm, otherwise see Feed Unit - Set Width for Wide
Cardboard Boxes on page 4-20.
a) Make sure that both guide units (1) are set in the inner position, as shown
below. If required change the position of both guide units (1) on the
holders (2) using the locking levers (3).

1
TechPub_2614345_0107 - 0401_3057027_01.fm

A
1

1
2

Guide units in inner position (with A ≤ 400 mm) -

3 Front view
1 Guide unit
2 Holder
3 Locking lever

(Cont'd)

Doc. No. MM-3047612-0101 4 - 15 (80)

4 Feed Unit 4 Feed Unit

(Cont'd)
b) Set the width between the two guide units (1) as follows:
• loosen the stop screws (4)
• apply the crank on the shaft (5)
• turn the crank and move the chain frame (6), until the width B between
the two guide units (1) is reached
• remove the crank and tighten the stop screws (4).

B Infeed direction

Top view
6

TechPub_2614345_0107 - 0401_3057027_01.fm
A
B=A

4 6 4
1 Guide unit
4 Stop screw
5 Shaft
6 Chain frame
5

(Cont'd)

4 - 16 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4 Feed Unit

(Cont'd)
Note! Check that the bottom rails (7) installed are correct for the packing
pattern to produce, see Check Bottom Rails on page 4-13.
c) Make sure that both bottom rails (7) are set in the inner position, as
shown below. If required change the position of both bottom rails (7),
using the spacers (8) and the screws (9).

7
TechPub_2614345_0107 - 0401_3057027_01.fm

7
7
8 A

7 Bottom rail Bottom rails in inner position (with A ≤ 400 mm) -

8 Spacer Front view
9 Screw

(Cont'd)

Doc. No. MM-3047612-0101 4 - 17 (80)

4 Feed Unit 4 Feed Unit

(Cont'd)
d) Make sure that both front flap folders (10) are set in the inner position, as
shown below. If required change the position of the brackets (11) with
the locking levers (12).

10 10 11 12

TechPub_2614345_0107 - 0401_3057027_01.fm
10

10 Front flap folder Front flap folders in inner position (with A ≤ 400 mm) -
11 Bracket Front view
12 Locking lever

(Cont'd)

4 - 18 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4 Feed Unit

(Cont'd)
e) On both rear flap folders (13), make sure that the fingers (14) are set in
the inner position, as shown below. If required change the position of
both fingers (14) as follows:
• remove the screw (16) and the flap guide (15)
• remove the knob (17) and change the position of the finger (14), then
assemble in the reverse order.

14 17
13
15

16
TechPub_2614345_0107 - 0401_3057027_01.fm

14
13

13 Rear flap folder

14 Finger Rear flap folders in inner position (with A ≤ 400 mm) -
15 Flap guide Front view
16 Screw
17 Knob

(Cont'd)

Doc. No. MM-3047612-0101 4 - 19 (80)

4 Feed Unit 4 Feed Unit

(Cont'd)
Feed Unit - Set Width for Wide Cardboard Boxes
Note! Perform this setting only when running with cardboard boxes with a
distance A > 400 mm, otherwise see Feed Unit - Set Width for Narrow
Cardboard Boxes on page 4-15.
a) Make sure that both guide units (1) are set in the outer position, as shown
below. If required change the position of both guide units (1) on the
holders (2) using the locking levers (3).

TechPub_2614345_0107 - 0401_3057027_01.fm
A
1

1
2

Guide units in outer position (with A > 400 mm) -

3 Front view
1 Guide unit
2 Holder
3 Locking lever

(Cont'd)

4 - 20 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4 Feed Unit

(Cont'd)
b) Set the width between the two guide units (1) as follows:
• loosen the stop screws (4)
• apply the crank on the shaft (5)
• turn the crank and move the chain frame (6), until the width B between
the two guide units (1) is reached
• remove the crank and tighten the stop screws (4).

B Infeed direction

Top view
6
TechPub_2614345_0107 - 0401_3057027_01.fm

A
B=A

4 6 4
1 Guide unit
4 Stop screw
5 Shaft
6 Chain frame
5

(Cont'd)

Doc. No. MM-3047612-0101 4 - 21 (80)

4 Feed Unit 4 Feed Unit

(Cont'd)
Note! Check that the bottom rails (7) installed are correct for the packing
pattern to produce, see Check Bottom Rails on page 4-13.
c) Make sure that both bottom rails (7) are set in the outer position, as
shown below. If required change the position of both bottom rails (7),
using the spacers (8) and the screws (9).

TechPub_2614345_0107 - 0401_3057027_01.fm
7 8
7
A
9

7 Bottom rail Bottom rails in outer position (with A > 400 mm) -
8 Spacer Front view
9 Screw

(Cont'd)

4 - 22 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4 Feed Unit

(Cont'd)
d) Make sure that both front flap folders (10) are set in the outer position, as
shown below. If required change the position of the brackets (11) with
the locking levers (12).

12
10 10 11
TechPub_2614345_0107 - 0401_3057027_01.fm

10

10 Front flap folder Front flap folders in outer position (with A > 400 mm) -
11 Bracket Front view
12 Locking lever

(Cont'd)

Doc. No. MM-3047612-0101 4 - 23 (80)

4 Feed Unit 4 Feed Unit

(Cont'd)
e) On both rear flap folders (13), make sure that the fingers (14) are set in
the outer position, as shown below. If required change the position of
both fingers (14) as follows:
• remove the screw (16) and the flap guide (15)
• remove the knob (17) and change the position of the finger (14), then
assemble in the reverse order.

14 17
13
15

16

TechPub_2614345_0107 - 0401_3057027_01.fm
14
13

13 Rear flap folder

14 Finger Rear flap folders in outer position (with A > 400 mm) -
15 Flap guide Front view
16 Screw
17 Knob

(Cont'd)

4 - 24 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4 Feed Unit

(Cont'd)
Feed Unit - Set Support Rail
Loosen the stop screw (1) and push the support rail (2) as much as possible
towards the shaft (3), making sure that the support rail (2) is still held by the
block (4) and the stop (5), then tighten the stop screw (1).

3
4
1
2

5
TechPub_2614345_0107 - 0401_3057027_01.fm

1 Stop screw
2 Support rail
3 Shaft
4 Block
5 Plate

(Cont'd)

Doc. No. MM-3047612-0101 4 - 25 (80)

4 Feed Unit 4 Feed Unit

(Cont'd)
Feed Unit - Set Bottom Rails
Note! Check that the bottom rails (7) installed are correct for the packing
pattern to produce, see Check Bottom Rails on page 4-13.
The function of the bottom rails (1) is to fold the bottom flaps of the tray.
As a basic settings, set both bottom rails (1) using the screws (2), at the
distance A from the guide units (3).
Note! During PRODUCTION, make sure that the bottom flaps are properly
folded by bottom rails (1) and they do not crush against the guide units. If
required fine adjust the position of both bottom rails (1).

3
1

TechPub_2614345_0107 - 0401_3057027_01.fm
A = 2 ÷ 5 mm

3 A

1 Bottom rail
2 Screw
Side view
3 Guide unit
2 1

(Cont'd)

4 - 26 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4 Feed Unit

(Cont'd)
Feed Unit - Set Wheels
Note! According to the cardboard box to be produced, make sure that the
guides (4) of the outfeed conveyor, are properly set, if required see the TeM
of the Tetra Conveyor Flexi 56 or UC 24.
a) Measure the distance A of the outside bottom of the cardboard box.
b) As a basic setting, set both supports (1) using the screws (2), so that the
wheel (3) is placed at the distance B, from the guides (4) and at the
distance C from the discharge conveyor (5).
Note! During PRODUCTION check if the cardboard boxes are well
discharged on the discharge conveyor. If required fine adjust the position of
the supports (1).

1
TechPub_2614345_0107 - 0401_3057027_01.fm

B = A + 15 ±0.5 mm
C = 10 ÷ 12 mm

4 B A

5 C 3

1 Support
2 Screw
3 Wheel
4 Guide
5 Discharge conveyor

1 2

Doc. No. MM-3047612-0101 4 - 27 (80)

4 Feed Unit 4 Feed Unit

4-7 Feed Unit - Set Rear Flap Folder

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2706485-0200

The function of the flap guides (1) is to keep lowered the bottom flaps and to
avoid crushes when the rear side flaps are folded by the fingers (2).

CAUTION
Risk of damage to the equipment.
Make sure that the flap guides (1) do not touch the packages inside the tray.
As a basic setting, set both flap guides (1) using the screws (3) at the
distance A from the fingers (2).
Note! During PRODUCTION, check that when the rear side flaps are folded
they do not crush against the bottom flaps. If required fine adjust the position
of the flap guides (1).

Setting in inner position - Setting in outer position -

Front view Front view
1

TechPub_2614345_0107 - 0401_3057027_01.fm
2
A A

3
A = 27 ±0.5 mm

1 Flap guide
2 Finger
3 Screw

4 - 28 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4 Feed Unit

4-8 Feed Unit - Set Front Flap Folder

Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 2706490-0100

Front Flap Folder - Vertical Setting

The function of the rails (1) is to keep all the side flaps folded until the box
reaches the hotmelt guns (4).
a) Measure the distance A of the outside bottom flap of the cardboard
blank.
b) As a basic setting, adjust the vertical position of both rails (1) with the
locking levers (2), so that:
• the rails (1) are parallel to the chain frames (3)
• the rails (1) are placed at least at the distance B, from the chain
frames (3).

1 2
TechPub_2614345_0107 - 0401_3057027_01.fm

B
A B = A + 10 ±0.5 mm

Side view

1 Rail
2 Locking lever
3 Chain frame
4 4 Hotmelt gun

(Cont'd)

Doc. No. MM-3047612-0101 4 - 29 (80)

4 Feed Unit 4 Feed Unit

(Cont'd)
Front Flap Folder - Longitudinal Setting
The function of the rails (1) is to fold the front side flaps. The longitudinal
position of the rails (1) depends on the width of the side flaps.

CAUTION
Risk of damage to the equipment.
Make sure that when the rear flap folders (3) are activated to fold the rear
side flaps, they do not touch the rails (1).
Set the longitudinal position of both rails (1) with the locking levers (2),
making sure that they are placed at least at the distance A from the rear flap
folders (3), in order to avoid any crush.
Note! During PRODUCTION, check that when the rear side flaps are folded
they do not crush against the rails (1). If required fine adjust the position of
the rails (1).

2 A 3

A = 5 ±0.5 mm

TechPub_2614345_0107 - 0401_3057027_01.fm
1

Side view
1 Rail
2 Locking lever
3 Rear flap folder

(Cont'd)

4 - 30 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4 Feed Unit

(Cont'd)
Front Flap Folder - Photocell Setting
The photocell (1) is used to detect when the box (2) is in the correct position
and ready for the hotmelt application. Set the photocell (1) as follows.
a) Make sure that the front flap folder (3) and the chain frame (4) are not
detected by the photocell (1). If required fine adjust the vertical position
of the photocell (1) using the two screws (5), until it is placed in the
space existing between the front flap folder (3) and the chain frame (4).

2
1 4
TechPub_2614345_0107 - 0401_3057027_01.fm

Side view

5 4

1 Photocell, W50B3100
2 Box
3 Front flap folder
4 Chain frame
1
5 Screw

(Cont'd)

Doc. No. MM-3047612-0101 4 - 31 (80)

4 Feed Unit 4 Feed Unit

(Cont'd)
Note! To set the sensitivity of the photocell (1), see Reflection Photocells -
Set on page 6-293.
b) To avoid the production of open boxes, set the sensitivity of the
photocell (1) so that, the light emitted reaches the middle of the box (2)
and not only the box side with the side flaps, making sure that no other
objects placed on the other machine side are detected. If the photocell (1)
detects one of the pusher (6), the PLC program will skip them.

2 1

6 6

TechPub_2614345_0107 - 0401_3057027_01.fm
Side view

Top view

1 Photocell, W50B3100
2 Box
6 Pusher
1

4 - 32 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4 Feed Unit

4-9 Feed Unit - Set Gun Holder

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2827630-0100

Set Lower Gun Holders

Note! This setting is valid for all machines. For machines equipped with WA
unit (OE), see also Set Upper Gun Holders on page 4-34.

WARNING
Risk of burns.
During PREHEATING and PRODUCTION the hotmelt guns and the covers
get hot.
Set the vertical position of the hotmelt dots (1) on both sides of the tray, by
adjusting the height of the two lower gun holders (2) with the screws (3).
Make sure that the two rails (4) do not interfere, if required fine adjust them
see 4-8 Feed Unit - Set Front Flap Folder on page 4-29.
Note! During PRODUCTION, check the position of the hotmelt dots (1), if
required fine adjust the height of the lower gun holders (2).
TechPub_2614345_0107 - 0401_3057027_01.fm

2
4
3
1

Tray

1 Hotmelt dot
2 Lower gun holder
3 Screw
4 Rail

(Cont'd)

Doc. No. MM-3047612-0101 4 - 33 (80)

4 Feed Unit 4 Feed Unit

(Cont'd)
Set Upper Gun Holders
Note! This setting is valid only for machines equipped with WA.

WARNING
Risk of burns.
During PREHEATING and PRODUCTION the hotmelt guns and the covers
get hot.
Set the vertical position of the hotmelt dots (1), on both sides of the type of
box to produce, by adjusting the height of the two upper gun holders (2) with
the screws (3). Make sure that the two rails (4) do not interfere, if required
fine adjust them see 4-8 Feed Unit - Set Front Flap Folder on page 4-29.
Note! During PRODUCTION, check the position of the hotmelt dots (1), if
required fine adjust the height of the upper gun holders (2).

2
WAIF WASF

TechPub_2614345_0107 - 0401_3057027_01.fm
1 1
3

Tray OF

1 Hotmelt dot
2 Upper gun holder
3 Screw
4 Rail

4 - 34 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4 Feed Unit

4-10 Feed Unit - Set Guide Unit

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2706503-0100

According to the type of box to produce, set both guide units (1) at the same
height with the locking levers (2), so that the guide units (1) press against the
bottom flaps (3) in correspondence of the hotmelt dots (4).
Note! During PRODUCTION check if the bottom flaps (3) are properly
folded and glued, if not fine adjust the position of the guides units (1).

2
TechPub_2614345_0107 - 0401_3057027_01.fm

2
WASF

3 4 4
3 3
Tray Tray OF

WAIF 1 Guide
2 Locking lever
3 Bottom flap
4
4 Hotmelt dot
3

Doc. No. MM-3047612-0101 4 - 35 (80)

4 Feed Unit 4 Feed Unit

4-11 Feed Unit - Referencing

Machine Status AIR ON
SPC Reference 663105-0100
Note! Perform this setting at the first start up of the machine or after the
replacement of the servo motor.
Preparation
a) On the TPOP, log on as: “tptechnician” or “supervisor” or “technician”,
see 6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) Step up the machine to AIR ON then continue by following the
instructions Feed Unit - Set Homing Position on page 4-38, if the
ABSOLUTE HOMING POSITION LOST alarm (1) appears continue
by following the instructions Absolute Homing Position Lost Alarm -
Reset on page 4-37.

TechPub_2614345_0107 - 0401_3057027_01.fm
1 Absolute homing position lost alarm

(Cont'd)

4 - 36 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4 Feed Unit

(Cont'd)
Absolute Homing Position Lost Alarm - Reset
a) Press the STEP UP button (1) to step up the machine to PREHEATING.
b) Touch the ALARM AKNOWLEDGE button (2), the alarm does not
disappear.
c) Touch the MAINTENANCE button (3) and the FEED UNIT button (4),
or touch the FEED UNIT tab (5).
d) Touch the OFFSET icon (6) or the HOME POSITION icon (7).
e) Touch the ON button (8) to select the function.
f) Press the STEP UP button (1) to step up the machine to AIR ON.
g) Continue by following the instructions Feed Unit - Set Homing Position
on page 4-38.

1 2 3 4
TechPub_2614345_0107 - 0401_3057027_01.fm

1 Step up button
2 Alarm aknowledge button
6 7
3 Maintenance button
4 Feed unit button
5 Feed unit tab
6 Offset icon
7 Home position icon 8
8 ON button

(Cont'd)

Doc. No. MM-3047612-0101 4 - 37 (80)

4 Feed Unit 4 Feed Unit

(Cont'd)
Feed Unit - Set Homing Position
a) With the machine in AIR ON, touch the MAINTENANCE button (1) and
the FEED UNIT button (2), or touch the FEED UNIT tab (3).
b) Touch the FEED MOTOR OFFSET icon (4), in order to display the
dialogue window.
c) Touch the ON button (5) to select the movement function.
d) Touch the OFFSET VALUE icon (6) to display the dialogue window.

1 2 3 4

TechPub_2614345_0107 - 0401_3057027_01.fm
1 Maintenance button 6
2 Feed unit button
3 Feed unit tab
4 Feed motor offset icon
5 ON button
6 Offset value icon

(Cont'd)

4 - 38 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4 Feed Unit

(Cont'd)
e) The offset value is displayed in the SETTING VALUE field (7). Set the
offset value to align the pushers to the reference marks existing on the
frames (see the next page), as follows:
• touch the FACTORY button (10) to display the factory value
• touch the DOUBLE-ARROW button (8) to increase the value of 10 mm
• touch the SINGLE-ARROW button (9) to increase the value of 1 mm
• touch the KEYBOARD button (11) to display the numeric keyboard, then
type the value.
f) When the new value is displayed in the OFFSET VALUE field (12),
touch the CONFIRMATION button (13) to move the pushers.

7
TechPub_2614345_0107 - 0401_3057027_01.fm

8 9 10 11

7 Setting value field

8 Double-arrow button
9 Single-arrow button 12 13
10 Factory button
11 Keyboard button
12 Offset value field
13 Confirmation button

(Cont'd)

Doc. No. MM-3047612-0101 4 - 39 (80)

4 Feed Unit 4 Feed Unit

(Cont'd)
g) The home position is reached when the sides marked in grey of two
pushers (14), are aligned to the reference marks (15) existing on the
frames.
Note! In case that the ABSOLUTE HOMING POSITION LOST alarm (16)
has been activated, after opening the door in order to check the alignment,
then continue from item b) on page 4-37.
h) If necessary repeat the instructions from item e) on page 4-39, using a
different offset value until the home position is reached, otherwise
confirm the home position as follows on the next page.

14

Infeed direction

TechPub_2614345_0107 - 0401_3057027_01.fm
16
15

14 Pusher
15 15 Reference mark
16 Absolute homing position lost alarm

(Cont'd)

4 - 40 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4 Feed Unit

(Cont'd)
i) Confirm the home position as follows:
• touch the OFF button (17) to deselect the movement function
• touch the FEED MOTOR ABSOLUTE HOMING icon (18)
• touch the ON button (19) to select the homing function
• touch the CONFIRMATION button (20) to confirm the home position
• touch the EXIT button (21).

17 18

19 20 21
TechPub_2614345_0107 - 0401_3057027_01.fm

17 OFF button
18 Feed motor absolute homing icon
19 ON button
20 Confirmation button
21 Exit button

Doc. No. MM-3047612-0101 4 - 41 (80)

4 Feed Unit 4 Feed Unit

4-12 Feed Unit - Synchronize Rear Flap Folder

Machine Status Mains Power ON
Air ON
Water ON
Special Equipment Torque Wrench min. 5 Nm
SPC Reference 2706485-0200
Note! Perform this synchronization at the first start up of the machine.
Mechanical Synchronization
a) Before starting perform the instruction 4-11 Feed Unit - Referencing on
page 4-36.
b) On both sides, unlock the sprockets (1) as follows:
• loosen the four screws (2) to separate the clamping element (4) from the
sprocket (1)
• pull out the clamping element (4), by screwing two screws (2) into the
holes (3), as a puller
• remove the two screws (2) from the holes (3).

TechPub_2614345_0107 - 0401_3057027_01.fm
4

3
1 Sprocket
2 2 Screw
1 3 Hole
4 Clamping element
(Cont'd)

4 - 42 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4 Feed Unit

(Cont'd)
Note! Make sure that the sides marked in grey of two pushers (5), are
aligned to the reference marks (6) existing on the frames, see 4-11 Feed
Unit - Referencing on page 4-36.
c) Synchronize both rear flap folders as follows:
• make sure that the finger (7) is positioned in the open position as shown
below
• slowly turn the cam (8) in the direction of the arrow
• the synchronization point is reached when the finger (7) start to close.

6
TechPub_2614345_0107 - 0401_3057027_01.fm

5 Pusher
6 Reference mark
7 Finger
8 Cam
8
(Cont'd)

Doc. No. MM-3047612-0101 4 - 43 (80)

4 Feed Unit 4 Feed Unit

(Cont'd)
d) On both sides, lock the sprockets (1) as follows:
• fit the clamping element (4) to the sprocket (1), with the four screws (2)
• tighten the screws (2) at 5 Nm.

TechPub_2614345_0107 - 0401_3057027_01.fm
1 Safety clutch
2
2 Screw
1 4 Clamping element

4 - 44 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4 Feed Unit

4-13 Feed Unit - Rephase Feed Motor

Machine Status AIR ON
SPC Reference 663105-0100
Note! Rephase the feed motor if the space between the pushers and the
counter fingers is changed.
a) With the machine in AIR ON, touch the PRODUCTION CONTROL
button (1) and the FEED UNIT button (2), or touch the FEED UNIT
tab (3).
b) Touch the FEED MOTOR REPHASING icon (4) to display the dialogue
window.
c) Touch the ON button (5) to select the rephasing function.
d) Touch the CONFIRMATION button (6) to rephase the motor.
e) Press the STEP UP button (7) to step up the program in HOMING.
f) Touch the EXIT button (8).

1 2 3 4
TechPub_2614345_0107 - 0401_3057027_01.fm

1 Production control button

2 Feed unit button
3 Feed unit tab 5 6
4 Motor rephasing icon
5 ON button
6 Confirmation button
7 Step up button
8 Exit button

7 8

Doc. No. MM-3047612-0101 4 - 45 (80)

4 Feed Unit 4 Feed Unit

4-14 Feed Unit - Set Chains Tension

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 663105-0100

Check the tension of both inner chains (1) and of both outer chains (2), by
measuring the distance A, in the bottom of the chain frames (3) and between
the two sliders (4) placed at the distance B from each other. If required adjust
the chain tension as follows on the next pages.
Note! During PRODUCTION, make sure that the chains (1) and (2) do not
touch the bottom side of the chain frames (3), if required fine adjust the
chain tension.

A = 10 ÷ 15 mm

TechPub_2614345_0107 - 0401_3057027_01.fm
3 1 4 B = 545 ±0.5 mm

3 2 4
1 Inner chain
2 Outer chain
3 Chain frame A
4 Slider

(Cont'd)

4 - 46 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4 Feed Unit

(Cont'd)
Inner Chains - Set Tension
Set the tension of both inner chains (1) as follows:
• loosen the two screws (2) on the side of the chain frame
• fine adjust the position of the chain tensioner (3) with the nuts (4)
• tighten the two screws (2).

2 1
4
TechPub_2614345_0107 - 0401_3057027_01.fm

1 Inner chain
2 Screw
3 Chain tensioner
4 Nut
2

(Cont'd)

Doc. No. MM-3047612-0101 4 - 47 (80)

4 Feed Unit 4 Feed Unit

(Cont'd)
Outer Chains - Set Tension
Set the tension of both outer chains (1) as follows:
• loosen the two screws (2) on the side of the chain frame
• fine adjust the position of the chain tensioner (3) with the nuts (4)
• tighten the two screws (2).

4 2 1

TechPub_2614345_0107 - 0401_3057027_01.fm
1 Outer chain
2 Screw
3 Chain tensioner
4 Nut
2

4 - 48 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4 Feed Unit

4-15 Feed Unit - Set Chains Offset

Machine Status AIR ON
SPC Reference 663105-0100
Note! Perform this setting to compensate the stretching of the chains. This
setting is valid only for the recipe currently loaded.
a) On the TPOP, log on as: “tptechnician” or “supervisor” or “technician”,
see 6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) With the machine in AIR ON, touch the MAINTENANCE button (1) and
the FEED UNIT button (2), or touch the FEED UNIT tab (3).
c) Touch the FEED MOTOR OFFSET icon (4), in order to display the
dialogue window.
d) Touch the ON button (5) to select the movement function.
e) Touch the OFFSET VALUE icon (6) to display the dialogue window.

1 2 3 4
TechPub_2614345_0107 - 0401_3057027_01.fm

1 Maintenance button
2 Feed unit button
3 Feed unit tab
4 Feed motor offset icon

(Cont'd)

Doc. No. MM-3047612-0101 4 - 49 (80)

4 Feed Unit 4 Feed Unit

(Cont'd)
f) The offset value is displayed in the SETTING VALUE field (5). Set the
offset value as follows:
• touch the DOUBLE-ARROW buttons (6) to increase or decrease the value
of 10 mm
• touch the SINGLE-ARROW buttons (7) to increase or decrease the value
of 1 mm
• touch the KEYBOARD button (8) to display the numeric keyboard, then
type the value
• touch the FACTORY button (9) to display the factory value.
g) Touch the EXIT button (10).

5 9 10

TechPub_2614345_0107 - 0401_3057027_01.fm
8

6 7 6
5 Setting value field
6 Double-arrow button
7 Single-arrow button
8 Keyboard button
9 Factory button
10 Exit button

4 - 50 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4 Feed Unit

4-16 Feed Unit - Check Chains

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 663105-0100

Check both inner chains (1) and both outer chains (2), making sure that:
• they are not worn or damaged, if required replace them see 4-17 Feed
Unit - Change Chains on page 4-52
• the chain tension is set correctly, see 4-14 Feed Unit - Set Chains
Tension on page 4-46.

1
TechPub_2614345_0107 - 0401_3057027_01.fm

1 Inner chain
2 Outer chain

Doc. No. MM-3047612-0101 4 - 51 (80)

4 Feed Unit 4 Feed Unit

4-17 Feed Unit - Change Chains

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 663105-0100
Note! Inner and outer chains are composed by eight parts, each part of the
chain can be replaced individually when damaged.
Inner Chains - Replacement
Note! The following instructions are valid for both inner chains (1).
a) Release the tension of the inner chain (1), see Inner Chains - Set Tension
on page 4-47.
b) Open the chain by removing the chain lock (2).
Note! During the assembling make sure that the counter finger (3) is placed
in the correct direction, as shown below.
c) Replace the parts damaged then lock the chain with the chain lock (2).
d) Reset the chain tension, see Inner Chains - Set Tension on page 4-47.

TechPub_2614345_0107 - 0401_3057027_01.fm
1

1 Inner chain
2 Chain lock
3 Counter finger

(Cont'd)

4 - 52 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4 Feed Unit

(Cont'd)
Outer Chains - Replacement
Note! The following instructions are valid for both outer chains (1).
a) Release the tension of the outer chain (1), see Outer Chains - Set Tension
on page 4-48.
b) Open the chain by removing the chain lock (2).
Note! During the assembling make sure that the pusher (3) is placed in the
correct direction, as shown below.
c) Replace the parts damaged then lock the chain with the chain lock (2),
making sure to place the two parts (4) between the chain and the
pusher (3).
d) Reset the chain tension, see Outer Chains - Set Tension on page 4-48.

1
TechPub_2614345_0107 - 0401_3057027_01.fm

4 3

1 Outer chain
2 Chain lock
3 Pusher
4 Part

Doc. No. MM-3047612-0101 4 - 53 (80)

4 Feed Unit 4 Feed Unit

4-18 Feed Unit - By-pass Down Stream Equipment

Machine Status IDLE (STEP ZERO)
SPC Reference 663105-0100

The following procedure allows to by-pass the down stream equipment, so

that the machine will not stop when the down stream equipment is not ready.
a) On the TPOP, log on as: “tptechnician” or “supervisor” or “technician”,
see 6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) With the machine in IDLE, touch the MAINTENANCE button (1) and the
FEED UNIT button (2), or touch the FEED UNIT tab (3).
c) Touch the DOWN STREAM EQUIPMENT icon (4) to display the
dialogue window.
d) Touch the ON button (5) to select the by-pass function.
e) Touch the CONFIRMATION button (6) to activate the by-pass of the
down stream equipment.
f) Touch the EXIT button (7).

1 2 4

TechPub_2614345_0107 - 0401_3057027_01.fm
3

1 Maintenance button
2 Feed unit button
3 Feed unit tab
4 Down stream equipment icon
5 ON button
6 Confirmation button
7 Exit button 5 6 7

4 - 54 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4.1 Rear Flap Folder

4.1 Rear Flap Folder

SPC Reference 2706485-0200

4.1-1 Rear Flap Folder - Basic Settings

Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment Torque Wrench min. 10 Nm
SPC Reference 2706485-0200
Note! Perform the following settings on both rear flap folders.
Safety Clutch - Setting
a) Remove the four screws (1), the washers and the cover (2).
b) Make sure that safety clutch (3) is placed at the distance A from the
bracket (4). If required fine adjust the position of the safety clutch (3)
using the screws (5) and (6), making sure to tighten the screw (5) at
40 Nm and the screw (6) at 10 Nm.
TechPub_2614345_0107 - 0401_3057028_01.fm

A = 20 ±0.5 mm
4

3
1 A

2
5

1
1 Screw
6
2 Cover
3 Safety clutch
4 Bracket
5 Screw
6 Screw Side view

(Cont'd)

Doc. No. MM-3047612-0101 4 - 55 (80)

4.1 Rear Flap Folder 4 Feed Unit

(Cont'd)
c) For a correct functioning, the torque of the safety clutch has to be set
at 13 Nm, check that the reference mark (7) is positioned at the correct
value indicated on the setting scale (8). If required loosen the screw (9)
and turn the adjusting ring (10) until the correct setting value is reached,
then tighten the screw (9).

10 7

TechPub_2614345_0107 - 0401_3057028_01.fm
7 Reference mark
8 Setting scale
9 Screw Side view
10 Adjusting ring

(Cont'd)

4 - 56 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4.1 Rear Flap Folder

(Cont'd)
Proximity Switch - Setting
a) Set the proximity switch (2) at the distance A from the ring (1) using the
two nuts (3).

3 2 1 A = 1 ÷ 2 mm
TechPub_2614345_0107 - 0401_3057028_01.fm

1 Ring
2 Proximity switch
3 Nut Side view

(Cont'd)

Doc. No. MM-3047612-0101 4 - 57 (80)

4.1 Rear Flap Folder 4 Feed Unit

(Cont'd)
b) With the finger (7) in open position and the ring (1) engaged, set the
proximity switch (2) at the distance B from the ring (1) using the two
screw (4). In order to avoid false detections during PRODUCTION,
manually move the bracket (5) and verify that the LED (6) is always
OFF, if the LED (6) goes ON slightly increase the distance B.
c) During PRODUCTION when the finger (7) start to close, if an over
torque happens the ring (1) will be disengaged and detected by the
proximity switch (2), the LED (6) must be lit.

B = 0.5 ±0.1 mm

Ring engaged

TechPub_2614345_0107 - 0401_3057028_01.fm
5
4 2 1
6 1

Ring disengaged
Side view

1 Ring 5 Bracket
2 Proximity switch 6 LED
4 Screw 7 Finger

(Cont'd)

4 - 58 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4.1 Rear Flap Folder

(Cont'd)
Final Operations
Fit back the cover (1) with the four screws (2).

2
TechPub_2614345_0107 - 0401_3057028_01.fm

1 Cover
2 Screw

Doc. No. MM-3047612-0101 4 - 59 (80)

4.1 Rear Flap Folder 4 Feed Unit

4.1-2 Rear Flap Folder - Disable Alarm

Machine Status Before PRODUCTION
SPC Reference 2706485-0200

The following procedure allows to disable the flap folders alarm, in order to
perform the maintenance operations on the feed unit.
a) On the TPOP, log on as: “tptechnician” or “supervisor” or “technician”,
see 6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) With the machine in a program step before PRODUCTION, touch the
MAINTENANCE button (1) and the FEED UNIT button (2), or touch the
FEED UNIT tab (3).
c) Touch the FLAP FOLDER icon (4) to display the dialogue window.
d) Touch the ON button (5) to disable the alarm function.
e) Touch the CONFIRMATION button (6) to activate the alarm disabled
function for the flap folders.
f) Touch the EXIT button (7).

1 2 4

TechPub_2614345_0107 - 0401_3057028_01.fm
3

1 Maintenance button
2 Feed unit button
3 Feed unit tab
4 Flap folder icon
5 ON button
6 Confirmation button
7 Exit button
5 6 7

4 - 60 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4.2 Front Flap Folder

4.2 Front Flap Folder

SPC Reference 2706490-0100

4.2-1 Front Flap Folder - Check Guides

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2706490-0100
Note! The following instructions are valid for both front flap folders.
Check the guides (1), for wear and damage. If required replace the guides (1)
by removing the screws (2), then assemble in the reverse order.
TechPub_2614345_0107 - 0401_3057029_01.fm

1 Guide
2 Screw
1 2

Doc. No. MM-3047612-0101 4 - 61 (80)

4.3 Frame 4 Feed Unit

4.3 Frame
SPC Reference 2706540-0100

4.3-1 Frame - Check

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2706540-0100

Check Wheels
On both sides, check that the wheels (1) are not worn or damaged and rotate
freely without play. If required replace the wheels (1) by removing the
locking ring (2), then assemble in the reverse order.

TechPub_2614345_0107 - 0401_3057030_01.fm
1

2
1 Wheel
2 Locking ring

(Cont'd)

4 - 62 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4.3 Frame

(Cont'd)
Check Guides and Sliders
a) If not already done, open and remove the inner chains (1) and the outer
chains (2), see 4-17 Feed Unit - Change Chains on page 4-52.

1
TechPub_2614345_0107 - 0401_3057030_01.fm

1 Inner chain
2 Outer chain

(Cont'd)

Doc. No. MM-3047612-0101 4 - 63 (80)

4.3 Frame 4 Feed Unit

(Cont'd)
b) On the chain frames, check that:
• the guides (3) are not worn and damaged, if required change them by
removing the screws (4)
• the sliders (6) are not worn and damaged, if required change them by
removing the screws (5).
c) Fit back the chains previously removed, see 4-17 Feed Unit - Change
Chains on page 4-52.

TechPub_2614345_0107 - 0401_3057030_01.fm
6

3 Guide
4 Screw
3 5 Screw
6 Slider

4 - 64 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4.4 Drive Shaft (for Inner Chains)

4.4 Drive Shaft (for Inner Chains)

SPC Reference 2706555-0200

4.4-1 Drive Shaft (for Inner Chains) - Check

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2706555-0200

Check that:
• the chain (1) is not worn or damaged, if required change it,
see 4.4-2 Drive Shaft (for Inner Chains) - Change Chain on page 4-66
• the chain (1) is well tensioned by the sprocket (4) of the tension arm, if
required fine adjust the tension with the screw (5)
• the sprocket (2) and the sprocket (4) are aligned to the sprocket (6), if
required fine adjust the position of the sprocket (2) with the stop
screw (3) and the position of the sprocket (4) with the two screws (7).

2 3
TechPub_2614345_0107 - 0401_3057031_01.fm

1 1
4

1 Chain 5 Screw
2 Sprocket 6 Sprocket
3 Stop screw 7 Screw
4 Sprocket

Doc. No. MM-3047612-0101 4 - 65 (80)

4.4 Drive Shaft (for Inner Chains) 4 Feed Unit

4.4-2 Drive Shaft (for Inner Chains) - Change Chain

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2706555-0100

a) Loosen the screw (3) to release the tension of the chain (1).
b) Open the chain (1) by removing the chain lock (4).
Note! According to the motion direction of the chain (1), make sure to fit the
chain lock (4) as shown below.
c) Fit the new chain (1) and then lock it with the chain lock (4).
d) Manually move the tension arm until the chain (1) is tensioned by the
sprocket (2) then tighten the screw (3).

Motion direction

1 1

TechPub_2614345_0107 - 0401_3057031_01.fm
2

1 Chain
2 Sprocket
3 Screw
4 Chain lock

4 - 66 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4.5 Drive Unit

4.5 Drive Unit

SPC Reference 2706560-0200

4.5-1 Drive Unit - Check

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2706560-0200

Short Chain - Check

Check that:
• the chain (1) is not worn or damaged, if required change it,
see 4.5-2 Drive Unit - Change Chains on page 4-70
• the chain (1) is well tensioned by the sliding profile (2), normally set the
chain tensioner (3) fully towards the chain (1) with the two screws (4)
• the sliding profile (2) and the two sprockets (6) are aligned, if required
fine adjust the position of the sprockets (6) with the stop screws (7) and
the position the sliding profile (3) with the two screws (5).

6
TechPub_2614345_0107 - 0401_3057032_01.fm

7 5

6
Top view

1 2

3
4
1 Chain 4 Screw 7 Stop screw
2 Sliding profile 5 Screw
3 Chain tensioner 6 Sprocket

(Cont'd)

Doc. No. MM-3047612-0101 4 - 67 (80)

4.5 Drive Unit 4 Feed Unit

(Cont'd)
Long Chain - Check
Check that:
• the chain (1) is not worn or damaged, if required change it,
see 4.5-2 Drive Unit - Change Chains on page 4-70
• the chain (1) is well tensioned by the sprocket (2) of the tension arm, if
required fine adjust the tension with the screw (3)

TechPub_2614345_0107 - 0401_3057032_01.fm
1

1 Chain
2 Sprocket 3
3 Screw
2

(Cont'd)

4 - 68 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4.5 Drive Unit

(Cont'd)
• the sprocket (2) of the tension arm and the two sprockets (5) are aligned,
if required fine adjust the position of the two sprockets (5) with the stop
screws (6) and the position of the sprocket (2) with the two screws (4).

Top view
TechPub_2614345_0107 - 0401_3057032_01.fm

6 6

5 4 2 5
2 Sprocket
4 Screw
5 Sprocket
6 Stop screw

Doc. No. MM-3047612-0101 4 - 69 (80)

4.5 Drive Unit 4 Feed Unit

4.5-2 Drive Unit - Change Chains

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2706560-0200

Short Chain - Change

a) Manually push the sliding profile (2) fully inside the chain tensioner (3)
and block it in position using a pin punch in the hole (4).
b) Open the chain (1) by removing the chain lock (5).
Note! According to the motion direction of the chain (1), make sure to fit the
chain lock (5) as shown below.
c) Fit the new chain (1) and then lock it with the chain lock (5).
d) Remove the pin punch from the hole (4) to tense the chain (1).

Motion direction

TechPub_2614345_0107 - 0401_3057032_01.fm
1 5

1 Chain 3
2 Sliding profile
3 Chain tensioner
4 Hole 4
5 Chain lock

(Cont'd)

4 - 70 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4.5 Drive Unit

(Cont'd)
Long Chain - Change
a) Loosen the screw (3) to release the tension of the chain (1).
b) Open the chain (1) by removing the chain lock (4).
Note! According to the motion direction of the chain (1), make sure to fit the
chain lock (4) as shown below.
c) Fit the new chain (1) and then lock it with the chain lock (4).
d) Manually move the tension arm until the chain (1) is tensioned by the
sprocket (2) then tighten the screw (3).

Motion direction

1 4

1
TechPub_2614345_0107 - 0401_3057032_01.fm

1 Chain
2 Sprocket
3 Screw
4 Chain lock 3
2

Doc. No. MM-3047612-0101 4 - 71 (80)

4.5 Drive Unit 4 Feed Unit

4.5.1 Bevel Gear

SPC Reference 2982763-0100

4.5.1-1 Bevel Gear - Check

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2982763-0100

On both sides check that:

• the chain (1) is not worn or damaged, if required change it,
see 4.5.1-2 Bevel Gear - Change Chains on page 4-73
• the chain (1) is well tensioned by the sliding profile (3) of the chain
tensioner (4), normally set the chain tensioner (4) fully towards the
chain (1) with the two screws (5) and the nuts.
• the sliding profile (3) and the sprocket (6) are aligned to the sprocket (2),
if required fine adjust the position of the sprocket (6) with the stop
screw (7) and the position the sliding profile (3) with the two screws (8).

TechPub_2614345_0107 - 0401_3057032_01.fm
Top view

5
3
1 2 3 4 5 6 7
1 Chain
2 Sprocket
3 Sliding profile 6
4 Chain tensioner
5 Screw
3
6 Sprocket 1 2
7 Stop screw
8 Screw
1

4 - 72 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4.5 Drive Unit

4.5.1-2 Bevel Gear - Change Chains

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2982763-0100
Note! The following instructions are valid for both chains (1).
a) Manually push the sliding profile (2) fully inside the chain tensioner (3)
and block it in position using a pin punch in the two holes (4) when they
are aligned.
b) Open the chain (1) by removing the chain lock (5).
Note! According to the motion direction of the chain (1), make sure to fit the
chain lock (5) as shown below.
c) Fit the new chain (1) and then lock it with the chain lock (5).
d) Remove the pin punch from the holes (4) to tense the chain (1).

3
Motion direction
TechPub_2614345_0107 - 0401_3057032_01.fm

5 1

2
2

1 Chain 1
2 Sliding profile
3 Chain tensioner
4 Hole
5 Chain lock

Doc. No. MM-3047612-0101 4 - 73 (80)

4.6 Adjustment Bracket 4 Feed Unit

4.6 Adjustment Bracket

SPC Reference 2708080-0100

4.6-1 Adjustment Bracket - Set Timing Belt Tension

Machine Status Mains Power OFF
Air OFF
Water OFF
Special Equipment Dynamometer TP No. 74767-0102
SPC Reference 2708080-0100

Apply the dynamometer in the middle of the span of the timing belt (1), with
a force of 8 N the deflection must be 5 ± 1 mm. If required loosen the
screw (2) and modify the position of the wheel (3), in order to fine adjust the
tension of the timing belt (1).

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1

1
2 1 Timing belt
2 Screw
3 Wheel

4 - 74 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4.7 Side Adjuster

4.7 Side Adjuster

SPC Reference 2721620-0100

4.7-1 Side Adjuster - Check Timing Belt

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2721620-0100

Check the condition of the timing belt (1), if required change it as follows:
• loosen the two stop screws (3) and remove both locking rings (2)
• turn clockwise the shaft (4) until there is space enough to replace the
timing belt (1)
• turn anticlockwise the shaft (4) then fit back both locking rings (2) and
tighten the two stop screws (3).

2
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1
2 4
1 Timing belt
2 Locking ring
3 Stop screw
4 Shaft

Doc. No. MM-3047612-0101 4 - 75 (80)

4.8 Drive Shaft (for Outer Chains) 4 Feed Unit

4.8 Drive Shaft (for Outer Chains)

SPC Reference 2721650-0100

4.8-1 Drive Shaft (for Outer Chains) - Check

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2721650-0100

Check that:
• the chain (1) is not worn or damaged, if required change it,
see 4.8-2 Drive Shaft (for Outer Chains) - Change Chain on page 4-77
• the chain (1) is well tensioned by the sliding profile (4), normally set the
chain tensioner (5) fully towards the chain (1) with the two screws (5)
• the sliding profile (4) and the sprockets (2) and (6) are aligned, if
required fine adjust the position of the sprockets (2) and (6) with the stop
screws (3) and the position of the sliding profile (4) with the two
screws (7).

TechPub_2614345_0107 - 0401_3057035_01.fm
2
3
1 1
5 4

6 8

1 Chain 5 Chain tensioner

2 Sprocket 6 Screw
3 Stop screw 7 Sprocket
4 Sliding profile 8 Screw

4 - 76 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4.8 Drive Shaft (for Outer Chains)

4.8-2 Drive Shaft (for Outer Chains) - Change Chain

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2721650-0100

a) Manually push the sliding profile (2) fully inside the chain tensioner (3)
and block it in position using a pin punch in the hole (4).
b) Open the chain (1) by removing the chain lock (5).
Note! According to the motion direction of the chain (1), make sure to fit the
chain lock (5) as shown below.
c) Fit the new chain (1) and then lock it with the chain lock (5).
d) Remove the pin punch from the hole (4) to tense the chain (1).

Motion direction

1 1
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3 2

1 Chain
2 Sliding profile
3 Chain tensioner
4 Hole
5 Chain lock

Doc. No. MM-3047612-0101 4 - 77 (80)

4.9 Chain Tensioner 4 Feed Unit

4.9 Chain Tensioner

SPC Reference 2838570-0100
2838575-0100

4.9-1 Chain Tensioner - Check

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2838570-0100
2838575-0100

a) If not already done, open and remove the inner chains (1) and the outer
chains (2), see 4-17 Feed Unit - Change Chains on page 4-52.
b) Check that the sprockets (3) rotate freely and without any play and that
they are not worn and damaged, if required perform the 4.9-2 Chain
Tensioner - Overhaul on page 4-79.
c) Fit back the inner chains (1) and the outer chains (2) previously
removed, see 4-17 Feed Unit - Change Chains on page 4-52.

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3
1

1 Inner chain
2 Outer chain
3 Sprocket

4 - 78 (80) Doc. No. MM-3047612-0101

 4 Feed Unit 4.9 Chain Tensioner

4.9-2 Chain Tensioner - Overhaul

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2838570-0100
2838575-0100

a) If not already done, open and remove the inner chains (1) and the outer
chains (2), see 4-17 Feed Unit - Change Chains on page 4-52.
b) Remove the screws (4) and the plate (3).
c) Remove the screw (5) and the chain tensioner.

3
2

1
4
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1 Inner chain
2 Outer chain
3 Plate
4 Screw
5 Screw

(Cont'd)

Doc. No. MM-3047612-0101 4 - 79 (80)

4.9 Chain Tensioner 4 Feed Unit

(Cont'd)
d) Remove the screws (6) and the cover (7).
e) Remove the retaining ring (8) then take out the sprocket (10) and the ball
bearings (9).
f) Replace the ball bearings (9) and the sprocket (10) if damaged, then
assemble in the reverse order.
g) Fit back the chains previously removed, see 4-17 Feed Unit - Change
Chains on page 4-52.

10
9
8
7

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6

6 Screw
10 7 Cover
9 8 Retaining ring
8 9 Ball bearing
7 10 Sprocket
6

4 - 80 (80) Doc. No. MM-3047612-0101

 5 Base Unit
TechPub_2614345_0107 - 0501_3057037_01.fm

Doc. No. MM-3047612-0101 5 - 1 (100)

 5 Base Unit

Base Unit - Description

SPC Reference 663106-0100
Note! If not indicated in a different way, all the pictures used in the chapter
show the Base Unit for a machine with Magazine Unit on the RH side.

5.2

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5.3

5.4

5.1
5.1 Installation
5.2 TPOP
5.3 Outfeeder
5.4 Frame

5 - 2 (100) Doc. No. MM-3047612-0101

 5 Base Unit Table of Contents

5.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5
5.1.1 Cleaning Equipment . . . . . . . . . . . . . . . . . . . . . . . 5 - 5
5.1.1-1 Cleaning Equipment - Check . . . . . . . . . . . . . . . . 5 - 5
5.1.2 Hotmelt Equipment Nordson . . . . . . . . . . . . . . . . 5 - 6
5.1.2-1 Hotmelt Equipment Nordson - Functional
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6
5.1.2-2 Hotmelt Equipment, Nordson - Check Hotmelt
Dot Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 8
5.1.2-3 Hotmelt Equipment, Nordson - Set . . . . . . . . . . . 5 - 9
5.1.2-4 Hotmelt Equipment, Nordson - By-pass Unit . . 5 - 18
5.1.2-5 Hotmelt Equipment, Nordson - Bleed System . . 5 - 19
5.1.2-6 Hotmelt Equipment, Nordson - F2 Alarm . . . . . 5 - 20
5.1.2-7 Hotmelt Equipment, Nordson - Change
Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 21
5.1.2-8 Hotmelt Equipment, Nordson - Change Filter . . 5 - 23
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5.1.2-9 Hotmelt Equipment, Nordson - Change Gun . . . 5 - 25

5.1.2-10 Hotmelt Equipment, Nordson - Clean Nozzles . 5 - 26

5.2 TPOP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 27
5.2.1 Touch Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 27
5.2.1-1 Touch Screen - Change . . . . . . . . . . . . . . . . . . . 5 - 27
5.2.1-2 Touch Screen - Check Firmware Version . . . . . . 5 - 31
5.2.1-3 Touch Screen - Check/Set IP Address and
Subnet Mask Address . . . . . . . . . . . . . . . . . . . . . 5 - 35
5.2.1-4 Touch Screen - Load Firmware . . . . . . . . . . . . . 5 - 42
5.2.1-5 Touch Screen - Remove Existing Program . . . . 5 - 53
5.2.1-6 Touch Screen - Download Program . . . . . . . . . . 5 - 56
5.2.1-7 Touch Screen - Set . . . . . . . . . . . . . . . . . . . . . . . 5 - 66
5.2.1-8 Touch Screen - Calibration . . . . . . . . . . . . . . . . . 5 - 76

5.3 Outfeeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 80
5.3.1 Outfeed Conveyor . . . . . . . . . . . . . . . . . . . . . . . . 5 - 80
5.3.1-1 Outfeed Conveyor - Configure Outfeed Side . . . 5 - 80
5.3.1-2 Outfeed Conveyor - Set Speed . . . . . . . . . . . . . . 5 - 82

Doc. No. MM-3047612-0101 5 - 3 (100)

Table of Contents 5 Base Unit

5.3.1-3 Outfeed Conveyor - Set Timer for Queue

Alarm Photocells . . . . . . . . . . . . . . . . . . . . . . . . 5 - 84
5.3.1-4 Outfeed Conveyor - Select Queue Photocell . . . 5 - 86
5.3.1-5 Outfeed Conveyor - Configure Switch . . . . . . . 5 - 88
5.3.1-6 Outfeed Conveyor - Select Switch Photocell
Expected Status . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 90
5.3.2 Outfeed Damper. . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 91
5.3.2-1 Outfeed Damper - Set . . . . . . . . . . . . . . . . . . . . 5 - 91
5.3.2-2 Outfeed Damper - Set Cylinder . . . . . . . . . . . . . 5 - 94
5.3.2-3 Outfeed Damper - Check . . . . . . . . . . . . . . . . . . 5 - 96

5.4 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 97
5.4.1 Bar (for WA unit) . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 97
5.4.1-1 Bar (for WA Unit) - Set Position . . . . . . . . . . . . 5 - 97

TechPub_2614345_0107 - 0501_3057037_01.fm

5 - 4 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.1 Installation

5.1 Installation
SPC Reference 2765932-0100

5.1.1 Cleaning Equipment

5.1.1-1 Cleaning Equipment - Check
Machine Status PRODUCTION
SPC Reference 2801446-0100

Make sure that the air valve (1) and water valve (2) are open, then check the
hoses and the connections for leakages, change them if required.
TechPub_2614345_0107 - 0501_3057038_01.fm

1 Air valve
2 2 Water valve
1

Doc. No. MM-3047612-0101 5 - 5 (100)

5.1 Installation 5 Base Unit

5.1.2 Hotmelt Equipment Nordson

5.1.2-1 Hotmelt Equipment Nordson - Functional Description
SPC Reference 2838614-0100

The hotmelt equipment consists of the hotmelt unit (1), hoses (2), and
guns (3) for dispensing the adhesive. The tank (4), the hoses (2), and the
guns (3) are electrically heated. The pump (5) and the valves (6) are
pressurized by compressed air, the pressure for the pump (5) is adjusted with
a regulator on the hotmelt unit (1), whilst the air supply for the guns (3), can
be fine adjusted with the regulators on the pneumatic panel of the machine.

6 4 5

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1

1 Hotmelt unit
2 Hose
3 Gun
4 Tank 2
5 Pump
6 Valve

(Cont'd)

5 - 6 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.1 Installation

(Cont'd)
When the system is turned ON, the tank (4) and hoses (2) begin to heat up.
When the temperatures of the tank and hoses are all within 19.5°C of their
set point temperatures, the guns (3) begin to heat up. The time delay provides
additional time for the adhesive in the tank to melt.
When ready, the green light (9) gets fixed light, and the pump (5) is enabled.
The adhesive passes through the pump and flows through a filter (7) into the
distribution manifold (10). Then it flows into the hoses (2), through the
filters (11) and finally through the guns (3).

9 10

8
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7 Filter
8 Filter replacement indicator
9 Ready indicator
10 Distribution manifold
11 11 Filter

Doc. No. MM-3047612-0101 5 - 7 (100)

5.1 Installation 5 Base Unit

5.1.2-2 Hotmelt Equipment, Nordson - Check Hotmelt Dot

Positions
Machine Status PRODUCTION

With the machine in PRODUCTION step, check the positions of the hotmelt
dots (1) on the: tray (2), tray OF (3), WAIF box (4) and WASF box (5).
The dots have to be positioned as shown below, where they are pressed by
the side pressure rails of the feed unit, and if installed on your machine, by
the folder and side pressure rails of the WA unit; otherwise the hotmelt glue
may not keep a tray folded and the glue may get into the tray. Check also that
no hotmelt is visible when a tray is folded and it has left the machine.
If required, set the positions of the hotmelt dots, see 4-9 Feed Unit - Set Gun
Holder, on page 4-33, then fine adjust he start positions and the length of the
hotmelt dots (1) by TPOP see the OM.

1
1

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2 3

1
1

1
1
4
5
1 Hotmelt dot 4 WAIF box
2 Tray 5 WASF box
3 Tray OF

5 - 8 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.1 Installation

5.1.2-3 Hotmelt Equipment, Nordson - Set

Machine Status Mains Power ON
Air ON
Water ON
Consumables see Recommended Hotmelt Types and Temperatures
on page 5-14
SPC Reference 2838614-0100

WARNING
Risk of burns.
During PREHEATING and PRODUCTION the hotmelt unit gets hot.
Do not touch the hotmelt unit and beware of the entrapped heat inside the
unit when service is performed!
Make sure that there is hotmelt material in the tank (1) and switch ON (2) the
hotmelt unit.
For recommended type of hotmelt material see “Consumables” in the table
above.
Note! The colour of the hotmelt material should be light yellow. If the hotmelt
material has become brown, exchange it. In order to obtain a prolonged
lifetime of the hotmelt material, the temperature can be decreased during
TechPub_2614345_0107 - 0501_3057038_01.fm

longer production stops.

When connecting hoses, always use port 1 (3). The port position is stamped
on the face of the manifold!

1 Tank
2 Power switch
3 Port 1

3 2
(Cont'd)

Doc. No. MM-3047612-0101 5 - 9 (100)

5.1 Installation 5 Base Unit

(Cont'd)
Hoses and Guns Connection
The hoses and guns are connected in the positions indicated below.

5
4
5
3
2
4
1
3

1 1 Hose/gun connection, lower LH side

TechPub_2614345_0107 - 0501_3057038_01.fm
2 Hose/gun connection, lower RH side
3 Hose/gun connection, upper LH side
4 Hose/gun connection, upper RH side
5 Hose/gun connection, WA

(Cont'd)

5 - 10 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.1 Installation

(Cont'd)
Operator Panel Overview

Note! For further information read the Nordson Pro Blue Adhesive Melters
Manual.

1 2 3 4

1 Fault LED
2 Ready LED 20
3 Hose-key
19
4 Gun-key
5 Multipurpose display 18
6 Up-key for multipurpose display 17 5
7 Down-key for multipurpose display 6
16
8 Clear/Reset-key
9 Enter-key 7
10 Setup-key 8
11 Seven day clock-key
15
12 Heater-key
9
13 Pump-key
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14 Standby-key
15 Keypad
16 Up-key for selector display
17 Selector display
18 Low level LED
19 Service LED 14 13 12 11 10
20 Tank-key

(Cont'd)

Doc. No. MM-3047612-0101 5 - 11 (100)

5.1 Installation 5 Base Unit

(Cont'd)
Parameter Settings
Parameter Function Description Setting for
standard machin
4 System-ready time Allows you to set the amount of 0 minutes
delay additional time for hotmelt material to
melt after all zones have reached their
set-point temperatures.
20 Celsius/Fahrenheit Allows you to display temperature Celsius
measurements in Celsius or Fahrenheit.
0 = Celsius
1 = Fahrenheit
21 Over temperature Allows you to specify the maximum 15°C
set-point temperature the features 1-3 can reach
before the system initiates a fault
condition.
22 Under temperature The number of degrees that the 5°C
delta temperature of any component can
decrease from its set-point temperature
before an under temperature fault (F2)
occurs.
30 Standard input 1 Hose/Gun 3 Enable/Disable 6

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31 Standard input 2 Hose/Gun 4 Enable/Disable 0
32 Standard input 3 Hose/Gun 5 Enable/Disable 0
33 Standard input 4 Disable 0
40 Standard output 1 Ready and Pump is on 2
41 Standard output 2 Fault 3
42 Standard output 3 Low level 4

(Cont'd)

5 - 12 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.1 Installation

(Cont'd)
Set the parameters as follows:
a) Press SETUP-KEY (1) and the selector display (2) flashes. Use UP-
KEY (3) (or keypad (8)), to select a parameter and confirm with the
ENTER-KEY (4).
b) Then the multipurpose display (5) starts flashing. Use UP-KEY (6), or
DOWN-KEY (7) (or use the keypad (8)) to select a required value and
confirm with the ENTER-KEY (4).
Note! If the setting is unadjustable the display is password protected! For
further information read Nordson Pro Blue Adhesive Melters Manual,
chapter 4, “Enter the Melter Password”.
c) When the selector display (2) shows next parameter and setting, either
continue with next parameter or exit by pressing the SETUP-KEY (1)
twice.

1 Setup-key
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2 Selector display 2 5
3 Up-key 3 6
4 Enter-key
5 Multipurpose display
7
6 Up-key 1
7 Down-key 8
8 Keypad
9
9 Clear/Reset-key
4
(Cont'd)

Doc. No. MM-3047612-0101 5 - 13 (100)

5.1 Installation 5 Base Unit

(Cont'd)
Recommended Hotmelt Types and Temperatures
In the table below, are listed the suggested setting values for the temperatures
of the tank (1), hoses (2) and guns (3), according to different hotmelt
suppliers and ambient temperature conditions.

Type of hotmelt Ambient Tank (1) Hose (2) Gun (3)

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

Note!
Too high temperature will make the adhesive deteriorate quicker, resulting
in reduced quality.

TechPub_2614345_0107 - 0501_3057038_01.fm
Too low temperature results in threads of adhesive, and decreased
cooling-off time.

3
3

1 Tank
2 Hose
3 Gun
2
(Cont'd)

5 - 14 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.1 Installation

(Cont'd)
Set the temperature of the tank as follows:
a) Press TANK-KEY (1) for 3 seconds.
b) The digit “1” appears flashing in selector display (2). If the digit “0”
appears, press UP-KEY (3) (or keypad (8)) for selector display until
digit “1” appears. Confirm the choice by pressing ENTER-KEY (4).
c) Then the MULTIPURPOSE display (5) starts flashing. Press the
multipurpose display DOWN-KEY (6) or UP-KEY (7) (or keypad (8))
to enter the required value.
d) Confirm the setting by pressing ENTER-KEY (4).
e) Exit by pressing the SETUP-KEY (9) twice.

1 Tank-key 2 5
2 Selector display 3 7
3 Up-key
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4 Enter-key
6
5 Multipurpose display
9
6 Down-key 8
7 Up-key 4
8 Keypad
9 Setup-key

Position Button Description Setting range

1 Tank-key Allows you to specify the tank set-point ≈ 155 ÷ 165 °C
temperature
(Cont'd)

Doc. No. MM-3047612-0101 5 - 15 (100)

5.1 Installation 5 Base Unit

(Cont'd)
Set the temperature of the hoses and guns as follows:
a) Press HOSE-KEY (1) or GUN-KEY (2) for 3 seconds.
b) The digit “1” appears flashing in selector display (3). Press UP-KEY (4)
(or keypad (9)) for selector display until digit “0” appears. Confirm the
choice by pressing ENTER-KEY (5).
c) Then the Multipurpose display (6) starts flashing. Press the
multipurpose display DOWN-KEY (7) or UP-KEY (8) (or keypad (9))
to enter the required value. Confirm the setting by pressing ENTER-
KEY (5).
d) Exit by pressing the SETUP-KEY (10) twice.

1 2

1 Hose-key
2 Gun-key 3 6

TechPub_2614345_0107 - 0501_3057038_01.fm
3 Selector display 4 8
4 Up-key
5 Enter-key
7
6 Multipurpose display 10
7 Down-key 9
8 Up-key 5
9 Keypad
10 Setup-key

Position Button Description Setting range

1 Hose-key Allows you to specify the hose set-point ≈ 160 ÷ 170 °C
temperature
2 Gun-key Allows you to specify the gun set-point ≈ 165 ÷ 180 °C
temperature

(Cont'd)

5 - 16 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.1 Installation

(Cont'd)
Air Pressure
a) Set the pressure of the hotmelt unit pump to 3 Bar (0.3 Mpa), by turning
the pressure regulator screw (1). The pressure value is indicated on the
pressure gauge (2).
b) Check also the setting of the pressure regulators (3) and (4) for the
hotmelt guns, see 2.2.1-2 Air Equipment - Set Regulators on
page 2-66.

3 4
TechPub_2614345_0107 - 0501_3057038_01.fm

1 Pressure regulator screw

1 2 Pressure gauge
2 3 Pressure regulator; hotmelt applicator RH
4 Pressure regulator; hotmelt applicator LH

Doc. No. MM-3047612-0101 5 - 17 (100)

5.1 Installation 5 Base Unit

5.1.2-4 Hotmelt Equipment, Nordson - By-pass Unit

Machine Status PREHEATING
SPC Reference 2838614-0100

The following procedure allows to by-pass the hotmelt unit, in order to step
up the machine program without waiting the end of the PREHEATING.
Note! The box produced will not be glued together.
a) On the TPOP, log on as: “tptechnician” or “supervisor” or “technician”,
see 6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) With the machine in PREHEATING, touch the MAINTENANCE
button (1) and the SERVICE PARTS button (2), or touch the SERVICE
PARTS tab (3).
c) Touch the HOTMELT UNIT icon (4) to display the dialogue window.
d) Touch the ON button (5) to select the by-pass function.
e) Touch the CONFIRMATION button (6) to activate the by-pass of the
hotmelt unit.
f) Touch the EXIT button (7).

1 2 4

TechPub_2614345_0107 - 0501_3057038_01.fm
3

1 Maintenance button
2 Service parts button
3 Service parts tab
4 Hotmelt unit icon
5 ON button
6 Confirmation button
7 Exit button
5 6 7

5 - 18 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.1 Installation

5.1.2-5 Hotmelt Equipment, Nordson - Bleed System

Machine Status Mains Power ON
Air ON
Water ON
SPC Reference 2838614-0100

WARNING
Risk of burns.
Hot adhesive! Wear safety glasses, protective gloves, and other protective
clothing to avoid injuries from adhesive pouring out through the nozzles.
Note! The machine must be preheated, and the guns have reached
operating temperature.
Bleed the system, as follows:
a) Remove the nozzles, see instructions in the Nordson Pro Blue Manual.
b) Reduce the pressure on the hotmelt unit to 1 bar (0.1 MPa) by turning the
pressure regulator screw (1). The pressure is stated on the pressure
gauge (2).
c) Place a container under the nozzle holes (3), to collect the adhesive.
d) Press the pin (4) on the hotmelt gun valve unit manually, and pump out
TechPub_2614345_0107 - 0501_3057038_01.fm

the adhesive until it is pure without air bubbles.

e) Fit the nozzles back.
f) Set the hotmelt unit pressure to 3 bar (0.3 MPa) by turning the pressure
regulator screw (1).

3 4

1 Pressure regulator screw

2 Pressure gauge
3 Nozzle hole
4 Pin
2 1

Doc. No. MM-3047612-0101 5 - 19 (100)

5.1 Installation 5 Base Unit

5.1.2-6 Hotmelt Equipment, Nordson - F2 Alarm

Machine Status Mains Power ON
Air ON
Water ON
SPC Reference 2838614-0100

If the guns are cooled down an alarm called “F2” locks the hotmelt unit. The
hotmelt unit needs to be reset and reheated.
a) Press the CLEAR/RESET-KEY (1).
b) Press the HEATER-KEY (2).
c) The hotmelt unit starts to heat up.

TechPub_2614345_0107 - 0501_3057038_01.fm
1

1 Clear/Reset-key
2 Heater-key

5 - 20 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.1 Installation

5.1.2-7 Hotmelt Equipment, Nordson - Change Adhesive

Machine Status Mains Power OFF
Air ON
Water ON
SPC Reference 2838614-0100

WARNING
Risk of burns.
Hot adhesive! Wear safety glasses, protective gloves, and other protective
clothing to avoid injuries from adhesive pouring out.
During tank drainage never touch the drain shut!
Note! The machine must be preheated before the work can start.
To change the adhesive, do the following:
a) Reduce the pressure on the hotmelt unit to 1 bar (0.1 MPa) by turning the
pressure regulator screw (1). The pressure is stated on the pressure
gauge (2).
TechPub_2614345_0107 - 0501_3057038_01.fm

2 1
1 Pressure regulator screw
2 Pressure gauge

(Cont'd)

Doc. No. MM-3047612-0101 5 - 21 (100)

5.1 Installation 5 Base Unit

(Cont'd)
b) Put a container under the drain shut (3).
c) Pull down the drain shut (3).
d) Open the drain valve (4) by slowly turning it to the left until the adhesive
begins to flow.
e) Empty the tank (5).
f) Close the drain valve (4) and pull up the drain shut (3). Fill the tank (5)
with adhesive.
To bleed the system see 5.1.2-5 Hotmelt Equipment, Nordson - Bleed
System on page 5-19.

3 5

TechPub_2614345_0107 - 0501_3057038_01.fm
3

3 Drain shut
4 Drain valve
5 Tank

5 - 22 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.1 Installation

5.1.2-8 Hotmelt Equipment, Nordson - Change Filter

Machine Status Mains Power OFF
Air OFF
Water OFF
Special Equipment Torque Wrench min. 4.5 Nm
SPC Reference 2838614-0100

WARNING
Risk of burns.
Hot adhesive! Wear safety glasses, protective gloves, and other protective
clothing to avoid injuries from adhesive pouring out.
Note! The machine must be preheated, and the guns have reached
operating temperature before the work can start.
Change the filters, as follows:
a) Press the PUMP-KEY (1) to stop the pump.
TechPub_2614345_0107 - 0501_3057038_01.fm

1 Pump-key

(Cont'd)

Doc. No. MM-3047612-0101 5 - 23 (100)

5.1 Installation 5 Base Unit

(Cont'd)
b) Use an 8 mm Allen key, wrench to the left, to loosen and then properly
dispose the old filter (2).
c) Before fitting the new filter, check that the O-ring (3) is in good
condition. Tighten the filter (2) to 4.5 Nm.
Note! Two different types of guns are used!
d) On the hose, unscrew the filter (4).
e) Change and fit the filter (4). Use a yellow filter with 100 mesh.
f) Press the pump-key (1) to start the pump.

TechPub_2614345_0107 - 0501_3057038_01.fm
2
4

2 Filter
3 O-ring
4 Filter

5 - 24 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.1 Installation

5.1.2-9 Hotmelt Equipment, Nordson - Change Gun

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2838614-0100

WARNING
Risk of burns.
Hot adhesive! Wear safety glasses, protective gloves, and other protective
clothing to avoid injuries from adhesive pouring out.
Note! The machine must be preheated, and the guns have reached
operating temperature.
a) Zero the pump air pressure by turning the pressure regulator screw (5).
The pressure is stated on the pressure gauge (6).
b) Press the PUMP-KEY (1) to stop the pump.
c) Remove the screws (2) and the gun (3). Replace it.
Note! Check that the O-rings (4) are in good condition and positioned
correctly!
d) Fit and tighten the screws (2).
TechPub_2614345_0107 - 0501_3057038_01.fm

e) Press the PUMP-KEY (1) to start the pump.

f) Set the pump air pressure by turning the pressure regulator screw (5)
at 3 Bar (0.3 MPa). The pressure is stated on the pressure gauge (6).

1
3 2
1 Pump-key
2 Screw
3 Gun
4 O-ring
5 Pressure regulator screw
6 5 6 Pressure gauge

Doc. No. MM-3047612-0101 5 - 25 (100)

5.1 Installation 5 Base Unit

5.1.2-10 Hotmelt Equipment, Nordson - Clean Nozzles

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2838614-0100

WARNING
Risk of burns.
Hot adhesive! Wear safety glasses, protective gloves, and other protective
clothing to avoid injuries from adhesive pouring out.
Note! The nozzles (2) and (3) are installed only on the machines equipped
with WA. For further information on how to remove and clean the nozzles,
see the Nordson manual.
Remove and clean the nozzles (1), (2) and (3) then fit back the nozzles.

TechPub_2614345_0107 - 0501_3057038_01.fm
2

3
1 Nozzle
2 Nozzle
3 Nozzle

5 - 26 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

5.2 TPOP
SPC Reference 2883556-0100

5.2.1 Touch Screen

5.2.1-1 Touch Screen - Change
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 90600-0980

a) In the rear of the TPOP, open the door (1) using the key (2) in the two
keyholes (3).
TechPub_2614345_0107 - 0501_3057039_01.fm

1 Door
2 Key
3 Keyhole 2

(Cont'd)

Doc. No. MM-3047612-0101 5 - 27 (100)

5.2 TPOP 5 Base Unit

(Cont'd)
b) Disconnect the wires of the power cable (4) and the ethernet cable (5)
from the touch screen (6).
c) At the top, the bottom and the sides of the touch screen (6), remove the
fixing screws and L-shaped brackets (7), then remove the touch
screen (6) from the TPOP.
d) Assemble the new touch screen (6) in the reverse order.

7
4

TechPub_2614345_0107 - 0501_3057039_01.fm
6

4 Power cable
5 Ethernet cable
6 Touch screen
7 Bracket

(Cont'd)

5 - 28 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

(Cont'd)
e) After the replacement of the touch screen, perform the following
instructions in the order given, according to your situation:
Situation 1 - (New Touch Screen)
The touch screen installed is new:
– check the firmware version in the module, see 5.2.1-2 Touch Screen -
Check Firmware Version on page 5-31, then continue as follows
according to the firmware version.
The firmware has the correct version:
– set the correct IP address and subnet mask address, see 5.2.1-3 Touch
Screen - Check/Set IP Address and Subnet Mask Address on
page 5-35
– set the touch screen, see 5.2.1-7 Touch Screen - Set on
page 5-66
– download the program, see 5.2.1-6 Touch Screen - Download
Program on page 5-56.
The firmware has an incorrect version:
– set the correct IP address and subnet mask address, see 5.2.1-3 Touch
Screen - Check/Set IP Address and Subnet Mask Address on
TechPub_2614345_0107 - 0501_3057039_01.fm

page 5-35
– download the correct version of the firmware, see 5.2.1-4 Touch
Screen - Load Firmware on page 5-42
– set the correct IP address and subnet mask address, see 5.2.1-3 Touch
Screen - Check/Set IP Address and Subnet Mask Address on
page 5-35
– set the touch screen, see 5.2.1-7 Touch Screen - Set on
page 5-66
– download the program, see 5.2.1-6 Touch Screen - Download
Program on page 5-56.
(Cont'd)

Doc. No. MM-3047612-0101 5 - 29 (100)

5.2 TPOP 5 Base Unit

(Cont'd)
Situation 2 - (Old Touch Screen)
The touch screen installed, has been previously used and a firmware or
application program update is required.
To upgrade the firmware:
– check/set the correct IP address and subnet mask address, see 5.2.1-3
Touch Screen - Check/Set IP Address and Subnet Mask Address on
page 5-35
– download the correct version of the firmware, see 5.2.1-4 Touch
Screen - Load Firmware on page 5-42
– set the correct IP address and subnet mask address, see 5.2.1-3 Touch
Screen - Check/Set IP Address and Subnet Mask Address on
page 5-35
– set the touch screen, see 5.2.1-7 Touch Screen - Set on
page 5-66.
To upgrade the program:
– check/set the correct IP address and subnet mask address, see 5.2.1-3
Touch Screen - Check/Set IP Address and Subnet Mask Address on
page 5-35

TechPub_2614345_0107 - 0501_3057039_01.fm
– remove the old program, in order to provide a sufficient memory for a
new program download, see 5.2.1-5 Touch Screen - Remove Existing
Program on page 5-53
– download the program, see 5.2.1-4 Touch Screen - Load Firmware on
page 5-56.

5 - 30 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

5.2.1-2 Touch Screen - Check Firmware Version

Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with CD drive
Program CD TP No. 2886185-0XXX
SPC Reference 90600-0980

Note! Power must be present at the touch screen to perform maintenance

on the screen.
Note! The touch screen may contain the latest version of the firmware or an
earlier version. The touch screen must be checked to determine the version
of the firmware installed.
a) On the TPOP, log on as: “tptechnician” or “supervisor” or “technician”,
see 6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) Touch the SYSTEM SETUP button (1), the SHUT DOWN button (2) and
the CONFIRMATION button (3) to display the MAIN window below.
c) In the MAIN window, touch the TERMINAL SETTINGS button (4).

Current application
TechPub_2614345_0107 - 0501_3057039_01.fm

1
Load Application Run Application Application Settings
[F1] [F2] [F3]

Delete Log Files Yes

Terminal Settings
[F4] Before Running
[F5] No

4 Reset 2
[F8]

3
1 System setup button
2 Shut down button
3 Confirmation button
4 Terminal settings button

(Cont'd)

Doc. No. MM-3047612-0101 5 - 31 (100)

5.2 TPOP 5 Base Unit

(Cont'd)
d) Select SYSTEM INFORMATION (5) and touch the ENTER button (6).

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

5
6
Close
[F8]

5 System information
6 Enter button

TechPub_2614345_0107 - 0501_3057039_01.fm
e) Select ABOUT RSVIEW ME STATION (7) and touch the ENTER
button (6).

About RSView ME Station

Terminal Information

6
Close
[F8]

6 Enter button
7 About RSView ME station

(Cont'd)

5 - 32 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

(Cont'd)
f) Insert the program CD into the PC CD drive.
g) Browse to the CD drive, then open the PDF file (indicated with an
arrow) included in the folder 2886191-1XXX, in order to identify the
correct version of the Firmware for the touch screen.
TechPub_2614345_0107 - 0501_3057039_01.fm

(Cont'd)

Doc. No. MM-3047612-0101 5 - 33 (100)

5.2 TPOP 5 Base Unit

(Cont'd)
h) The firmware version number (8) installed in the touch screen module is
displayed. If necessary, upgrade the firmware, see 5.2.1-4 Touch Screen
- Load Firmware on page 5-42.

Firmware Version:

4.00.05.60 (CPR 7) (Major, Minor, Patch, Build, Release)

Technical Support Close

[F1] [F8]

TechPub_2614345_0107 - 0501_3057039_01.fm
8 Firmware version number

5 - 34 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

5.2.1-3 Touch Screen - Check/Set IP Address and Subnet Mask

Address
Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 90600-0980

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

see 6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) Touch the SYSTEM SETUP button (1), the SHUT DOWN button (2) and
the CONFIRMATION button (3) to display the MAIN window below.
c) In the MAIN window, touch the TERMINAL SETTINGS button (4).

Current application

1
Load Application Run Application Application Settings
[F1] [F2] [F3]
TechPub_2614345_0107 - 0501_3057039_01.fm

Delete Log Files Yes

Terminal Settings
[F4] Before Running
[F5] No

4 Reset 2
[F8]

3
1 System setup button
2 Shut down button
3 Confirmation button
4 Terminal settings button

(Cont'd)

Doc. No. MM-3047612-0101 5 - 35 (100)

5.2 TPOP 5 Base Unit

(Cont'd)
d) Select NETWORKS AND COMMUNICATIONS (5) and touch the ENTER
button (6).

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

6
Close
[F8]

5 Networks and communications

6 Enter button

TechPub_2614345_0107 - 0501_3057039_01.fm
e) Select NETWORK CONNECTIONS (7) and touch the ENTER button (6).

KEP Server Serial Port ID’s

Networks Conections
RSLinx Enterprise Communications

6
Close
[F8]

6 Enter button
7 Network connections

(Cont'd)

5 - 36 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

(Cont'd)
f) Select NETWORK ADAPTORS (8) and touch the ENTER button (6).

Device Name
Network Adaptors
Network Identification

6
Close
[F8]

6 Enter button
8 Network adaptors
TechPub_2614345_0107 - 0501_3057039_01.fm

g) Touch the IP ADDRESS button (9).

Built-in Ethernet Controller

Name Servers IP Address Close

[F1] [F2] [F8]

9 IP address button

(Cont'd)

Doc. No. MM-3047612-0101 5 - 37 (100)

5.2 TPOP 5 Base Unit

(Cont'd)
h) If the IP ADDRESS (10), the SUBNET MASK address (11) and the
GATEWAY address (12) are correct, then continue from item o) on
page 5-41, otherwise continue as follows.
i) If the IP ADDRESS (10), the SUBNET MASK address (11) and the
GATEWAY address (12) are incorrect, then touch the USE DHCP
button (13) to clear the values.

10 11 12 13

IP Address Use DHCP

[F1] ?!.!.?.?? [F4]

Subnet Mask
[F2] ?!?.?!?.!.?

Gateway
[F3] ?.!.?.?

TechPub_2614345_0107 - 0501_3057039_01.fm
Mac ID: OK Cancel
[F7] [F8]
XX.XX.XX.XX

10 IP address
11 Subnet mask address
12 Gateway address
13 Use DHCP button

(Cont'd)

5 - 38 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

(Cont'd)
j) Touch the IP ADDRESS button (14).
k) Use the KEYBOARD (15) and type “10.255.1.0” for the IP
ADDRESS (10), then touch the ENTER button (16).
l) Touch the OK button (17).

IP Address Use DHCP

[F1] 10.255.1.0 [F4]

14
Subnet Mask
[F2]
10

Gateway
17
[F3]

Mac ID: OK Cancel

[F7] [F8]
XX.XX.XX.XX
TechPub_2614345_0107 - 0501_3057039_01.fm

15

16

10 IP address 16 Enter button

14 IP address button 17 OK button
15 Keyboard
(Cont'd)

Doc. No. MM-3047612-0101 5 - 39 (100)

5.2 TPOP 5 Base Unit

(Cont'd)
m) Touch the SUBNET MASK button (18).
n) Use the KEYBOARD (15) and type “255.255.0.0” for the SUBNET MASK
address (11), then touch the ENTER button (16).
Note! Do not touch the GATEWAY button (19), no value is required for the
GATEWAY address.

18 IP Address
[F1] 10.255.1.0
Use DHCP
[F4]

Subnet Mask
[F2] 255.255.0.0

19
Gateway
11
[F3]

Mac ID: OK Cancel

[F7] [F8]
XX.XX.XX.XX

TechPub_2614345_0107 - 0501_3057039_01.fm
15

16

11 Subnet mask address 18 Subnet mask button

15 Keyboard 19 Gateway button
16 Enter button

(Cont'd)

5 - 40 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

(Cont'd)
o) Touch the OK button (17) twice.
p) Repeatedly touch the CLOSE button until the MAIN window appears,
then touch the RESET button and the YES button.
The PC can now communicate with the touch screen module.

IP Address Use DHCP

[F1] 10.255.1.0 [F4]

Subnet Mask
[F2] 255.255.0.0

Gateway
17
[F3]

Mac ID: OK Cancel

[F7] [F8]
XX.XX.XX.XX
TechPub_2614345_0107 - 0501_3057039_01.fm

17 OK button

Doc. No. MM-3047612-0101 5 - 41 (100)

5.2 TPOP 5 Base Unit

5.2.1-4 Touch Screen - Load Firmware

Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with CD drive
CompactFlash Reader
Program CD TP No. 2886185-0XXX
CompactFlash Card TP No.90459-3145
SPC Reference 90600-0980

Preparation
Note! Before starting, check the current version of Firmware installed, see
the Firmware - Installation List on page 6-251, included in the chapter
6.7.2-1 HMI Installation List - Check Version of Software and Firmware
Installed.
Note! Upgrade the firmware only if the version installed on the module is
different from the version indicated in the PDF file included in the program
CD, see Copy Firmware to CompactFlash Card on page 5-48.
(Cont'd)

TechPub_2614345_0107 - 0501_3057039_01.fm

5 - 42 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

(Cont'd)
a) Connect the CompactFlash Reader (1) to the PC (2).
b) Insert the program CD into the PC CD drive and the CompactFlash
Card (3) in the CompactFlash Reader (1).
c) Browse to the CD drive to the folder 2886196-1XXX, then copy the
folder Rockwell Software to the CompactFlash Card (3).

3
TechPub_2614345_0107 - 0501_3057039_01.fm

1 CompactFlash reader
2 PC
3 CompactFlash card

(Cont'd)

Doc. No. MM-3047612-0101 5 - 43 (100)

5.2 TPOP 5 Base Unit

(Cont'd)
d) On the TPOP, log on as: “tptechnician” or “supervisor” or “technician”,
see 6.7.1-2 HMI User Management - Log On as a User on page 6-237.
e) Touch the SYSTEM SETUP button (4), the SHUT DOWN button (5) and
the CONFIRMATION button (6) to display the MAIN window below.
f) In the MAIN window, touch the TERMINAL SETTINGS button (7).

Current application

4
Load Application Run Application Application Settings
[F1] [F2] [F3]

Delete Log Files Yes

Terminal Settings
[F4] Before Running
[F5] No

7 Reset
[F8]
5

TechPub_2614345_0107 - 0501_3057039_01.fm
6
4 System setup button
5 Shut down button
6 Confirmation button
7 Terminal settings button

(Cont'd)

5 - 44 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

(Cont'd)
g) Select STARTUP OPTIONS (8) and touch the ENTER button (9).

Alarms
Diagnostic Setup
Display
File Management
Font Linking
Input Devices
Networks and Communications
Print Setup
Startup Options
System Event Log
System Information

8 Time/Date/Regional Settings

9
Close
[F8]

8 Startup options
9 Enter button
TechPub_2614345_0107 - 0501_3057039_01.fm

h) Select RSVIEW ME STATION STARTUP (10) and touch the ENTER

button (9).

RSView ME Station Startup

Startup Test

10

9
Close
[F8]

9 Enter button
10 RSView ME station startup

(Cont'd)

Doc. No. MM-3047612-0101 5 - 45 (100)

5.2 TPOP 5 Base Unit

(Cont'd)
i) Touch the ON STARTUP button (11).
j) Select the GO TO CONFIGURATION MODE checkbox (12) then touch
the CONFIGURATION MODE OPTION button (13).

12

Go To Configuration Mode

On Startup Configuration Mode Option

[F2]

11 13
Run Current Application

Run Option

OK Cancel
[F7] [F8]

TechPub_2614345_0107 - 0501_3057039_01.fm
11 On startup button
12 Go to configuration mode checkbox
13 Configuration mode option button

(Cont'd)

5 - 46 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

(Cont'd)
k) Touch the LOAD CURRENT APPLICATION button (14).
l) Select the NO checkbox (15) then touch the OK button (16) twice.
m) Touch the CLOSE button until the MAIN window appears, then touch the
RESET button and the YES button, to restart the TPOP panel and to
empty the memory.
The PC can now communicate with the touch screen module.

15

Yes
Load Current
Application
[F1]
No

14
Yes
Replace RSLinx
Enterprise
Communication
[F2] No
TechPub_2614345_0107 - 0501_3057039_01.fm

OK Cancel
[F7] [F8]

16
14 Load current application button
15 NO checkbox
16 OK button

(Cont'd)

Doc. No. MM-3047612-0101 5 - 47 (100)

5.2 TPOP 5 Base Unit

(Cont'd)
Copy Firmware to CompactFlash Card
a) Browse to the CD drive, then open the PDF file (indicated with an
arrow) included in the folder 2886191-1XXX, in order to identify the
correct version of the Firmware for the touch screen.
b) Browse again to the CD drive and locate the corresponding subfolder.
c) Make sure that the Compact Flash Card is inside the CompactFlash
Reader, then copy the files Autorun.exe and MFCCE400.DLL and the
folder Upgrade from the CD to the CompactFlash Card. Remove the
CompactFlash Card.

TechPub_2614345_0107 - 0501_3057039_01.fm

(Cont'd)

5 - 48 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

(Cont'd)
Install Firmware from Compact Flash Card to Touch Screen
a) In the rear of the TPOP, open the door (1) using the key (2) in the two
keyholes (3).
b) Insert the CompactFlash Card (5) inside the slot (4), making sure that the
thin edge (6) is placed on the outer side.

4
1
3
TechPub_2614345_0107 - 0501_3057039_01.fm

5
6

1 Door
2 Key
2
3 Keyhole
4 Slot
5 CompactFlash card
6 Edge

(Cont'd)

Doc. No. MM-3047612-0101 5 - 49 (100)

5.2 TPOP 5 Base Unit

(Cont'd)
c) Touch the UPGRADE button (7) when the following window message
appears.

7
7 Upgrade button

TechPub_2614345_0107 - 0501_3057039_01.fm
d) Touch the YES button (8) and wait until the upgrading process is
finished.

8
8 Yes button

(Cont'd)

5 - 50 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

(Cont'd)
e) Follow the instructions on the touch screen to calibrate it. Using a
pointed object (not too pointed) touch in the middle of the cross that will
appear on each corner of the screen, as shown in the pictures from 1 to 4.
f) Touch the screen again within 30 seconds to confirm the new calibration,
or wait 30 seconds to reset the previous calibration.

Picture 1 Picture 2
TechPub_2614345_0107 - 0501_3057039_01.fm

Picture 4 Picture 3

(Cont'd)

Doc. No. MM-3047612-0101 5 - 51 (100)

5.2 TPOP 5 Base Unit

(Cont'd)
g) Wait until the upgrading process is finished then touch the EXIT
button (9). The panel will restart automatically.
h) Remove the CompactFlash Card.
i) Perform the instructions 5.2.1-7 Touch Screen - Set on page 5-66.
j) At the end, set the correct IP address, see 5.2.1-3 Touch Screen - Check/
Set IP Address and Subnet Mask Address on page 5-35.

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9

9 Exit button

5 - 52 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

5.2.1-5 Touch Screen - Remove Existing Program

Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 90600-0980

Before a new application program can be installed, all files associated with
the old program must be deleted, to make space in the memory for the new
program. Proceed as follows.
a) On the TPOP, log on as: “tptechnician” or “supervisor” or “technician”,
see 6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) Touch the SYSTEM SETUP button (1), the SHUT DOWN button (2) and
the CONFIRMATION button (3) to display the MAIN window below.
c) In the MAIN window, touch TERMINAL SETTINGS button (4).

Current application

1
Load Application Run Application Application Settings
[F1] [F2] [F3]
TechPub_2614345_0107 - 0501_3057039_01.fm

Delete Log Files Yes

Terminal Settings
[F4] Before Running
[F5] No

4 Reset 2
[F8]

3
1 System setup button
2 Shut down button
3 Confirmation button
4 Terminal settings button

(Cont'd)

Doc. No. MM-3047612-0101 5 - 53 (100)

5.2 TPOP 5 Base Unit

(Cont'd)
d) Select FILE MANAGEMENT (5) and touch the ENTER button (6).

Alarms
Diagnostic Setup
Display
File Management
Font Linking
Input Devices

5 Networks and Communications

Print Setup
Startup Options
System Event Log
System Information
Time/Date/Regional Settings

Close
[F8]

5 File management
6 Enter button

TechPub_2614345_0107 - 0501_3057039_01.fm
e) Select DELETE FILES (7) and touch the ENTER button (6).

Copy Files
Delete Files

Close
[F8]

6 Enter button
7 Delete files

(Cont'd)

5 - 54 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

(Cont'd)
f) Select DELETE APPLICATIONS (8) and touch the ENTER button (6).

Delete applications
Delete fonts
Delete log files

Close
[F8]

6 Enter button
8 Delete applications
TechPub_2614345_0107 - 0501_3057039_01.fm

g) Select the appropriate program (9) to be deleted, then touch the DELETE
button (10).
h) Touch the CLOSE button (11) until the MAIN window appears. The
touch screen now has enough memory available to download the new
program.

Source Delete
[F1] [F2]
10
CBP30 Speed

Close
[F8]
11

9 Program 11 Close button

10 Delete button

Doc. No. MM-3047612-0101 5 - 55 (100)

5.2 TPOP 5 Base Unit

5.2.1-6 Touch Screen - Download Program

Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with CD Drive
CompactFlash Reader
Program CD TP No. 2886185-0XXX
CompactFlash Card TP No.90459-3145
SPC Reference 90600-0980

Preparation
Note! Before starting, check the current version of Software installed, see
the Software - Installation List on page 6-248, included in the chapter
6.7.2-1 HMI Installation List - Check Version of Software and Firmware
Installed.
Note! After a program download, the default passwords are reset, see
6.7.1-1 HMI User Management - Description on page 6-235.
a) Connect the CompactFlash Reader (1) to the PC (2).
b) Insert the program CD into the PC CD drive and the CompactFlash
Card (3) in the CompactFlash Reader (1).
c) Browse to the CD drive to the folder 2886196-1XXX, then copy all the

TechPub_2614345_0107 - 0501_3057039_01.fm
folders and files to the CompactFlash Card (3). Remove the
CompactFlash Card (3).

1 CompactFlash reader
2 PC
3 CompactFlash card

(Cont'd)

5 - 56 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

(Cont'd)
d) On the TPOP, log on as: “tptechnician” or “supervisor” or “technician”,
see 6.7.1-2 HMI User Management - Log On as a User on page 6-237.
e) Touch the SYSTEM SETUP button (4), the SHUT DOWN button (5) and
the CONFIRMATION button (6) to display the MAIN window below.

Current application

4
Load Application Run Application Application Settings
[F1] [F2] [F3]

Delete Log Files Yes

Terminal Settings
[F4] Before Running
[F5] No

Reset
[F8]
5

6
TechPub_2614345_0107 - 0501_3057039_01.fm

4 System setup button

5 Shut down button
6 Confirmation button

(Cont'd)

Doc. No. MM-3047612-0101 5 - 57 (100)

5.2 TPOP 5 Base Unit

(Cont'd)
Copy Application Program
a) In the rear of the TPOP, open the door (1) using the key (2) in the two
keyholes (3).
b) Insert the CompactFlash Card (5) inside the slot (4), making sure that the
thin edge (6) is placed on the outer side.

4
1
3

TechPub_2614345_0107 - 0501_3057039_01.fm
5
6

1 Door
2 Key
2
3 Keyhole
4 Slot
5 CompactFlash card
6 Edge

(Cont'd)

5 - 58 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

(Cont'd)
c) If the panel does not restart automatically, wait some minutes then touch
the RESET button (8) in the MAIN window and the YES button.

Current application

Load Application Run Application Application Settings

[F1] [F2] [F3]

Delete Log Files Yes

Terminal Settings
[F4] Before Running
[F5] No

Reset
[F8]

8
7 Reset button

(Cont'd)
TechPub_2614345_0107 - 0501_3057039_01.fm

Doc. No. MM-3047612-0101 5 - 59 (100)

5.2 TPOP 5 Base Unit

(Cont'd)
d) Wait until at the end of the following window appears the message
“press any key to continue...”, then close the window with a single click
on the cross.

File Edit Help X

Pocket CMD V 4.10
***********************************************************************
*
* Tetra Pak PVP Installer Version 1.0
* Please wait ...
*
***********************************************************************
Copied 1 file(s).
Copied 1 file(s).
Copied 1 file(s).
Copied 1 file(s).
Copied 1 file(s).
Copied 1 file(s).
Registry import complete!
Copied 1 file(s).
Copied 1 file(s).
Copied 1 file(s).
Copied 1 file(s).
Copied 1 file(s).

TechPub_2614345_0107 - 0501_3057039_01.fm
***********************************************************************
*
* Tetra Pak PVP Installer has been completed.
* remove compact flash or USB flash and press the close button
* to reset the terminal.
*
***********************************************************************
Press any key to continue...

(Cont'd)

5 - 60 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

(Cont'd)
Load Application Program
a) Touch the LOAD APPLICATION button (1).

Current application

Load Application Run Application Application Settings

[F1] [F2] [F3]

1 Delete Log Files Yes

Terminal Settings
[F4] Before Running
[F5] No

Reset
[F8]

1 Load application button

TechPub_2614345_0107 - 0501_3057039_01.fm

(Cont'd)

Doc. No. MM-3047612-0101 5 - 61 (100)

5.2 TPOP 5 Base Unit

(Cont'd)
b) Make sure that the INTERNAL STORAGE checkbox (2) is selected,
then select the application program (3) which contains the proper
language translation according to the following table. Touch the LOAD
button (2).
Application program Languages (*)
CBP30 Speed 2886196_100XA.mer English, German, French, Spanish,
Swedish, Italian, Portoguese, Danish,
Greek, Finnish, Polish, Dutch,
Norwegian, Icelandic, Turkish
CBP30 Speed 2886196_100XB.mer English, Czech, Serbian, Croatian,
Slovenian, Slovak, Romanian,
Bulgarian, Bosnian, Hungarian,
Macedonian, Russian, Latvian,
Estonian, Lithuanian
CBP30 Speed 2886196_100XC.mer English, Arabic, Persian, Malay,
Japanese, Simplified Chinese, Thai,
Korean, Vietnamese, Traditional
Chinese

(*) Some languages may not be available yet.

TechPub_2614345_0107 - 0501_3057039_01.fm
2 4

Internal Storage
Source Load
[F1] External Storage 1 [F2]
External Storage 2

CBP30 Speed 2886196_1003A.mer

3 CBP30 Speed 2886196_1003B.mer

CBP30 Speed 2886196_1003C.mer

2 Internal storage checkbox

Cancel
3 Application program [F8]
4 Load button

(Cont'd)

5 - 62 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

(Cont'd)
c) Touch the YES button (5) when the following message appears.

Do you want to replace the terminal s current communication

configuration with the application s communication configuration?

5
Yes No
[F7] [F8]

5 Yes button
TechPub_2614345_0107 - 0501_3057039_01.fm

d) Wait until the loading process is finished, then touch the TERMINAL
SETTINGS button (6).

Current application
Loading...

Load Application Run Application Application Settings

[F1] [F2] [F3]

Delete Log Files Yes

Terminal Settings
[F4] Before Running
[F5] No

6 Reset
[F8]

6 Terminal settings button

(Cont'd)

Doc. No. MM-3047612-0101 5 - 63 (100)

5.2 TPOP 5 Base Unit

(Cont'd)
e) Select STARTUP OPTIONS (7) and touch the ENTER button (8).

Alarms
Diagnostic Setup
Display
File Management
Font Linking
Input Devices
Networks and Communications
Print Setup
Startup Options
System Event Log
System Information

7 Time/Date/Regional Settings

8
Close
[F8]

7 Startup options
8 Enter button

TechPub_2614345_0107 - 0501_3057039_01.fm
f) Select RSVIEW ME STATION STARTUP (9) and touch the ENTER
button (8).

RSView ME Station Startup

Startup Test

8
Close
[F8]

8 Enter button
9 RSView ME station startup

(Cont'd)

5 - 64 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

(Cont'd)
g) Select the RUN CURRENT APPLICATION checkbox (10), then touch
the OK button (11).
h) Touch the CLOSE button until the MAIN window appears.

Go To Configuration Mode

On Startup Configuration Mode Option

[F2]

Run Current Application

Run Option

10
OK Cancel
[F7] [F8]

10 Run current application checkbox

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11 OK button 11

i) In the MAIN window, touch the RESET button (12) or continue with the
settings described on the next pages.

Current application
Loading...

Load Application Run Application Application Settings

[F1] [F2] [F3]

Delete Log Files Yes

Terminal Settings
[F4] Before Running
[F5] No

Reset
[F8]

12 Reset button
12

Doc. No. MM-3047612-0101 5 - 65 (100)

5.2 TPOP 5 Base Unit

5.2.1-7 Touch Screen - Set

Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 90600-0980

The following basic settings can be made on the touch screen:

• Date, Time and Regional Settings see page 5-67
• Screen Saver see page 5-73.
Preparation
a) On the TPOP, log on as: “tptechnician” or “supervisor” or “technician”,
see 6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) Touch the SYSTEM SETUP button (1), the SHUT DOWN button (2) and
the CONFIRMATION button (3) to display the MAIN window below.

Current application

1
Load Application Run Application Application Settings
[F1] [F2] [F3]

TechPub_2614345_0107 - 0501_3057039_01.fm
Delete Log Files Yes
Terminal Settings
[F4] Before Running
[F5] No

Reset
[F8]
2

1 System setup button

2 Shut down button
3 Confirmation button

(Cont'd)

5 - 66 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

(Cont'd)
Date, Time and Regional Settings
a) In the MAIN window, touch the TERMINAL SETTINGS button (1).

Current application

Load Application Run Application Application Settings

[F1] [F2] [F3]

Delete Log Files Yes

Terminal Settings
[F4] Before Running
[F5] No

1
Reset
[F8]

1 Terminal settings button

TechPub_2614345_0107 - 0501_3057039_01.fm

b) Select TIME/DATE/REGIONAL SETTING (2) and touch the ENTER

button (3).

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

3
2
Close
[F8]

2 Time/date/regional settings
3 Enter button

(Cont'd)

Doc. No. MM-3047612-0101 5 - 67 (100)

5.2 TPOP 5 Base Unit

(Cont'd)
c) Select TIME ZONE (4) and touch the ENTER button (5).

Date
Regional Settings
Time
Time Zone

Close
[F8]

4 Time zone
5 Enter button

TechPub_2614345_0107 - 0501_3057039_01.fm
d) Scroll the list and select the CORRECT TIME ZONE (6), then touch the
OK button (7).

(GMT) Greenwich Mean Time

___________________________________
___________________________________

6 ___________________________________
___________________________________
___________________________________
___________________________________
___________________________________
___________________________________
___________________________________
___________________________________
___________________________________

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

6 Correct time zone

7 OK button 7

(Cont'd)

5 - 68 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

(Cont'd)
e) Select TIME (8) and touch the ENTER button (9).

Date
Regional Settings
Time
Time Zone

Close
[F8]

8 Time
9 Enter button
TechPub_2614345_0107 - 0501_3057039_01.fm

(Cont'd)

Doc. No. MM-3047612-0101 5 - 69 (100)

5.2 TPOP 5 Base Unit

(Cont'd)
f) Set the current time as follows:
• touch the HOUR button (10) and insert the hour using the
KEYBOARD (13), then touch the ENTER button (14)
• touch the MINUTE button (11) and insert the minutes using the
KEYBOARD (13), then touch the ENTER button (14)
• touch the SECONDS button (12) and insert the seconds using the
KEYBOARD (13), then touch the ENTER button (14).
g) Touch the OK button (15).

Enter time in 24 hour format:

16 45 30

Hour Minute Seconds

[F1] [F2] [F3]

10 12

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11 OK
[F7]
Cancel
[F8]

15

13

10 Hour button
11 Minute button 14
12 Seconds button
13 Keyboard
14 Enter button
15 OK button

(Cont'd)

5 - 70 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

(Cont'd)
h) Select DATE (16) and touch the ENTER button (17).

Date
Regional Settings
Time
Time Zone
16

17
Close
[F8]

16 Date
17 Enter button
TechPub_2614345_0107 - 0501_3057039_01.fm

(Cont'd)

Doc. No. MM-3047612-0101 5 - 71 (100)

5.2 TPOP 5 Base Unit

(Cont'd)
i) Set the current date as follows:
• touch the YEAR button (18) and insert the year using the
KEYBOARD (13), then touch the ENTER button (14)
• touch the MONTH button (19) and insert the month using the
KEYBOARD (13), then touch the ENTER button (14)
• touch the DAY button (20) and insert the day using the KEYBOARD (13),
then touch the ENTER button (14).
j) Touch the OK button (21), then repeatedly touch the CLOSE button until
the main window appears.

2007 5 25

Year Month Day

[F1] [F2] [F3]

18 20

TechPub_2614345_0107 - 0501_3057039_01.fm
19 OK
[F7]
Cancel
[F8]

21

13

13 Keyboard
14 Enter button 14
18 Year button
19 Month button
20 Day button
21 OK button

(Cont'd)

5 - 72 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

(Cont'd)
Screen Saver
a) In the MAIN window, touch the TERMINAL SETTINGS button (1).

Current application

Load Application Run Application Application Settings

[F1] [F2] [F3]

Delete Log Files Yes

Terminal Settings
[F4] Before Running
[F5] No

1
Reset
[F8]

1 Terminal settings button

TechPub_2614345_0107 - 0501_3057039_01.fm

b) Select DISPLAY (2) and touch the ENTER button (3).

Alarms
Diagnostic Setup
Display
File Management
Font Linking

2
Input Devices
Networks and Communications
Print Setup
Startup Options
System Event Log
System Information
Time/Date/Regional Settings

Close
[F8]

2 Display
3 Enter button

(Cont'd)

Doc. No. MM-3047612-0101 5 - 73 (100)

5.2 TPOP 5 Base Unit

(Cont'd)
c) Select SCREEN SAVER (4) and touch the ENTER button (5).

Display
Display Temperature
Screen Saver
Cursor

Close
[F8]

4 Screen saver
5 Enter button

TechPub_2614345_0107 - 0501_3057039_01.fm
d) Set the intensity to 0% with the SINGLE ARROW button (6).
e) Select the DISABLED checkbox (7) and touch the ADVANCED
SETTINGS button (8).

Intensity
Disabled

5 Minutes

10 Minutes 7
Screen
Saver 15 Minutes
0%
[F1]
20 Minutes

25 Minutes

30 Minutes

6
Advanced
OK Cancel
Settings
[F7] [F8]
[F2]

8
6 Single arrow button 8 Advanced settings button
7 Disabled checkbox

(Cont'd)

5 - 74 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

(Cont'd)
f) Select the DISABLED checkbox (9).
g) Touch the OK button (10) twice.
h) Touch the CLOSE button until the MAIN window appears, then touch the
RESET button and the YES button, to restart the TPOP.

Enabled
Screen Saver
Image
Disabled

OK Cancel
[F7] [F8]
TechPub_2614345_0107 - 0501_3057039_01.fm

10
9 Disabled checkbox
10 OK button

Doc. No. MM-3047612-0101 5 - 75 (100)

5.2 TPOP 5 Base Unit

5.2.1-8 Touch Screen - Calibration

Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 90600-0980

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

see 6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) Touch the SYSTEM SETUP button (1), the SHUT DOWN button (2) and
the CONFIRMATION button (3) to display the MAIN window below.
c) In the MAIN window, touch TERMINAL SETTINGS button (4).

Current application

1
Load Application Run Application Application Settings
[F1] [F2] [F3]

Delete Log Files Yes

Terminal Settings
[F4] Before Running

TechPub_2614345_0107 - 0501_3057039_01.fm
[F5] No

4 Reset 2
[F8]

3
1 System setup button
2 Shut down button
3 Confirmation button
4 Terminal settings button

(Cont'd)

5 - 76 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

(Cont'd)
d) Select INPUT DEVICES (5) and touch the ENTER button (6).

Alarms
Diagnostic Setup
Display
File Management
Font Linking
Input Devices
Networks and Communications
Print Setup

5
Startup Options
System Event Log
System Information
Time/Date/Regional Settings

Close
[F8]

5 Input devices
6 Enter button
TechPub_2614345_0107 - 0501_3057039_01.fm

e) Select TOUCH SCREEN (7) and touch the ENTER button (6).

Keyboard
Mouse
Touch Screen
String Pop-Up

Close
[F8]

6 Enter button
7 Touch screen

(Cont'd)

Doc. No. MM-3047612-0101 5 - 77 (100)

5.2 TPOP 5 Base Unit

(Cont'd)
f) Select CALIBRATION (8) and touch the ENTER button (6).

Calibration
Double Tap Sensitivity

Close
[F8]

6 Enter button
8 Calibration

TechPub_2614345_0107 - 0501_3057039_01.fm
(Cont'd)

5 - 78 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.2 TPOP

(Cont'd)
g) Follow the instructions on the touch screen to calibrate it. Using a
pointed object (not too pointed) touch in the middle of the cross that will
appear on each corner of the screen, as shown in the pictures from 1 to 4.
h) Touch the screen again within 30 seconds to confirm the new calibration,
or wait 30 seconds to reset the previous calibration.
i) Touch the CLOSE button three times to go back to the MAIN window.
TechPub_2614345_0107 - 0501_3057039_01.fm

Picture 1 Picture 2

Picture 4 Picture 3

Doc. No. MM-3047612-0101 5 - 79 (100)

5.3 Outfeeder 5 Base Unit

5.3 Outfeeder
SPC Reference 2936077-0100

5.3.1 Outfeed Conveyor

5.3.1-1 Outfeed Conveyor - Configure Outfeed Side
Machine Status PREHEATING
SPC Reference 2812820-0100
Note! Configure the outfeed side at the first start up of the machine.
a) On the TPOP, log on as “tptechnician”, see 6.7.1-2 HMI User
Management - Log On as a User on page 6-237.
b) With the machine in PREHEATING, touch the MACHINE
CONFIGURATION button (1).
Note! The icon (2), means that the outfeed conveyor side has not been
configurated.
c) In the MACHINE CONFIGURATION window, touch the icon (2).

1 2

TechPub_2614345_0107 - 0501_3057040_01.fm
1 Machine configuration button
2 Icon (outfeed conveyor side not configured)

(Cont'd)

5 - 80 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.3 Outfeeder

(Cont'd)
d) In the SETTING window (3), proceed as follows:
• touch the SINGLE-ARROW buttons (4) to change the outfeed side of the
conveyor
• at the end touch the CONFIRMATION button (7), to confirm the outfeed
conveyor side displayed in the window (6), or touch the CLEAR
button (5) to abort the selection.
Note! In the CONFIGURATION window will appear the icons (9), (10), (11),
or (12), according to the outfeed conveyor side previously configurated.
e) Touch the EXIT button (8).

6 7 8 9

3
10
TechPub_2614345_0107 - 0501_3057040_01.fm

11
4 5

3 Setting window
4 Single-arrow button
5 Clear button 12
6 Outfeed side window
7 Confirmation button
8 Exit button
9 Icon (LH side outfeed conveyor - motorized)
10 Icon (RH side outfeed conveyor - motorized)
11 Icon (straight outfeed conveyor - motorized)
12 Icon (straight outfeed conveyor - not motorized)

Doc. No. MM-3047612-0101 5 - 81 (100)

5.3 Outfeeder 5 Base Unit

5.3.1-2 Outfeed Conveyor - Set Speed

Machine Status PREHEATING
Special Equipment Tachometer TP No. 90243-105
SPC Reference 2812820-0100
Note! Perform this setting at the first start up of the machine.
a) On the TPOP, log on as: “tptechnician” or “supervisor” or “technician”,
see 6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) With the machine in PREHEATING, touch the MAINTENANCE
button (1) and the FEED UNIT button (2), or touch the FEED UNIT
tab (3).
c) Touch the OUTFEED CONVEYOR icon (4) to display the dialogue
window.
d) Touch the ON button (5) to select the outfeed conveyor starting function.
e) Touch the CONFIRMATION button (6) to run the outfeed conveyor, at
the same time using a tachometer, measure the speed in m/min.

TechPub_2614345_0107 - 0501_3057040_01.fm
1 2 3 4

1 Maintenance button
2 Feed unit button
3 Feed unit tab
4 Outfeed conveyor icon
6
5 ON button
6 Confirmation button

(Cont'd)

5 - 82 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.3 Outfeeder

(Cont'd)
f) According to the speed previously measured, if required touch the
NOMINAL SPEED icon (7), then set the new value for the speed, as
follows:
• the new speed value set, is displayed in the SETTING VALUE field (8)
• touch the FACTORY button (12) to display the factory value
• touch the DOUBLE-ARROW buttons (9) to increase or decrease the value
of 10 m/min
• touch the SINGLE-ARROW buttons (10) to increase or decrease the
value of 1 m/min
• touch the KEYBOARD button (11) to display the numeric keyboard, then
type the value
• touch the CONFIRMATION button (13) to confirm the speed value set
g) Touch the EXIT button (14).

12 13 14
7
TechPub_2614345_0107 - 0501_3057040_01.fm

11

9 10 9

7 Nominal speed icon 11 Keyboard button

8 Setting value field 12 Factory button
9 Double-arrow button 13 Confirmation button
10 Single-arrow button 14 Exit button

Doc. No. MM-3047612-0101 5 - 83 (100)

5.3 Outfeeder 5 Base Unit

5.3.1-3 Outfeed Conveyor - Set Timer for Queue Alarm

Photocells
Machine Status PREHEATING
SPC Reference 2812820-0100
Note! The values set affect the number of boxes produced before the queue
alarm activation. Verify that there is enough space on the outfeed conveyor
to support the boxes produced.
a) On the TPOP, log on as: “tptechnician” or “supervisor” or “technician”,
see 6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) Touch the MAINTENANCE button (1) and the FEED UNIT button (2),
or touch the FEED UNIT tab (3).
c) Touch the OUTFEED QUEUE PHOTOCELLS icon (4) to display the
dialogue window.

1 2 3 4

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1 Maintenance button
2 Feed unit button
3 Feed unit tab
4 Outfeed queue photocells icon

(Cont'd)

5 - 84 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.3 Outfeeder

(Cont'd)
d) Touch the QUEUE ALARM ACTIVATION DELAY icon (5) or the
QUEUE ALARM DEACTIVATION DELAY icon (6), then set the new
value as follows:
• the new time set, is displayed in the SETTING VALUE field (7)
• touch the FACTORY button (11) to display the factory value
• touch the DOUBLE-ARROW buttons (8) to increase or decrease the value
of 10 seconds
• touch the SINGLE-ARROW buttons (9) to increase or decrease the value
of 1 second
• touch the KEYBOARD button (10) to display the numeric keyboard, then
type the value
• touch the CONFIRMATION button (12) to confirm the new value set
e) Touch the EXIT button (13).

5
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11 12 13
6

10

8 9 8
5 Queue alarm activation delay icon 10 Keyboard button
6 Queue alarm deactivation delay icon 11 Factory button
7 Setting value field 12 Confirmation button
8 Double-arrow button 13 Exit button
9 Single-arrow button

Doc. No. MM-3047612-0101 5 - 85 (100)

5.3 Outfeeder 5 Base Unit

5.3.1-4 Outfeed Conveyor - Select Queue Photocell

Machine Status AIR ON
SPC Reference 2812820-0100
Note! Make sure to select the correct queue photocell to be monitored
according to the switch position. See the EM for more information about the
reference designation of the queue photocells.
a) On the TPOP, log on as: “tptechnician” or “supervisor” or “technician”,
see6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) With the machine in AIR ON, touch the MAINTENANCE button (1) and
the FEED UNIT button (2), or touch the FEED UNIT tab (3).
c) Touch the QUEUE PHOTOCELL icon (4) to display the dialogue
window.

1 2 3 4

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1 Maintenance button
2 Feed unit button
3 Feed unit tab
4 Queue photocell icon

(Cont'd)

5 - 86 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.3 Outfeeder

(Cont'd)
d) The queue photocell actually selected is displayed in the CURRENT
SELECTION field (5). If required touch the CURRENT SELECTION
field (5) and change the queue photocell as follows:
• the new queue photocell selected is displayed in the SELECTION
field (6)
• touch the SINGLE-ARROW buttons (7) to change the queue photocell or
touch the CLEAR button (8) to abort the selection
• touch the CONFIRMATION button (9) to confirm the new queue
photocell selected.
e) Touch the EXIT button (10).

9 10
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7 8
5 Current selection field
6 Selection field
7 Single-arrow button
8 Clear button
9 Confirmation button
10 Exit button

Doc. No. MM-3047612-0101 5 - 87 (100)

5.3 Outfeeder 5 Base Unit

5.3.1-5 Outfeed Conveyor - Configure Switch

Machine Status IDLE (STEP ZERO)
SPC Reference 2812820-0100
Note! Perform the following configuration only if the machine is installed in a
line equipped with the switch.
a) On the TPOP, log on as: “tptechnician” or “supervisor” or “technician”,
see 6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) With the machine in IDLE, touch the MACHINE CONFIGURATION
button (1).
Note! A cross over the SWITCH icon (2), means that the switch has not been
installed.
c) In the MACHINE CONFIGURATION window, touch the SWITCH
icon (2).

1 2

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1 Machine configuration button
2 Switch icon (not installed)

(Cont'd)

5 - 88 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.3 Outfeeder

(Cont'd)
d) Touch the INSTALLATION icon (3).
e) Touch the ON button (4), to select the installation of the switch, then
touch the CONFIRMATION button (5) to confirm the installation.
Note! In the MACHINE CONFIGURATION window will disappear the cross
over the SWITCH icon (6).
f) Touch the EXIT button (7).

3 4 5 6
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3 Installation icon
4 ON button
7
5 Confirmation button
6 Switch icon (installed)
7 Exit button

Doc. No. MM-3047612-0101 5 - 89 (100)

5.3 Outfeeder 5 Base Unit

5.3.1-6 Outfeed Conveyor - Select Switch Photocell Expected

Status
Machine Status Any STEP
SPC Reference 2812820-0100
Note! Only for the lines equipped with switch, select the expected status of
the switch photocell.
a) On the TPOP, log on as: “tptechnician” or “supervisor” or “technician”,
see 6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) Touch the MAINTENANCE button (1) and the FEED UNIT button (2),
or touch the FEED UNIT tab (3).
c) Touch the SWITCH icon (4) to display the dialogue window.
d) Touch the ON button (5) or the OFF button (6) to select the status that
the switch photocell must have in the desired switch position, then touch
the CONFIRMATION button (7) to confirm the selection.
e) Touch the EXIT button (8).

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1 2 3

1 Maintenance button
2 Feed unit button
3 Feed unit tab
4 Switch icon
5 ON button
6 OFF button
7 Confirmation button
8 Exit button
5 6 7

5 - 90 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.3 Outfeeder

5.3.2 Outfeed Damper

Note! The outfeed damper is installed only on the machines equipped with
outfeed conveyor on the LH side or the RH side.
5.3.2-1 Outfeed Damper - Set
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2838578-0100

a) Unlock the locking lever (1) then move sideways the unit, until the stop
plate (2) is centred to the cardboard box (3). Lock the unit in position
with the locking lever (1).

= =
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2 Front view of outfeeder for

3 LH side out

1 Locking lever
2 Stop plate
3 Cardboard box

(Cont'd)

Doc. No. MM-3047612-0101 5 - 91 (100)

5.3 Outfeeder 5 Base Unit

(Cont'd)
b) Loosen the screw (6) then lift or lower the unit, until there is the
distance A, between the cylinder (4) and the cardboard box (3).
Make sure that there is at least the distance B, between the stop plate (2)
and the guide (5) of the outfeed conveyor, so that the stop plate (2) can
move freely, then tighten the screw (6).

3
4
2
A

B 5

6
A = 10 ±0.5 mm
B = 5 ±0.5 mm

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Side view of outfeeder for
LH side out
2 Stop plate
3 Cardboard box
4 Cylinder
5 Guide
6 Screw

(Cont'd)

5 - 92 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.3 Outfeeder

(Cont'd)
Note! According to the cardboard box to be produced, make sure that the
width between the guides (5) of the outfeed conveyor, is properly set, if
required see the TeM of the Tetra Conveyor Flexi 56.
The stroke length of the cylinder piston (8) is 100 mm.
c) Unlock the locking lever (7) then move forward or backward the unit, so
that:
• with the cylinder pistons (8) fully in, the stop plate (2) is placed at the
distance C from the guide (5)
• with the cylinder pistons (8) fully out, the stop plate (2) is placed at the
distance D from the guide (5).
d) Lock the unit in position with the locking lever (7).

8 2

2 2
Cylinder pistons Cylinder pistons D
fully in fully out

C
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5 5
Side view of outfeeder for
LH side out

C = 90 ±0.5 mm
D = 10 ±0.5 mm

2 Stop plate
5 Guide
7 Locking lever
8 Cylinder piston
7

Doc. No. MM-3047612-0101 5 - 93 (100)

5.3 Outfeeder 5 Base Unit

5.3.2-2 Outfeed Damper - Set Cylinder

Machine Status Mains Power ON
Air ON
Water ON
SPC Reference 2838578-0100

a) When the box pushes the stop plate (2), if required increase or decrease
the braking force of the cylinder (1), by turning the flow valve (3).

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1 Cylinder
2 Stop plate
3 Flow valve

(Cont'd)

5 - 94 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.3 Outfeeder

(Cont'd)

CAUTION
Risk of damage to the equipment.
Make sure that the stop plate (2) does not hit the cylinder (1) too strong,
when it goes back to the box waiting position.
b) When the stop plate (2) goes back to the waiting position for a new box,
if required fine adjust the return speed of the cylinder (1), by turning the
flow valve (4).

1
4
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1 Cylinder
2 Stop plate
4 Flow valve

Doc. No. MM-3047612-0101 5 - 95 (100)

5.3 Outfeeder 5 Base Unit

5.3.2-3 Outfeed Damper - Check

Machine Status PRODUCTION
SPC Reference 2838578-0100

Check that:
• the cylinder pistons (1) move freely and smoothly
• there are no air leaks in the air connections (2).

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1

1 Cylinder piston
2 Air connection

5 - 96 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.4 Frame

5.4 Frame
SPC Reference 2765931-0100

5.4.1 Bar (for WA unit)

Note! The bar is installed only on the machines equipped the WA unit (OE).
5.4.1-1 Bar (for WA Unit) - Set Position
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2917280-0100
Note! Perform this setting, only if the machine is equipped with the WA unit
(OE) and has to produce WAIF or WASF boxes with family packs.
(Cont'd)
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Doc. No. MM-3047612-0101 5 - 97 (100)

5.4 Frame 5 Base Unit

(Cont'd)
The function of the bar (1), is to avoid any contact between the flight bars (2)
and the adhesive of the hotmelt dots (3), that have been applied on the lid of
the WAIF and WASF cardboard blanks.

WAIF

2
3

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1
WASF

1 Bar
2 Flight bar
3 Hotmelt dot

(Cont'd)

5 - 98 (100) Doc. No. MM-3047612-0101

 5 Base Unit 5.4 Frame

(Cont'd)
The bar (1) can be placed in three different vertical positions, using the pairs
of holes existing on both beams (5) and indicated in the picture below with
arrows. If required change the position of the bar (1) with the screws (4).

5
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4
5
1 Bar
4 Screw
5 Beam

(Cont'd)

Doc. No. MM-3047612-0101 5 - 99 (100)

5.4 Frame 5 Base Unit

(Cont'd)
Note! Make sure that the bottom steering (6) is set correctly, see
Bottom Steering - Set Height on page 2-14.
Insert the cardboard blank (7) between the dead plate (8) and the feed unit,
until the bottom side of the blank is fully against the bottom steering (6), then
set the bar (1) below the hotmelt dots (3) and above the crease line (9).
In PRODUCTION, check that the flight bars (2) are not soiled with adhesive.

3 3

WAIF WASF
2

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7 1

8 Side view

6
6 8

1 Bar 7 Cardboard blank

2 Flight bar 8 Dead plate
3 Hotmelt dot 9 Crease line
6 Bottom steering

5 - 100 (100) Doc. No. MM-3047612-0101

 6 Electrical System
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Doc. No. MM-3047612-0101 6 - 1 (308)

 6 Electrical System

Electrical System - Description

SPC Reference 663107-0100

6.8

6.10

6.9

6.4 6.2
6.1

6.6

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6.5

6.3 6.1 PLC (Rockwell)

6.2 Distributed I/O
6.3 Servo System
6.4 Safety System
6.5 Frequency Converters
6.6 Power Supply
6.7 HMI and PLMS
6.8 Cooling Unit
6.9 Signal Exchange
6.10 Box
6.11 Electrical Components on the Machine

6 - 2 (308) Doc. No. MM-3047612-0101

 6 Electrical System Table of Contents

6.1 PLC (Rockwell) . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7

6.1.1 Preparation for PLC Communication . . . . . . . . . . 6 - 7
6.1.1-1 Preparation for PLC Communication -
Configure PC Network Communications . . . . . . 6 - 7
6.1.1-2 Preparations for PLC Communication -
Configure RSLinx . . . . . . . . . . . . . . . . . . . . . . . 6 - 17
6.1.1-3 Preparations for PLC Communication - Register
EDS File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 21
6.1.2 CPU Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 30
6.1.2-1 CPU Module - Change . . . . . . . . . . . . . . . . . . . . 6 - 30
6.1.2-2 CPU Module - Load Firmware . . . . . . . . . . . . . 6 - 36
6.1.2-3 CPU Module - Convert Program . . . . . . . . . . . . 6 - 42
6.1.2-4 CPU Module - Download Program . . . . . . . . . . 6 - 45
6.1.2-5 CPU Module - LED Description . . . . . . . . . . . . 6 - 56
6.1.2-6 CPU Module - Change Battery . . . . . . . . . . . . . 6 - 58
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6.1.3 EtherNet/IP Module . . . . . . . . . . . . . . . . . . . . . . . 6 - 59

6.1.3-1 EtherNet/IP Module - Change . . . . . . . . . . . . . . 6 - 59
6.1.3-2 EtherNet/IP Module - Set IP Address . . . . . . . . 6 - 65
6.1.3-3 EtherNet/IP Module - Load Firmware . . . . . . . . 6 - 79
6.1.3-4 EtherNet/IP Module - LED Description . . . . . . 6 - 80
6.1.4 Digital Input Module . . . . . . . . . . . . . . . . . . . . . . . 6 - 82
6.1.4-1 Digital Input Module - Change . . . . . . . . . . . . . 6 - 82
6.1.4-2 Digital Input Module - Load Firmware . . . . . . . 6 - 86

6.2 Distributed I/O . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 87

6.2-1 Distributed I/O - Description . . . . . . . . . . . . . . . 6 - 87
6.2.1 DeviceNet Scanner Module . . . . . . . . . . . . . . . . . 6 - 89
6.2.1-1 DeviceNet Scanner Module - Change . . . . . . . . 6 - 89
6.2.1-2 DeviceNet Scanner Module - Set Node Address
and Baud Rate . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 93
6.2.1-3 DeviceNet Scanner Module - Load Firmware . . 6 - 96
6.2.1-4 DeviceNet Scanner Module - Download
Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 97
6.2.1-5 DeviceNet Scanner Module -
LED Description . . . . . . . . . . . . . . . . . . . . . . . 6 - 114

Doc. No. MM-3047612-0101 6 - 3 (308)

Table of Contents 6 Electrical System

6.2.1-6 DeviceNet Scanner Module - Error Codes . . . 6 - 116

6.2.2 DeviceNet Point I/O Adapter. . . . . . . . . . . . . . . . 6 - 119
6.2.2-1 DeviceNet Point I/O Adapter - Change . . . . . . 6 - 119
6.2.2-2 DeviceNet Point I/O Adapter - Set Node
Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 123
6.2.2-3 DeviceNet Point I/O Adapter - Download
Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 124
6.2.2-4 DeviceNet Point I/O Adapter - LED
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 140
6.2.3 DeviceNet Point I/O Module . . . . . . . . . . . . . . . 6 - 144
6.2.3-1 DeviceNet Point I/O Module - Change . . . . . . 6 - 144
6.2.3-2 DeviceNet Point I/O Module - LED
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 147
6.2.4 DeviceNet PowerFlex Adapter . . . . . . . . . . . . . 6 - 152
6.2.4-1 DeviceNet PowerFlex Adapter - Change . . . . 6 - 152
6.2.4-2 DeviceNet PowerFlex Adapter - Set . . . . . . . . 6 - 155

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6.2.4-3 DeviceNet PowerFlex Adapter - LED
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 158

6.3 Servo System . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 164

6.3-1 Servo System - Description . . . . . . . . . . . . . . . 6 - 164
6.3.1 Sercos Module. . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 168
6.3.1-1 Sercos Module - Change . . . . . . . . . . . . . . . . . 6 - 168
6.3.1-2 Sercos Module - Load Firmware . . . . . . . . . . . 6 - 172
6.3.1-3 Sercos Module - LED Description . . . . . . . . . 6 - 173
6.3.2 Servo Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 176
6.3.2-1 Servo Drive - Change . . . . . . . . . . . . . . . . . . . 6 - 176
6.3.2-2 Servo Drive - Set . . . . . . . . . . . . . . . . . . . . . . . 6 - 182
6.3.2-3 Servo Drive - Load Firmware . . . . . . . . . . . . . 6 - 184
6.3.2-4 Servo Drive - LED Description . . . . . . . . . . . . 6 - 185
6.3.2-5 Servo Drive - Error Codes . . . . . . . . . . . . . . . . 6 - 187

6.4 Safety System . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 194

6.4-1 Safety System - Description . . . . . . . . . . . . . . 6 - 194
6.4-2 Safety System - Troubleshooting . . . . . . . . . . . 6 - 195
6.4.1 Pluto Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 197

6 - 4 (308) Doc. No. MM-3047612-0101

 6 Electrical System Table of Contents

6.4.1-1 Pluto Module - Load Program . . . . . . . . . . . . . 6 - 197

6.4.1-2 Pluto Module - LED Description . . . . . . . . . . . 6 - 205
6.4.1-3 Pluto Module - Configure in an Existing
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 207
6.4.1-4 Pluto Module - Set ID-FIX Address after
Replacing an ID-FIX . . . . . . . . . . . . . . . . . . . . 6 - 209
6.4.1-5 Pluto Module - Error Codes . . . . . . . . . . . . . . . 6 - 218

6.5 Frequency Converters . . . . . . . . . . . . . . . . . . 6 - 222

6.5-1 Frequency Converters - Change . . . . . . . . . . . . 6 - 222
6.5-2 Frequency Converters - Parameters . . . . . . . . . 6 - 228
6.5-3 Frequency Converters - Error Codes . . . . . . . . 6 - 230

6.6 Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 232

6.6.1 Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 232
6.6.1-1 Fuses - Rated Current . . . . . . . . . . . . . . . . . . . . 6 - 232
6.6.2 Overload Protection. . . . . . . . . . . . . . . . . . . . . . 6 - 233
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6.6.2-1 Overload Protection - Set . . . . . . . . . . . . . . . . . 6 - 233

6.6.3 Residual Current Device (RCD) . . . . . . . . . . . . 6 - 234
6.6.3-1 Residual Current Device (RCD) - Check . . . . . 6 - 234

6.7 HMI and PLMS . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 235

6.7.1 HMI User Management. . . . . . . . . . . . . . . . . . . . 6 - 235
6.7.1-1 HMI User Management - Description . . . . . . . 6 - 235
6.7.1-2 HMI User Management - Log On as a User . . 6 - 237
6.7.1-3 HMI User Management - Change User
Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 240
6.7.1-4 HMI User Management - Enable/Disable
Operator Settings . . . . . . . . . . . . . . . . . . . . . . . 6 - 246
6.7.2 HMI Installation List . . . . . . . . . . . . . . . . . . . . . . 6 - 247
6.7.2-1 HMI Installation List - Check Version of Software
and Firmware Installed . . . . . . . . . . . . . . . . . . . 6 - 247
6.7.3 HMI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 254
6.7.3-1 HMI - Enable/Disable Languages . . . . . . . . . . 6 - 254
6.7.3-2 HMI - Set Machine Capacity . . . . . . . . . . . . . . 6 - 256

Doc. No. MM-3047612-0101 6 - 5 (308)

Table of Contents 6 Electrical System

6.7.4 PLMS NRG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 259

6.7.4-1 PLMS NRG - Install Software . . . . . . . . . . . . . 6 - 259
6.7.5 PLMS NRG Configurator. . . . . . . . . . . . . . . . . . 6 - 260
6.7.5-1 PLMS NRG Configurator - Set Machine ID . . 6 - 260

6.8 Cooling Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 263

6.8-1 Cooling Unit - Clean Filter . . . . . . . . . . . . . . . 6 - 263
6.8-2 Cooling Unit - Change Filter . . . . . . . . . . . . . . 6 - 265
6.8-3 Cooling Unit - Check . . . . . . . . . . . . . . . . . . . . 6 - 267
6.8-4 Cooling Unit - Overhaul . . . . . . . . . . . . . . . . . 6 - 269
6.8-5 Cooling Unit - Troubleshooting . . . . . . . . . . . . 6 - 275

6.9 Signal Exchange . . . . . . . . . . . . . . . . . . . . . . . 6 - 276

6.9.1-1 Signal Exchange - Select Line Automation . . . 6 - 276
6.9.2.2 PLC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . 6 - 277
6.9.2.2-1 PLC Power Supply - Change . . . . . . . . . . . . . . 6 - 277

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6.9.2.2-2 PLC Power Supply - Download Program . . . . 6 - 279
6.9.2.2-3 PLC Power Supply - Change Battery . . . . . . . 6 - 289
6.9.2.3 DeviceNet Slave Module . . . . . . . . . . . . . . . . . . . 6 - 290
6.9.2.3-1 DeviceNet Slave Module - Reset
Genius Communication . . . . . . . . . . . . . . . . . . 6 - 290

6.10 Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 291

6.10.1 Overvoltage Protector. . . . . . . . . . . . . . . . . . . . 6 - 291
6.10.1-1 Overvoltage Protector - Change . . . . . . . . . . . 6 - 291

6.11 Electrical Components on the Machine . . . . . 6 - 292

6.11.1 Photocells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 292
6.11.1-1 Photocells - Set Sensitivity . . . . . . . . . . . . . . . 6 - 292
6.11.1-2 Photocells - Check and Clean . . . . . . . . . . . . . 6 - 299
6.11.2 Armorblocks . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 301
6.11.2-1 Armorblocks - Set the Node Address . . . . . . . 6 - 301
6.11.2-2 Armorblocks - LED Description . . . . . . . . . . . 6 - 304

6 - 6 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

6.1 PLC (Rockwell)

SPC Reference 2867989-0100

6.1.1 Preparation for PLC Communication

6.1.1-1 Preparation for PLC Communication - Configure PC
Network Communications
Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with CD drive
SPC Reference 2867989-0100

Before data can be sent to the PLC from the PC via an ethernet cable, the PC
network settings must first be configured. The following procedure describes
how to configure the PC network communications.
(Cont'd)
TechPub_2614345_0107 - 0601_3057043_01.fm

Doc. No. MM-3047612-0101 6 - 7 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
Disable Wireless Network Connection
a) Open the START menu (1) on the PC and select SETTINGS (2) and then
NETWORK CONNECTIONS (3) to open the NETWORK CONNECTIONS
window (4).

2 3

TechPub_2614345_0107 - 0601_3057043_01.fm
1 Start menu
2 Settings
3 Network connections
4 Network connections window

(Cont'd)

6 - 8 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
b) In the NETWORK CONNECTIONS window (4) select the WIRELESS
NETWORK CONNECTION (5).
c) Right click the PC mouse and select DISABLE (6).

5
TechPub_2614345_0107 - 0601_3057043_01.fm

4 Network connections window

5 Wireless network connection
6 Disable

(Cont'd)

Doc. No. MM-3047612-0101 6 - 9 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
Disable Firewall Protection
Open the firewall protection software on the PC and perform one of the
following instructions to disable the firewall protection:
• In the section INTERNET STATUS (1), select CURRENT STATUS (2).
Select the DISABLE button (3) to disable the PC firewall.
• In the section CLIENT FIREWALL (4), select INTERNET ZONE
CONTROL (5). Select the TRUSTED tab (6) and then select the ADD
button (7).

2
3

TechPub_2614345_0107 - 0601_3057043_01.fm
4

1 Internet status
2 Current status
3 Disable button
4 Client firewall
6 7
5 Internet zone control
6 Trusted tab
7 Add button

(Cont'd)

6 - 10 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
• Select the USING A RANGE checkbox (8). Enter an IP ADDRESS
range (9), for example from 10.255.100.0 to 10.255.100.99, then select
the OK button (10).
• If the dialogue box (11) appears, then select the OK button (12).
• Select the CANCEL button (13).

9
TechPub_2614345_0107 - 0601_3057043_01.fm

10 11 13

8 Using a range checkbox 12

9 IP address range
10 OK button
11 Dialogue box
12 OK button
13 Cancel button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 11 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
• Make sure that the IP address range introduced is correct, then select the
OK button (14).

TechPub_2614345_0107 - 0601_3057043_01.fm
14
14 OK button

(Cont'd)

6 - 12 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
Configure PC IP Address
a) Open the START menu (1) on the PC and select SETTINGS (2) and then
NETWORK CONNECTIONS (3) to open the NETWORK CONNECTIONS
window (4).

2 3

4
TechPub_2614345_0107 - 0601_3057043_01.fm

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

(Cont'd)

Doc. No. MM-3047612-0101 6 - 13 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
Note! The LOCAL AREA CONNECTION (5) is given only as an example, if
multiple area connections are listed in the NETWORK CONNECTIONS
window (4), select the required network connection.
b) In the NETWORK CONNECTIONS window (4) select the LOCAL AREA
CONNECTION (5) and right click the PC mouse to select
PROPERTIES (6).

TechPub_2614345_0107 - 0601_3057043_01.fm
6
4 Network connections window
5 Local area connection
6 Properties

(Cont'd)

6 - 14 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
c) In the LOCAL AREA CONNECTION PROPERTIES window (7) select
the INTERNET PROTOCOL (TCP/IP) (8) and then select the
PROPERTIES button (9).

8
9
TechPub_2614345_0107 - 0601_3057043_01.fm

7 Local area connection properties window

8 Internet protocol (TCP/IP)
9 Properties button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 15 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
Note! The unique number “XX” must be within the range of the permitted IP
addresses if the firewall protection is configured to allow a range of IP
addresses (see the section Disable Firewall Protection on page 6-10) and
higher than the number 30 to avoid possible conflicts with machine device IP
addresses.
d) Select the USE THE FOLLOWING IP ADDRESS checkbox (10) and
the USE THE FOLLOWING DNS SERVER ADDRESSES
checkbox (11).
e) In the IP ADDRESS field (12) enter an IP address using the following
format: 10.255.100.XX, where “XX” is a unique number not already
assigned to any PC or PLC connected to the same network.
f) In the SUBNET MASK field (13) enter the subnet mask as indicated in
the illustration.
g) Select the OK button (14) to confirm the setting and close the window.

TechPub_2614345_0107 - 0601_3057043_01.fm
10 12

13
11

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

6 - 16 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

6.1.1-2 Preparations for PLC Communication - Configure

RSLinx
Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with CD drive
Ethernet communication cable, TP No. 351501-0100
SPC Reference 2867989-0100

The RSLinx software enables seamless communication between the PC and

the PLC and its components over different networks such as ethernet and
DeviceNet. Before communication is possible, the network and IP addresses
for the PC and PLC must be set in RSLinx as follows:
a) Open the START menu on the PC and select PROGRAMS (1),
ROCKWELL SOFTWARE (2), RSLINX (3) and then RSLINX
CLASSIC (4).

1 2 3 4
TechPub_2614345_0107 - 0601_3057043_01.fm

1 Programs
2 Rockwell software
3 RSLinx
4 RSLinx classic

(Cont'd)

Doc. No. MM-3047612-0101 6 - 17 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
b) The RSLINX CLASSIC PROFESSIONAL window (5) appears, select
the CONFIGURE DRIVERS button (6).
c) In the CONFIGURE DRIVERS window (7), select ETHERNET
DEVICES (8) from the drop down menu.
d) Select the ADD NEW button (9).

7 6 8 9

TechPub_2614345_0107 - 0601_3057043_01.fm

5 RSlinx classic professional window

6 Configure drivers button
7 Configure drivers window
8 Ethernet devices
9 Add new button

(Cont'd)

6 - 18 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
e) Accept the default driver name that appears by selecting the OK
button (10).
f) Enter the PC’s IP address (set in 6.1.1-1 Preparation for PLC
Communication - Configure PC Network Communications on page 6-7)
in the HOST NAME field (11) and then select the ADD NEW button (12).

10
TechPub_2614345_0107 - 0601_3057043_01.fm

12

11

10 OK button
11 Host name field
12 Add new button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 19 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
g) Enter the IP address 10.255.1.21 for the PLC in the HOST NAME
field (13).
h) Select the OK button (14) to save the configuration.

13

TechPub_2614345_0107 - 0601_3057043_01.fm
14
13 Host name field
14 OK button

6 - 20 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

6.1.1-3 Preparations for PLC Communication - Register EDS

File
Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with CD Drive
Program CD TP No. 2886185-0XXX
SPC Reference 2867989-0100

a) Open the START menu (1) on the PC, then select PROGRAMS (2),
ROCKWELL SOFTWARE (3), RSLINX TOOLS (4) and then EDS
HARDWARE INSTALLATION TOOL (5).
TechPub_2614345_0107 - 0601_3057043_01.fm

1 2 3 4 5
1 Start menu
2 Programs
3 Rockwell software
4 RSLinx tools
5 EDS hardware installation tool

(Cont'd)

Doc. No. MM-3047612-0101 6 - 21 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
b) Select the ADD button (6).

TechPub_2614345_0107 - 0601_3057043_01.fm
6 Add button

(Cont'd)

6 - 22 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
c) Make sure to select the checkbox (7).
d) Insert the program CD into the PC CD drive, then select the BROWSE
button (8).
e) Browse to the CD drive to locate the EDS file (9), select the folder
2886193-1XXX, then select the OK button (10).

8
TechPub_2614345_0107 - 0601_3057043_01.fm

10

7 Checkbox
8 Browse button
9 EDS file
10 OK button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 23 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
f) Make sure to select the checkbox (11).
g) Select the NEXT button (12) to continue.

TechPub_2614345_0107 - 0601_3057043_01.fm
11 12

11 Checkbox
12 Next button

(Cont'd)

6 - 24 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
h) Select the NEXT button (13) to continue.
TechPub_2614345_0107 - 0601_3057043_01.fm

13

13 Next button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 25 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
i) Select the NEXT button (14) to continue.

TechPub_2614345_0107 - 0601_3057043_01.fm
14
14 Next button

(Cont'd)

6 - 26 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
j) Select the NEXT button (15) to continue.
TechPub_2614345_0107 - 0601_3057043_01.fm

15
15 Next button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 27 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
k) When the installation is completed, select the FINISH button (16).

TechPub_2614345_0107 - 0601_3057043_01.fm
16
16 Finish button

(Cont'd)

6 - 28 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
l) Select the EXIT button (17).
TechPub_2614345_0107 - 0601_3057043_01.fm

17

17 Exit button

Doc. No. MM-3047612-0101 6 - 29 (308)

6.1 PLC (Rockwell) 6 Electrical System

6.1.2 CPU Module

6.1.2-1 CPU Module - Change
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 90459-3143 (Series A)
90459-6558 (Series B)

Note! New CPU modules are supplied with basic firmware. The functionality
of the application is not verified when the new CPU modules have a different
firmware revision. Contact the Machine System Liaison for more
information. The correct firmware revision must be installed before the PLC
program can be downloaded to the CPU module.
Note! The firmware revision of the new CPU module may be equal to, or
newer than the firmware revision of the old CPU module. Using a newer
firmware revision may create errors when going online, such as
unrecognized device or device mismatch, if the PC does not contain the
very latest EDS files.
Note! The functionality of the application is not verified when the new CPU
modules have a different series and of consequence they have a different
90000 TP part number. Contact the Machine System Liaison for more

TechPub_2614345_0107 - 0601_3057043_01.fm
information.
Note! If the EtherNet/IP modules have still the MAC address programmed
as a factory setting, or if they have a different IP address setting, then
perform the 6.1.3-2 EtherNet/IP Module - Set IP Address on page 6-65.
Preparation
Before changing the CPU module:
• Use the RSLinx Classic program to verify and record the firmware
version of the PLC program.
• Use the Flow Chart of Procedures for Changing the CPU module on the
next page to determine which procedures must be performed and their
correct sequence.
(Cont'd)

6 - 30 (308) Doc. No. MM-3047612-0101

 TechPub_2614345_0107 - 0601_3057043_01.fm

Flow Chart of Procedures for Changing the CPU module

Change the CPU module

(Cont'd)
6 Electrical System

No No No
New module with New module with New module with New module with a
same series and no same series and old same series and new series and new
firmware firmware new firmware firmware

Yes Yes Yes Yes

Fit the new module, see Fit the new module, see Fit the new module, see It is NOT RECOMMENDED to fit
Change the CPU Module on Change the CPU Module on Change the CPU Module on a CPU module with a different
page 6-33 page 6-33 page 6-33 series. The PLC program and
machine functionality is only
verified to work with the existing

Upgrade the firmware to the Upgrade the firmware to the Downgrade the firmware to
same revision as the PLC same revision as the PLC the same revision as the PLC Fit the new module, see Change
program, see 6.1.2-2 CPU program, see 6.1.2-2 CPU program, see 6.1.2-2 CPU the CPU Module on page 6-33

Doc. No. MM-3047612-0101

Module - Load Firmware on Module - Load Firmware on Module - Load Firmware on
page 6-36 page 6-36 page 6-36

Convert the PLC program to the

new firmware revision, see
Download the PLC program, Download the PLC program, Download the PLC program, 6.1.2-3 CPU Module - Convert
see 6.1.2-4 CPU Module - see 6.1.2-4 CPU Module - see 6.1.2-4 CPU Module - Program on page 6-42
Download Program on Download Program on Download Program on
page 6-45 page 6-45 page 6-45

Download the PLC program, see

6.1.2-4 CPU Module - Download
Program on page 6-45

(Cont'd)

6 - 31 (308)
6.1 PLC (Rockwell)
6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
Note! It is recommended that the Mains Power is turned OFF before the
PLC is removed or installed. The PLC may be removed or installed with the
chassis power ON and the system operating, but doing this repeatedly may
cause excessive wear to the contacts on the module and its mating
connector. Worn contacts can create electrical resistance that may effect the
operation of the module.
Note! If the CPU module is removed with the power turned ON, all the
devices connected to CPU module will go to their configured default state.
Note! A CompactFlash card fitted inside the CPU module is used to store a
back-up of the PLC program and the recipes. When the CPU module is
changed, the CompactFlash card must be transferred from the old CPU
module to the new CPU module.
(Cont'd)

TechPub_2614345_0107 - 0601_3057043_01.fm

6 - 32 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
Change the CPU Module
a) Press the locking tabs on the top and the bottom of the CPU module.
b) Slide the CPU module out of the chassis.
c) Push the retaining clip (1) to the LH side and press the eject button (2) to
remove the CompactFlash card (3) from the CPU module. Discard the
CPU module.
d) Store the CompactFlash card (3) in a safe and clean place.

3
TechPub_2614345_0107 - 0601_3057043_01.fm

1 Retaining clip 1
2 Eject button
3 CompactFlash card
2

(Cont'd)

Doc. No. MM-3047612-0101 6 - 33 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
e) Fit the CompactFlash card (3) into the new CPU module, making sure
that the thin edge (4) is placed on the RH side.

3 CompactFlash card

TechPub_2614345_0107 - 0601_3057043_01.fm
4 Edge

(Cont'd)

6 - 34 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
f) Insert the key (5) into the new CPU module.
g) Turn the key (5) to the REM position.
h) Align the new CPU module with the top and the bottom guides in the
chassis.
i) Slide the CPU module into the chassis. Make sure it is flush with the
power supply or the other modules and the top and bottom latches are
engaged.
j) Turn the Mains Power switch to the ON position.
k) Check the status of the CPU module LEDs according to the table in
section 6.1.2-5 CPU Module - LED Description on page 6-56.
l) Continue with the necessary procedures as described in Flow Chart of
Procedures for Changing the CPU module on page 6-31.
TechPub_2614345_0107 - 0601_3057043_01.fm

5 Key 5

Doc. No. MM-3047612-0101 6 - 35 (308)

6.1 PLC (Rockwell) 6 Electrical System

6.1.2-2 CPU Module - Load Firmware

Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with CD Drive
Ethernet communication cable, TP No. 351501-0100
Program CD TP No. 2886185-0XXX
SPC Reference 90459-3143 (Series A)
90459-6558 (Series B)

Note! Before starting, check the current version of firmware installed, see
the Firmware - Installation List on page 6-251, included in the chapter
6.7.2-1 HMI Installation List - Check Version of Software and Firmware
Installed.
Note! Upgrade the firmware only if the version installed on the module is
different from the version indicated in the PDF file included in the program
CD, see next page.
CAUTION
Risk of damage to the equipment.
If a firmware download is interrupted, for example by a loss of power or if the
communication fails between the module and the PC, the module will be

TechPub_2614345_0107 - 0601_3057043_01.fm
corrupted.
Note! The following procedure is valid for all PLC rack mounted or
distributed modules requiring firmware.
(Cont'd)

6 - 36 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
a) Insert the program CD into the PC CD drive.
b) Browse to the CD drive, then open the PDF file (indicated with an
arrow) included in the folder 2886191-1XXX, in order to identify the
correct version of the Firmware for the module.
c) Browse again to the CD drive and locate the corresponding subfolder,
then double click on the installation files and follow the instructions
displayed on the screen in order to complete the installation of the
Firmware on your PC.
TechPub_2614345_0107 - 0601_3057043_01.fm

(Cont'd)

Doc. No. MM-3047612-0101 6 - 37 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
d) Make sure that the PC is configured as described in 6.1.1-1 Preparation
for PLC Communication - Configure PC Network Communications on
page 6-7 and in 6.1.1-2 Preparations for PLC Communication -
Configure RSLinx on page 6-17.
e) Open the START menu on the PC and select PROGRAMS (1), FLASH
PROGRAMMING TOOLS (2) and CONTROLFLASH (3).

1 3

TechPub_2614345_0107 - 0601_3057043_01.fm
1 Programs
2 Flash programming tools
3 Controlflash

(Cont'd)

6 - 38 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
f) In the CONTROLFLASH PROGRAM window (4), select the NEXT
button (5) and follow the instructions to load the firmware.

5
TechPub_2614345_0107 - 0601_3057043_01.fm

4 Controlflash program window

5 Next button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 39 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
g) Select the catalogue number of the target device, then select the NEXT
button (6).

TechPub_2614345_0107 - 0601_3057043_01.fm
6
6 Next button

(Cont'd)

6 - 40 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
h) In the network, find and select the device to be updated.
i) Select the OK button (7) to load the firmware.
TechPub_2614345_0107 - 0601_3057043_01.fm

7
7 OK button

Doc. No. MM-3047612-0101 6 - 41 (308)

6.1 PLC (Rockwell) 6 Electrical System

6.1.2-3 CPU Module - Convert Program

Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with CD drive
Ethernet communication cable, TP No. 351501-0100
Program CD TP No. 2886185-0XXX
SPC Reference 90459-3143 (Series A)
90459-6558 (Series B)

Perform the following instruction, after the installation of a new CPU

module with a different series, in order to convert the PLC program to a new
firmware revision.
Note! To connect to the CPU module using an ethernet communication
cable, the PC must first be configured for this type of communication. See
6.1.1-1 Preparation for PLC Communication - Configure PC Network
Communications on page 6-7 and 6.1.1-2 Preparations for PLC
Communication - Configure RSLinx on page 6-17 for more details.
a) Connect the ethernet communication cable between a vacant connection
port on the ethernet switch (1) and the PC (2).

TechPub_2614345_0107 - 0601_3057043_01.fm
1

1 Ethernet switch
2 PC

(Cont'd)

6 - 42 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
b) Insert the program CD into the PC CD drive.
c) Browse to the CD drive and copy the program file included in the folder
2886189-1XXX to the PC desktop.
Note! The conversion to a new firmware revision, could require the
installation of a new license of RSLogix.
d) Double click on the program file to automatically start the RSLogix
program and open the program file.
e) Select the CONTROLLER PROPERTIES button (3).
f) Select the GENERAL tab (4) and then the CHANGE CONTROLLER
button (5).

3
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3 Controller properties button

4 General tab
5 Change controller button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 43 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
g) Select the correct FIRMWARE REVISION (6) from the drop down list.
h) Select the OK button (7) then wait until the conversion process is
finished, select the OK button if some message windows will appear.

TechPub_2614345_0107 - 0601_3057043_01.fm
6 7
6 Firmware revision
7 Ok button

6 - 44 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

6.1.2-4 CPU Module - Download Program

Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with CD drive
Ethernet communication cable, TP No. 351501-0100
Program CD TP No. 2886185-0XXX
SPC Reference 90459-3143 (Series A)
90459-6558 (Series B)

Note! Before starting, check the current version of Software installed, see
the Software - Installation List on page 6-248, included in the chapter
6.7.2-1 HMI Installation List - Check Version of Software and Firmware
Installed.
Note! To connect to the CPU module using an ethernet communication
cable, the PC must first be configured for this type of communication. See
6.1.1-1 Preparation for PLC Communication - Configure PC Network
Communications on page 6-7 and 6.1.1-2 Preparations for PLC
Communication - Configure RSLinx on page 6-17 for more details.
a) Connect the ethernet communication cable between a vacant connection
port on the ethernet switch (1) and the PC (2).
TechPub_2614345_0107 - 0601_3057043_01.fm

1 Ethernet switch
2 PC

(Cont'd)

Doc. No. MM-3047612-0101 6 - 45 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
b) Insert the program CD into the PC CD drive.
c) Browse to the CD drive and copy the program file included in the folder
2886189-1XXX to the PC desktop.
d) Double click on the program file to automatically start the RSLogix
program and open the program file.
e) Select the COMMUNICATIONS menu (3) and then select GO
ONLINE (4).

TechPub_2614345_0107 - 0601_3057043_01.fm
4

3 Communications menu
4 Go online

(Cont'd)

6 - 46 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
Note! If the program matches the program in the CPU module, an online
connection will be established without any further messages. A download of
the program is not necessary.
f) The CONNECTED TO GO ONLINE window (5) appears.
g) Select the DOWNLOAD button (6).

5
TechPub_2614345_0107 - 0601_3057043_01.fm

6
5 Connected to go online window
6 Download button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 47 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
Note! All the values and settings in the CPU module will be replaced with
those from the downloaded program.
h) Select the DOWNLOAD button (7) in the DOWNLOAD window (8).
i) When the download is complete the dialogue box (9) appears, select the
YES button (10) to put the PLC in RUN mode.
j) If the download is to a replacement PLC controller, then set the
nonvolatile memory, see Set Nonvolatile Memory on the next page.

TechPub_2614345_0107 - 0601_3057043_01.fm
7 9 10

7 Download button
8 Download window
9 Dialogue box
10 Yes button

(Cont'd)

6 - 48 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
Set Nonvolatile Memory
a) Select the COMMUNICATIONS menu (1) and then select GO
ONLINE (2).

2
TechPub_2614345_0107 - 0601_3057043_01.fm

1 Communications menu
2 Go online

(Cont'd)

Doc. No. MM-3047612-0101 6 - 49 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
b) Select the COMMUNICATIONS menu (1), then select PROGRAM
MODE (3).
c) When the dialogue box (4) appears, select the YES button (5) to put the
PLC in PROGRAM mode.

TechPub_2614345_0107 - 0601_3057043_01.fm
4

1 Communications menu
3 Program mode 5
4 Dialogue box
5 Yes button

(Cont'd)

6 - 50 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
d) Select the CONTROLLER PROPERTIES button (6).
e) Select the NONVOLATILE MEMORY tab (7).
f) Select the LOAD/STORE button (8).

8
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6 Controller properties button

7 Nonvolatile memory tab
8 Load/store button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 51 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
g) In the NONVOLATILE MEMORY LOAD/STORE window (9), select ON
CORRUPT MEMORY from the drop down list of the LOAD IMAGE
option (10).
h) In the NONVOLATILE MEMORY LOAD/STORE window (9), select
RUN (REMOTE ONLY) from the drop down list of the LOAD MODE
option (11).
i) Select the STORE button (12).

9 10 11

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12

9 Nonvolatile memory load/store window

10 Load image option
11 Load mode option
12 Store button

(Cont'd)

6 - 52 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
j) Select the YES button (13) to confirm the store.
k) During the process a dialogue box indicates that the store is in progress,
select the OK button (14).
TechPub_2614345_0107 - 0601_3057043_01.fm

13

14
13 Yes button
14 OK button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 53 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
l) Select the OK button (15) to close the CONTROLLER PROPERTIES
window.

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15
15 OK button

(Cont'd)

6 - 54 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
m) Select the COMMUNICATIONS menu (1) and then select GO
ONLINE (2).
n) Select the COMMUNICATIONS menu (1), then select RUN MODE (16) to
put the PLC in RUN mode.
o) Select the YES button (17) to confirm.

2
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16

1 Communications menu 17
2 Go online
16 Run mode
17 Yes button

Doc. No. MM-3047612-0101 6 - 55 (308)

6.1 PLC (Rockwell) 6 Electrical System

6.1.2-5 CPU Module - LED Description

Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 90459-3143 (Series A)
90459-6558 (Series B)

LED Colour Description

RUN (1) Off The module is in Program or Test mode.
Solid green The module is in Run mode.
I/O (2) Off There are no devices in the I/O configuration of the
module.
or
The module does not contain a project (module
memory is empty).
Solid green The module is communicating with all the devices
in its I/O configuration.
Flashing green One or more devices in the I/O configuration of the
module are not responding.
Flashing red The chassis is bad. Replace the chassis.

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FORCE (3) Off No tags contain I/O force values.
I/O forces are inactive (disabled).
Solid amber I/O forces are active (enabled).
I/O force values may or may not exist.
RS232 (4) Off There is no activity.
Solid green Data is being received or transmitted.

1 2
3 4

1 Run LED
2 I/O LED
3 Force LED
4 RS232 LED

(Cont'd)

6 - 56 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)

LED Colour Description

BAT (5) Off The battery supports memory.
Solid red The battery is not installed.
or
The battery is 95% discharged and should be
replaced.
OK (6) Off No power is applied.
Flashing red If the module is new, then the module requires a
firmware update.
If the module is not new, then a board major fault has
occurred.
To clear the fault, either turn the key switch to PROG,
then to RUN and then back to PROG again or go on-
line with RSLogix 5000 software.
Solid red The module detected a non-recoverable fault, so it
cleared the project from memory. To recover:
1. Cycle power to the chassis.
2. Download the project.
3. Change to Run mode.
If the OK LED remains solid red, contact your
Rockwell Automation representative or local
distributor.
TechPub_2614345_0107 - 0601_3057043_01.fm

Solid green The module is ok.

Flashing green The module is storing or loading a project to or from
nonvolatile memory.

5 6

5 Bat LED
6 OK LED

Doc. No. MM-3047612-0101 6 - 57 (308)

6.1 PLC (Rockwell) 6 Electrical System

6.1.2-6 CPU Module - Change Battery

Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 90459-2489 (for CPU series A)
90459-6726 (for CPU series B)

CAUTION
Loss of data.
Make sure that the Mains Power switch is turned to the ON position. Failure
to do this may result in the data stored in the CPU module being lost.
a) Press the clip (1) and disconnect the battery cable connection (2) from
the connection (3) and remove the battery (4).
b) Connect the battery cable for the new battery to the connection (3) and
fit the new battery. Make sure that the new battery is fitted with the
arrow (5) pointing upwards.
c) Write the date of the battery installation on the battery label (6).

TechPub_2614345_0107 - 0601_3057043_01.fm
1 2
5

UP

1 Clip
2 Battery cable connection
3 Connection
4 Battery
5 Arrow
6 Label
6 4 3

6 - 58 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

6.1.3 EtherNet/IP Module

6.1.3-1 EtherNet/IP Module - Change
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 90459-2477

Note! The functionality of the application is not verified when the new
EtherNet/IP modules have a different firmware revision. Contact the
Machine System Liaison for more information. The correct firmware revision
must be installed to the EtherNet/IP modules.
Note! The firmware revision of the new EtherNet/IP module may be equal
to, or newer than the firmware revision of the old EtherNet/IP module. Using
a newer firmware revision may create errors when going online, such as
unrecognized device or device mismatch, if the PC does not contain the
very latest EDS files.
Note! The functionality of the application is not verified, when the new
EtherNet/IP modules have a different series and of consequence they have
a different 90000 TP part number. Contact the Machine System Liaison for
more information.
TechPub_2614345_0107 - 0601_3057043_01.fm

(Cont'd)

Doc. No. MM-3047612-0101 6 - 59 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
Note! The following instructions are valid for both EtherNet/IP modules (1)
and (2).
Preparation
Before changing the EtherNet/IP module:
• Use the RSLinx Classic program to verify and record the firmware
version of the existing EtherNet/IP module.
• Use the Flow Chart of Procedures for Changing the EtherNet/IP Module
on the next page to determine which procedures must be performed and
their correct sequence.

2
1

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1 EtherNet/IP module (line controller network, level 6)
2 EtherNet/IP module (machine internal network, level 7)

(Cont'd)

6 - 60 (308) Doc. No. MM-3047612-0101

 TechPub_2614345_0107 - 0601_3057043_01.fm

Flow Chart of Procedures for Changing the EtherNet/IP Module

Change the EtherNet/IP module

(Cont'd)
6 Electrical System

No No No
New module with New module with New module with New module with a
same series and same series and old same series and new series and new
same firmware firmware new firmware firmware

Yes Yes Yes Yes

Fit the new module, see Change Fit the new module, see Change Fit the new module, see Change Fit the new module, see Change
the EtherNet/IP Module on the EtherNet/IP Module on the EtherNet/IP Module on the EtherNet/IP Module on
page 6-62 page 6-62 page 6-62 page 6-62

Set the IP address, see 6.1.3-2 Upgrade the firmware to the Downgrade the firmware to the Set the IP address, see 6.1.3-2

Doc. No. MM-3047612-0101

EtherNet/IP Module - Set IP same revision as the old module, same revision as the old module, EtherNet/IP Module - Set IP
Address on page 6-65 see 6.1.3-3 EtherNet/IP Module - see 6.1.3-3 EtherNet/IP Module - Address on page 6-65
Load Firmware on page 6-79 Load Firmware on page 6-79

Set the IP address, see 6.1.3-2 Set the IP address, see 6.1.3-2
EtherNet/IP Module - Set IP EtherNet/IP Module - Set IP
Address on page 6-65 Address on page 6-65

(Cont'd)

6 - 61 (308)
6.1 PLC (Rockwell)
6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
Change the EtherNet/IP Module
a) Remove the cable connection (1) from the EtherNet/IP module.
b) Press the locking tabs on the top and the bottom of the EtherNet/IP
module.
c) Slide the EtherNet/IP module out of the chassis. Discard the EtherNet/IP
module.

TechPub_2614345_0107 - 0601_3057043_01.fm
1

1 Cable connection

(Cont'd)

6 - 62 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
d) Verify and record the MAC address (2) of the new EtherNet/IP module
printed in the position indicated in the illustration.

2
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2 MAC address

(Cont'd)

Doc. No. MM-3047612-0101 6 - 63 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
e) Align the new EtherNet/IP module with the top and the bottom guides in
the chassis.
f) Slide the EtherNet/IP module into the chassis. Make sure it is flush with
the other modules and the top and bottom latches are engaged.
g) Fit the cable connection (1) to the EtherNet/IP module.
h) Turn the Mains Power switch to the ON position.
i) Check the status of the EtherNet/IP module LEDs according to the table
in section 6.1.3-4 EtherNet/IP Module - LED Description on page 6-80.
Note! If the new EtherNet/IP module has still the MAC address programmed
as a factory setting, or if it has a different IP address setting, then perform
the 6.1.3-2 EtherNet/IP Module - Set IP Address on page 6-65.
j) Continue with the necessary procedures as described in Flow Chart of
Procedures for Changing the EtherNet/IP Module on page 6-61.

1 TechPub_2614345_0107 - 0601_3057043_01.fm

1 Cable connection

6 - 64 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

6.1.3-2 EtherNet/IP Module - Set IP Address

Machine Status Mains Power OFF
Air OFF
Water OFF
Special Equipment PC with CD drive
Ethernet communication cable, TP No. 351501-0100
Cross cable
SPC Reference 90459-2477

Note! Before starting connect the PC using one of the two following types of
connection: Connection with Ethernet Communication Cable as described
below, or Connection with Cross Cable on page 6-66.
Connection with Ethernet Communication Cable
Connect the ethernet communication cable between a vacant connection port
on the ethernet switch (1) and the PC (2).
TechPub_2614345_0107 - 0601_3057043_01.fm

1 Ethernet switch
2 PC

(Cont'd)

Doc. No. MM-3047612-0101 6 - 65 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
Connection with Cross Cable
Connect the cross cable between the correct EtherNet/IP module (1) and the
PC (2).

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2

1 EtherNet/IP module
2 PC

(Cont'd)

6 - 66 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
Note! The new EtherNet/IP modules have a MAC address programmed as
a factory setting. The MAC address must be changed to an IP address, as
described below, otherwise for EtherNet/IP modules with a different IP
address, change the IP address, see Change IP Address for Ethernet/IP
Modules with Different IP Address on page 6-72.
Change IP Address for Ethernet/IP Modules with MAC Address
a) Make sure that the PC is connect.
b) Open the RSLinx Classic professional program and select EXIT AND
SHUTDOWN (1).
c) Repeat the following instructions, included in the chapter
6.1.1-1 Preparation for PLC Communication - Configure PC Network
Communications:
• Disable Wireless Network Connection on page 6-8
• Disable Firewall Protection on page 6-10.
.
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1
1 Exit and shutdown

(Cont'd)

Doc. No. MM-3047612-0101 6 - 67 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
d) Open the START menu on the PC and select PROGRAMS (2),
ROCKWELL SOFTWARE (3), BOOTP-DHCP SERVER (4) and then
BOOTP-DHCP SERVER (5).

2 3 4 5

2 Programs
3 Rockwell software

TechPub_2614345_0107 - 0601_3057043_01.fm
4 BOOTP-DHCP server
5 BOOTP-DHCP server

(Cont'd)

6 - 68 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
Note! If it is the first time the BOOT DHCP Server program is used, a
network setting will be requested. Otherwise continue with step g).
e) Enter 255.255.0.0 as the SUBNET MASK (6). All other settings should
be set to zero.
f) Select the OK button (7).

6
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6 Subnet mask
7 OK button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 69 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
g) When the MAC address appears in the REQUEST HISTORY
window (9) of the BOOTP/DHCP SERVER window (8), check that the
same address is displayed on the EtherNet module and select the NEW
button (10) to begin the conversion from the MAC address to an IP
address.
h) When the MAC address appears in the RELATION LIST window (11),
select the MAC address.

The MAC address will be displayed here

9

TechPub_2614345_0107 - 0601_3057043_01.fm
10
The MAC address will appear here
11

8 BOOT/DHCP server window

9 Request history window
10 New button
11 Relation list window

(Cont'd)

6 - 70 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
i) Enter the MAC address in the MAC ADDRESS field (12) and the new
IP address in the IP ADDRESS field (13) of the NEW ENTRY
window (14), according to the table below:
EtherNet/IP module
PLC Slot No. Pos. No. Module type Description IP address
1 A01K3020 1756-ENBT Line controller 10.0.0.206
network, level 6
2 A01K3030 1756-ENBT Machine internal 10.255.1.21
network, level 7

j) Select the OK button (15). The new IP address will appear in the
REQUEST HISTORY window (9).
k) Select the EtherNet/IP module in the RELATION LIST window (11)
and then select the DISABLE BOOTP/DHCP button (16).
l) After the EtherNet/IP module has been configured, check that the correct
IP address appears on the display on the EtherNet/IP module.
m) Disconnect the PC.

14
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12
9 13

15
11
16

9 Request history window 14 New entry window

11 Relation list window 15 OK button
12 MAC address field 16 Disable BOOTP/DHCP button
13 IP address field
(Cont'd)

Doc. No. MM-3047612-0101 6 - 71 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
Change IP Address for Ethernet/IP Modules with Different IP
Address
a) Make sure that the PC is connect.
b) Using the current IP address, that can be read on the display of the new
EtherNet/IP module once powered on, repeat the following instructions:
• 6.1.1-1 Preparation for PLC Communication - Configure PC Network
Communications, starting from Disable Wireless Network Connection
on page 6-8
• 6.1.1-2 Preparations for PLC Communication - Configure RSLinx, on
page 6-17.
c) The old EtherNet/IP module (1) that has been removed, is indicated as
UNRECOGNIZED DEVICE (2) by the RSLinx Classic professional
program.

TechPub_2614345_0107 - 0601_3057043_01.fm
1
2

1 Old EtherNet/IP module

2 Unrecognized device

(Cont'd)

6 - 72 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
d) The program indicates if new EtherNet/IP module (3), with a different IP
address, has been installed.

3 New EtherNet/IP module

TechPub_2614345_0107 - 0601_3057043_01.fm

(Cont'd)

Doc. No. MM-3047612-0101 6 - 73 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
e) Select the new EtherNet/IP module installed, then right click the PC
mouse and select MODULE CONFIGURATION (4), the actual IP
address is shown in the IP ADDRESS field (5).

TechPub_2614345_0107 - 0601_3057043_01.fm
5

4 Module configuration
5 IP address field

(Cont'd)

6 - 74 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
f) Enter the new IP address in the IP ADDRESS field (5), according to the
table below:
EtherNet/IP module
PLC Slot No. Pos. No. Module type Description IP address
1 A01K3020 1756-ENBT Line controller 10.0.0.206
network, level 6
2 A01K3030 1756-ENBT Machine internal 10.255.1.21
network, level 7

g) Select the OK button (6).

5
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5 IP address field
6 OK button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 75 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
h) When the dialogue box (7) appears, select the YES button (8) to
continue.
i) Repeat the instructions 6.1.1-1 Preparation for PLC Communication -
Configure PC Network Communications, starting from Disable Wireless
Network Connection on page 6-8.

TechPub_2614345_0107 - 0601_3057043_01.fm
7 Dialogue box
8 Yes button

(Cont'd)

6 - 76 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
j) Wait until the new IP address (9) previously set, has been recognized by
the RSLinx Classic professional program.

The pictures display the new IP

address set, of the EtherNet/IP
TechPub_2614345_0107 - 0601_3057043_01.fm

module for the machine internal

network, level 7.

9 IP address

(Cont'd)

Doc. No. MM-3047612-0101 6 - 77 (308)

6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
k) Select the new EtherNet/IP module (3) previously installed, then right
click the PC mouse and select REMOVE (10).

3 10

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3 New EtherNet/IP module
10 Remove

6 - 78 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

6.1.3-3 EtherNet/IP Module - Load Firmware

Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with CD Drive
Ethernet communication cable, TP No. 351501-0100
Program CD TP No. 2886185-0XXX
SPC Reference 90459-2477

Follow the instructions in 6.1.2-2 CPU Module - Load Firmware on

page 6-36, to load the firmware for the EtherNet/IP module.
TechPub_2614345_0107 - 0601_3057043_01.fm

Doc. No. MM-3047612-0101 6 - 79 (308)

6.1 PLC (Rockwell) 6 Electrical System

6.1.3-4 EtherNet/IP Module - LED Description

Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 90459-2477

LED Colour Description

LINK (1) Off No data transmission. Module is not ready for
transmission
Solid green Ready. Module is ready to communicate.
Flashing green Module is communicating over the network.
NET (2) Off Module is not powered or does not have an IP
address. Verify there is chassis power and make
sure the module has been configured.
Solid green Module has an IP address and has established
at least one connection.
Flashing green Module has an IP address and but has no
established connections.
Solid red A duplicate IP address has been detected. Make
sure that the IP address assigned to this module
is not the same as that for any other device

TechPub_2614345_0107 - 0601_3057043_01.fm
already on the network.
Flashing red A connection has timed out. One or more of the
connections targeting the module has timed out.

1 LINK LED
2 NET LED

(Cont'd)

6 - 80 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)

LED Colour Description

OK (3) Off The module does not have 24 V DC power.
Verify there is chassis power and make sure the
module has been correctly inserted in the
chassis.
Solid green Module is operating correctly.
Flashing green Module is not configured.
Solid red Major fault. An non-recoverable fault has been
detected, cycle the power to the module. If the
fault remains replace the module.
Flashing red A duplicate IP address has been detected. Make
sure that the IP address assigned to this module
is not the same as that for any other device
already on the network.
Or
A recoverable fault has been detected. This
could be caused by an error in the configuration.
Flashing red/ The module is performing the self-test on
green power up.
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3 OK LED

Doc. No. MM-3047612-0101 6 - 81 (308)

6.1 PLC (Rockwell) 6 Electrical System

6.1.4 Digital Input Module

6.1.4-1 Digital Input Module - Change
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 90459-6556

Note! The functionality of the application is not verified when the new Digital
Input modules have a different firmware revision. Contact the Machine
System Liaison for more information. The correct firmware revision must be
installed to the Digital Input modules.
Note! The firmware revision of the new Digital Input module may be equal
to, or newer than the firmware revision of the old Digital Input module. Using
a newer firmware revision may create errors when going online, such as
unrecognized device or device mismatch, if the PC does not contain the
very latest EDS files.
Note! The functionality of the application is not verified, when the new
Digital Input modules have a different series and of consequence they have
a different 90000 TP part number. Contact the Machine System Liaison for
more information.

TechPub_2614345_0107 - 0601_3057043_01.fm
Preparation
Before changing the Digital Input module:
• Use the RSLinx Classic program to verify and record the firmware
version of the existing Digital Input module.
• Use the Flow Chart of Procedures for Changing the Digital Input
Module on the next page to determine which procedures must be
performed and their correct sequence.
(Cont'd)

6 - 82 (308) Doc. No. MM-3047612-0101

 TechPub_2614345_0107 - 0601_3057043_01.fm

Flow Chart of Procedures for Changing the Digital Input Module

Change the Digital Input

(Cont'd)
6 Electrical System

No No No
New module with New module with New module with New module with a
same series and same series and old same series and new series and new
same firmware firmware new firmware firmware

Yes Yes Yes Yes

Fit the new module, see Fit the new module, see Fit the new module, see Fit the new module, see
Change the Digital Input Change the Digital Input Change the Digital Input Change the Digital Input
Module on page 6-84 Module on page 6-84 Module on page 6-84 Module on page 6-84

Upgrade the firmware to the

Doc. No. MM-3047612-0101

same revision as the old
module, see 6.1.4-2 Digital
Input Module - Load Firmware
on page 6-86

(Cont'd)

6 - 83 (308)
6.1 PLC (Rockwell)
6.1 PLC (Rockwell) 6 Electrical System

(Cont'd)
Change the Digital Input Module

WARNING
Risk of personal injury.
Make sure that the Mains Power switch is turned to the OFF position, when
disconnect the removable terminal block (2), otherwise an electrical arc can
occur.
a) Lift the locking tab (1) and disconnect the removable terminal block (2).
b) Press the locking tabs on the top and the bottom of the Digital Input
module (3).
c) Slide the Digital Input module (3) out of the chassis. Discard the Digital
Input module (3).

3
1

TechPub_2614345_0107 - 0601_3057043_01.fm

2
1 Locking tab
2 Removable terminal block
3 Digital input module

(Cont'd)

6 - 84 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.1 PLC (Rockwell)

(Cont'd)
d) Align the new Digital Input module (3) with the top and the bottom
guides in the chassis.
e) Slide the Digital Input module (3) into the chassis. Make sure it is flush
with the other modules and the top and bottom latches are engaged.
f) If required lift the locking tab (1) then connect the removable terminal
block (2) to the Digital Input module (3), making sure that the guides (4)
are engaged. At the end lower the locking tab (1).
g) Turn the Mains Power switch to the ON position.
h) Continue with the necessary procedures as described in Change the
Digital Input Module on page 6-84.

3
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4
2
1 Locking tab
2 Removable terminal block
3 Digital input module
4 Guide

Doc. No. MM-3047612-0101 6 - 85 (308)

6.1 PLC (Rockwell) 6 Electrical System

6.1.4-2 Digital Input Module - Load Firmware

Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with CD Drive
Ethernet communication cable, TP No. 351501-0100
Program CD TP No. 2886185-0XXX
SPC Reference 90459-6556

Follow the instructions in 6.1.2-2 CPU Module - Load Firmware on

page 6-36, to load the firmware for the Digital Input module.

TechPub_2614345_0107 - 0601_3057043_01.fm

6 - 86 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

6.2 Distributed I/O

SPC Reference 2867988-0100

6.2-1 Distributed I/O - Description

SPC Reference 2867988-0100

Communication between all the distributed I/O devices in the machine is

provided through a DeviceNet network. DeviceNet is a bi-directional
communications network which allows communication between the
PLC module and distributed I/O devices such as sensors and actuators.
The DeviceNet network on the machine utilizes a master and slave
architecture and the physical network is composed of two trunk lines (1) with
multiple drops (2). Each drop terminates with a slave node (3) and each
sensor or actuator in the machine is connected to a node. The DeviceNet
master (4) is located in the PLC rack serving as a intermediary allowing
direct communication with the CPU module.
MainNetwork
DeviceNet master (4) DeviceNet slave nodes (3)
TechPub_2614345_0107 - 0601_3057044_01.fm

1 Trunk line
2 Drop line
3 Slave node
4 DeviceNet master

(Cont'd)

Doc. No. MM-3047612-0101 6 - 87 (308)

6.2 Distributed I/O 6 Electrical System

(Cont'd)
SubNetwork
Note! The DeviceNet master (1) of the SubNetwork, works as a slave
node (2) of the MainNetwork, see the previous page.

DeviceNet master (1) DeviceNet slave nodes (2)

1 DeviceNet master

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2 Slave node

6 - 88 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

6.2.1 DeviceNet Scanner Module

6.2.1-1 DeviceNet Scanner Module - Change
Machine Status Mains Power OFF
Air OFF
Water OFF
Special Equipment PC with CD Drive
Ethernet communication cable, TP No. 351501-0100
SPC Reference 90459-2479 (Series A/B)
90600-4543 (Series C)
90600-5840 (Series D)

Note! The functionality of the application is not verified when the new
DeviceNet scanner modules have a different firmware revision. Contact the
Machine System Liaison for more information. The correct firmware revision
must be installed to the DeviceNet scanner modules.
Note! The firmware revision of the new DeviceNet scanner module may be
equal to, or newer than the firmware revision of the old DeviceNet scanner
module. Using a newer firmware revision may create errors when going
online, such as unrecognized device or device mismatch, if the PC does not
contain the very latest EDS files.
Note! The functionality of the application is not verified when the new
TechPub_2614345_0107 - 0601_3057044_01.fm

DeviceNet scanner modules have a different series and of consequence

they have a different 90000 TP part number. Contact the Machine System
Liaison for more information.
Preparation
Before changing the DeviceNet scanner module:
• Use the RSLinx Classic program to verify and record the firmware
version of the DeviceNet scanner module.
• Use the Flow Chart of Procedures for Changing the DeviceNet Scanner
Module on the next page to determine which procedures must be
performed and their correct sequence.
(Cont'd)

Doc. No. MM-3047612-0101 6 - 89 (308)

 Flow Chart of Procedures for Changing the DeviceNet Scanner Module

Change the DeviceNet Scanner

module

6 - 90 (308)
(Cont'd)
6.2 Distributed I/O

No No No
New module with New module with New module with New module with a
same series and same series and old same series and new series and new
same firmware firmware new firmware firmware

Yes Yes Yes Yes

Fit the new module, see Change Fit the new module, see Change Fit the new module, see Change Fit the new module, see Change
the DeviceNet Scanner Module the DeviceNet Scanner Module the DeviceNet Scanner Module the DeviceNet Scanner Module
on page 6-91 on page 6-91 on page 6-91 on page 6-91

Set the node address and baud Set the node address and baud Set the node address and baud Set the node address and baud
rate, see 6.2.1-2 DeviceNet rate, see 6.2.1-2 DeviceNet rate, see 6.2.1-2 DeviceNet rate, see 6.2.1-2 DeviceNet
Scanner Module - Set Node Scanner Module - Set Node Scanner Module - Set Node Scanner Module - Set Node
Address and Baud Rate on Address and Baud Rate on Address and Baud Rate on Address and Baud Rate on

Doc. No. MM-3047612-0101

page 6-93 page 6-93 page 6-93 page 6-93

Load the scanner program, see Upgrade the firmware to the Downgrade the firmware to the Load the scanner program, see
6.2.1-4 DeviceNet Scanner same revision as the old module, same revision as the old module, 6.2.1-4 DeviceNet Scanner
Module - Download Program on see 6.2.1-3 DeviceNet Scanner see 6.2.1-3 DeviceNet Scanner Module - Download Program on
page 6-97 Module - Load Firmware on Module - Load Firmware on page 6-97
page 6-96 page 6-96

Load the scanner program, see Load the scanner program, see
6.2.1-4 DeviceNet Scanner 6.2.1-4 DeviceNet Scanner
Module - Download Program on Module - Download Program on
page 6-97 page 6-97

(Cont'd)
6 Electrical System

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 6 Electrical System 6.2 Distributed I/O

(Cont'd)
Change the DeviceNet Scanner Module
a) Remove the cable connector (1) from the DeviceNet scanner module.
b) Press the locking tabs on the top and the bottom of the DeviceNet
scanner module.
c) Slide the DeviceNet scanner module out of the chassis. Discard the
DeviceNet scanner module.

A DeviceNet Scanner Module Series A/B,

is shown
TechPub_2614345_0107 - 0601_3057044_01.fm

1 Cable connector

(Cont'd)

Doc. No. MM-3047612-0101 6 - 91 (308)

6.2 Distributed I/O 6 Electrical System

(Cont'd)
d) Align the new DeviceNet scanner module with the top and the bottom
guides in the chassis.
e) Slide the DeviceNet scanner module into the chassis. Make sure it is
flush with the other modules and the top and bottom latches are engaged.
f) Fit the cable connector (1) to the DeviceNet scanner module.
g) Turn the Mains Power switch to the ON position.
h) Check the status of the DeviceNet scanner module LEDs according to
the table in section 6.2.1-5 DeviceNet Scanner Module - LED
Description on page 6-114.
i) Continue with the necessary procedures as described in Flow Chart of
Procedures for Changing the DeviceNet Scanner Module on page 6-120.

A DeviceNet Scanner Module Series A/B,

is shown

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1

1 Cable connector

6 - 92 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

6.2.1-2 DeviceNet Scanner Module - Set Node Address and

Baud Rate
Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 90459-2479 (Series A/B)
90600-4543 (Series C)
90600-5840 (Series D)

Use the illustration below to identify the series of the DeviceNet Scanner
module installed on the machine, then follow the setting procedure for the
module:
• for DeviceNet Scanner Module with Series A/B see page 6-94
• for DeviceNet Scanner Module with Series C/D see page 6-95.
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Module 1756 DNB Series A/B Module 1756 DNB Series C/D

(Cont'd)

Doc. No. MM-3047612-0101 6 - 93 (308)

6.2 Distributed I/O 6 Electrical System

(Cont'd)
DeviceNet Scanner Module with Series A/B

WARNING
Personnel requirements.
Changing the parameters can effect the machine in unexpected ways. Only
authorized and skilled personnel are allowed to change the parameters.
Note! The push button (1) has two functions; with the network cable
connected, the push button (1) is used to set the node address and with the
network cable disconnected, the push button (1) is used to set the baud
rate. If a fault is made during the setting procedure, remove the module from
the chassis, then fit the module back to the chassis and repeat the setting
procedure.
a) Make sure that the 24 V on the network cable is connected.
b) Push the button (1) and release it when the display (2) shows 00 to set
the node address.
c) Disconnect the network cable with the 24 V.
d) Push the button (1) and release it when the display (2) shows 500 to set
the baud rate.
e) Connect the network cable with the 24 V.

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2

1 Push button
2 Display

(Cont'd)

6 - 94 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)
DeviceNet Scanner Module with Series C/D

WARNING
Personnel requirements.
Changing the parameters can effect the machine in unexpected ways. Only
authorized and skilled personnel are allowed to change the parameters.
Set the switches (1), (2) and (3) according to the table below.

Switch Setting Note

Number Position
1 2 Sets the baud rate to 500 Kbps
2 0 Sets the first digit of the node address
3 0 Sets the second digit of the node address

Top of module
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1 2 3

Front of module

1 Switch for baud rate

2 Switch for node address
3 Switch for node address

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6.2 Distributed I/O 6 Electrical System

6.2.1-3 DeviceNet Scanner Module - Load Firmware

Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with CD Drive
Ethernet communication cable, TP No. 351501-0100
Program CD TP No. 2886185-0XXX
SPC Reference 90459-2479 (Series A/B)
90600-4543 (Series C)
90600-5840 (Series D)

a) Turn the key on the CPU module to the PROG mode position.
b) Follow the instructions in 6.1.2-2 CPU Module - Load Firmware on
page 6-36, to load the firmware for the DeviceNet scanner module.
c) Turn the key on the CPU module to the RUN mode position and then to
the REM mode position.

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6 - 96 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

6.2.1-4 DeviceNet Scanner Module - Download Program

Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with CD Drive
Ethernet communication cable, TP No. 351501-0100
Program CD TP No. 2886185-0XXX
SPC Reference 90459-2479 (Series A/B)
90600-4543 (Series C)
90600-5840 (Series D)

Preparation
Note! Before starting, check the current version of Software installed, see
the Software - Installation List on page 6-248, included in the chapter
6.7.2-1 HMI Installation List - Check Version of Software and Firmware
Installed.
Note! To connect to the CPU module using an ethernet communication
cable, the PC must first be configured for this type of communication. See
6.1.1-1 Preparation for PLC Communication - Configure PC Network
Communications on page 6-7 and 6.1.1-2 Preparations for PLC
Communication - Configure RSLinx on page 6-17 for more details.
(Cont'd)
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Doc. No. MM-3047612-0101 6 - 97 (308)

6.2 Distributed I/O 6 Electrical System

(Cont'd)
a) Set the address and baud rate for the DeviceNet scanner module, see
6.2.1-2 DeviceNet Scanner Module - Set Node Address and Baud Rate
on page 6-93.
b) Connect the ethernet communication cable between a vacant connection
port on the ethernet switch (1) and the PC (2).
Note! The DeviceNet scanner module that is being loaded must not be in
RUN position for the program load.
c) Turn the key on the CPU module to the PROG mode position.
d) Insert the program CD into the PC CD drive.
e) Browse to the CD drive and copy the program file included in the folder
2886192-1XXX to the PC desktop.

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2

1 Ethernet switch
2 PC

(Cont'd)

6 - 98 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)
f) Double click on the program file to automatically start the RSNetWorx
program and to open the program file.
g) Select the NETWORK menu (3) and then select ONLINE (4).

3 4

3 Network menu
4 Online
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(Cont'd)

Doc. No. MM-3047612-0101 6 - 99 (308)

6.2 Distributed I/O 6 Electrical System

(Cont'd)
h) Browse the network and select the DeviceNet MainNetwork (5), then
select the OK button (6).

TechPub_2614345_0107 - 0601_3057044_01.fm
6
5 DeviceNet, MainNetwork
6 OK button

(Cont'd)

6 - 100 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)
i) Check the MainNetwork, if no FIRMWARE MISMATCH symbols (7)
are displayed on the various modules, then continue with Download
Program on page 6-113, otherwise continue as follows on the next pages.

7
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7 Firmware mismatch symbol

(Cont'd)

Doc. No. MM-3047612-0101 6 - 101 (308)

6.2 Distributed I/O 6 Electrical System

(Cont'd)
j) If a FIRMWARE MISMATCH symbol (7) is displayed on a
PowerFlex 40 (8), double click on the module to open the DEVICE
MISMATCH DIALOG window, otherwise continue from the next page.
k) If the MAJOR FIRMWARE release (9) of the module, does not match the
MAJOR FIRMWARE release (10) in the project (Offline Firmware
release), then continue from Solve Firmware Mismatch - Type 1 on
page 6-104; otherwise continue from Solve Firmware Mismatch - Type 2
on page 6-110.

TechPub_2614345_0107 - 0601_3057044_01.fm
7 Firmware mismatch
symbol
8 Powerflex 40
9 Major firmware release
(module)
10 Major firmware release
(project)

9 10
(Cont'd)

6 - 102 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)
l) If a FIRMWARE MISMATCH symbol (7) is displayed on one of the
others modules: the DeviceNet Master (11), the Armorblock (12) or the
DeviceNet Slave (13), then continue from Solve Firmware Mismatch -
Type 2 on page 6-110.

11

12
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13
7 Firmware mismatch symbol
11 Devicenet master
12 Armorblock
13 Devicenet slave

(Cont'd)

Doc. No. MM-3047612-0101 6 - 103 (308)

6.2 Distributed I/O 6 Electrical System

(Cont'd)
Solve Firmware Mismatch - Type 1
Note! The following instructions are valid only for PowerFlex PF40 with
different Major Firmware Revision.
If any of the PowerFlex PF40 has a Major Firmware release of the module,
that does not match the Major Firmware release in the project, the
FIRMWARE MISMATCH symbol (1) appears on the module, and the Identity
Mismatch message for the node is displayed.
In this case the module configuration (i.e. parameters, settings and in case of
ADN scanner also the scan list) are not downloaded to the module, until the
mismatch is solved and a new download is performed. The parameters of the
inverter have to be introduced manually.
a) Solve the Firmware mismatch for each PowerFlex PF40 module, by
repeating the following instructions:
• double click on the FIRMWARE MISMATCH symbol (1) of a module

TechPub_2614345_0107 - 0601_3057044_01.fm

1 Firmware mismatch symbol

(Cont'd)

6 - 104 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)
• when the DEVICE MISMATCH DIALOG window (2) appears, read
carefully what reported and follow the instructions, then select the OK
button (3)
Note! If a module has a Firmware release (RSNetworx reports online the
Firmware release), that is older than the Firmware release in the project
(Offline Firmware release), then it is strongly recommended to substitute the
module with one having the latest Firmware release.

2
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3
2 Device mismatch dialog window
3 OK button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 105 (308)

6.2 Distributed I/O 6 Electrical System

(Cont'd)
• when the RESOLVE DEVICE MISMATCH window (4) appears, select
the CANCEL button (5)

4 5

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4 Resolve device mismatch window
5 Cancel button

(Cont'd)

6 - 106 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)
• when the DEVICE window (6) appears, select the PARAMETERS tab (7)

7 6
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6 Device window
7 Parameters tab

(Cont'd)

Doc. No. MM-3047612-0101 6 - 107 (308)

6.2 Distributed I/O 6 Electrical System

(Cont'd)
• when the EDS EDITOR window (8) appears, select the DOWNLOAD
button (9) and wait until the downloading is finished

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8 EDS editor window
9 Download button

(Cont'd)

6 - 108 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)
• select the OK button (10).
b) Continue from Download Program on page 6-113.
TechPub_2614345_0107 - 0601_3057044_01.fm

10
10 OK button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 109 (308)

6.2 Distributed I/O 6 Electrical System

(Cont'd)
Solve Firmware Mismatch - Type 2
Note! The following instructions are valid for PowerFlex PF40 with the same
Major Firmware Revision and all the other modules of the MainNetwork.
If any of the modules has a Firmware release, that differs from the project
online, the FIRMWARE MISMATCH symbol (1) appears on the module, and
the Identity Mismatch message for the node is displayed.
In this case the module configuration (i.e. parameters, settings and in case of
ADN scanner also the scan list) are not downloaded to the module, until the
mismatch is solved and a new download is performed.
a) Solve the Firmware mismatch for each module, by repeating the
following instructions:
• double click on the FIRMWARE MISMATCH symbol (1) of a module

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1 Firmware mismatch symbol

(Cont'd)

6 - 110 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)
• when the DEVICE MISMATCH DIALOG window (2) appears, read
carefully what reported and follow the instructions, then select the OK
button (3)
Note! If a module has a Firmware release (RSNetworx reports online the
Firmware release), that is older than the Firmware release in the project
(Offline Firmware release), then it is strongly recommended to substitute the
module with one having the latest Firmware release.

2
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3
2 Device mismatch dialog window
3 OK button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 111 (308)

6.2 Distributed I/O 6 Electrical System

(Cont'd)
• when the DEVICE window (4) appears, select the OK button (5).
b) Continue from Download Program on page 6-113.

TechPub_2614345_0107 - 0601_3057044_01.fm
5
4 Device window
5 OK button

(Cont'd)

6 - 112 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)
Download Program
a) Highlight the DeviceNet scanner (1) and right click the PC mouse, select
DOWNLOAD TO DEVICE (2) to start the download.
b) When the dialogue box (3) appears, select the YES button (4) to
continue.
c) When the download is complete, close the RSNetWorx program.
d) Turn the key on the CPU module to the RUN mode position and then to
the REM mode position.

1
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2 3

1 Devicenet scanner
2 Download to device
4
3 Dialogue box
4 Yes button

Doc. No. MM-3047612-0101 6 - 113 (308)

6.2 Distributed I/O 6 Electrical System

6.2.1-5 DeviceNet Scanner Module - LED Description

Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 90459-2479 (Series A/B)
90600-4543 (Series C)
90600-5840 (Series D)

LED Colour Description

MOD/NET (1) Off Scanner is not online.
The scanner has not completed the
Dup_MAC_ID test or the device is not powered
Solid green Scanner is operating normally and is online with
connections established
Flashing green Scanner is operating normally and is online but
with NO connections established. The Scanner
has passed the Dup_MAC_ID test but has NO
established connections to other Nodes
Flashing red Recoverable fault and/or one or more I/O
connection in timed out state
Solid red Scanner has an unrecoverable fault and made

TechPub_2614345_0107 - 0601_3057044_01.fm
need to be replaced.
Failed communication device.
The Scanner has detected an error (duplicate
MAC ID or bus-off) that has rendered it
incapable of communicating on the network

1 MOD/NET LED

(Cont'd)

6 - 114 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)

LED Colour Description

I/O (2) Off Scanner is not online
Solid green Scanner is in RUN mode, outputs are under
control and inputs are being consumed
Flashing green Scanner is in IDLE mode, outputs are not under
control and inputs are being consumed
OK (3) Off No power applied to the scanner.
Apply chassis power. Verify module is
completely inserted into chassis and backplane
Solid green Scanner is operating normally. The scanner is
connected to at least one CPU module
Flashing green Stand-by mode. The scanner is operating
correctly, however no CPU module is controlling
the scanner. Verify the scanner is correctly
configured in the CPU module I/O configuration
Solid red The scanner has an unrecoverable fault; change
the device or the scanner is in self test during
power up; wait until self test has finished
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2 I/O LED
3 OK LED

Doc. No. MM-3047612-0101 6 - 115 (308)

6.2 Distributed I/O 6 Electrical System

6.2.1-6 DeviceNet Scanner Module - Error Codes

Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with CD Drive
Ethernet communication cable, TP No. 351501-0100
SPC Reference 90459-2479 (Series A/B)
90600-4543 (Series C)
90600-5840 (Series D)

During normal operation the display (1) toggles between displaying the node
address of the DeviceNet scanner module and the current operating mode.
When an error occurs, the display (1) toggles between displaying the node
address of the DeviceNet scanner module followed by the node address of
the device from where the error originated and finally the error code.
Refer to the error codes table below to identify error code and the corrective
actions.

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Error code Description Action
70 Scanner failed Duplicate Node Change the scanner address to
Address check the correct node address A#00
71 Illegal data in scan list table Reconfigure the scan list table
(node number alternately and remove any illegal data
flashes)
72 Slave device stopped Inspect the slave devices and
communicating (node number verify the connections
alternately flashes)
73 Device’s identity information Verify that the correct device is at
does not match electronic key this node number. Make sure
in scan list table entry (node that the device at the scrolling
number alternately flashes) node address matches the
desired electronic key (vendor,
product code, product type, etc.)

(Cont'd)

6 - 116 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)

Error code Description Action

74 Data overrun on port detected Modify your configuration and
check for invalid data.
Check network communication
traffic
75 No traffic detected on network Check the network configuration
76 No direct network traffic for None. The scanner hears other
scanner detected network communication but none
for itself
77 Data size expected by the Reconfigure the module for the
device does not match scan correct transmit and receive data
list entry (node number sizes
alternately flashes)
78 Slave device in scan list table Add the device to the network or
does not exist (node number delete the scan list entry for that
alternately flashes) device
79 Scanner has failed to transmit Make sure the module is
a message connected to the network.
Check for disconnected cables
80 Scanner is in IDLE mode Put the module in run mode.
Enable RUN bit in Module
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Command Register
81 Scanner is in FAULT mode Check Module Command
Register for FAULT bit set
82 Error detected in sequence of Check scan list table entry for
fragmented I/O messages from slave device
device (node number
alternately flashes)
83 Slave device is returning error Check accuracy of scan list table
responses when scanner entry. Check slave device
attempts to communicate with configuration. Slave device may
it (node number alternately be in another master’s scan list.
flashes) Reboot slave device
84 Scanner is initializing the None.
DeviceNet network. This code clears itself once
scanner attempts to initialize all
devices on the network
85 Data size was incorrect for this Slave device is transmitting
device at runtime. incorrect length data. Try
replacing slave device
86 Device is producing zero Check device configuration and
length data (idle state) while slave node status
scanner is in RUN mode.

(Cont'd)

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6.2 Distributed I/O 6 Electrical System

(Cont'd)

Error code Description Action

90 User has disabled Check Module Command
communication port. Register for DISABLE bit set
91 Bus-off condition detected con Check DeviceNet connections
comm. port. Scanner is and physical media integrity.
detecting communication Check system for failed slave
errors. devices or other possible
sources of network interference
92 No network power detected on Provide network power. Make
communication port. sure that module drop cable is
proving network power to
scanner communication port
95 Application FLASH update in None.
progress. Do not disconnect the module
while application flash is in
progress.
If this is done existing data in the
scanner’s memory will be lost.
97 Scanner halted by user Check Module Command
command. Register for HALT bit set
98 General firmware error. Replace module

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A#00 Normal operation. No action
to The numeric display matches
A#63 the scanners node address on
the DeviceNet network.
IDLE Scanner is in IDLE mode. Put the CPU module in RUN
mode.
Enable RUN bit in Module
Command Register
Network User has disabled Reconfigure the module.
Disabled communication port. Check Module Command
Register
No Network No network power detected on Provide network power. Make
Power communication port. sure that module drop cable is
proving network power to
scanner communication port
NoRX No scan list is active in the Enter a scan list. Check
module or no messages have DeviceNet connection on front of
been received by the scanner. module
NoTX No direct network traffic for None.
scanner device. The scanner hears other network
communication

6 - 118 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

6.2.2 DeviceNet Point I/O Adapter

6.2.2-1 DeviceNet Point I/O Adapter - Change
Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with CD Drive
Ethernet communication cable, TP No. 351501-0100
SPC Reference 90459-2494

Note! The DeviceNet Point I/O adapters are not supposed to be flashed.
Note! The firmware revision of the new DeviceNet Point I/O adapter may be
equal to, or newer than the firmware revision of the old DeviceNet Point I/O
adapter. Using a newer firmware revision may create errors when going
online, such as unrecognized device or device mismatch, if the PC does not
contain the very latest EDS files.
Note! The functionality of the application is not verified when the new
DeviceNet Point I/O adapters have a different series and of consequence
they have a different 90000 TP part number. Contact the Machine System
Liaison for more information.
Preparation
TechPub_2614345_0107 - 0601_3057044_01.fm

Before changing the DeviceNet Point I/O adapter:

• Use the RSLinx Classic program to verify and record the firmware
version of the DeviceNet Point I/O adapter.
• Verify and record the node address of the DeviceNet Point I/O adapter.
• Use the Flow Chart of Procedures for Changing the DeviceNet Point I/O
Adapter on the next page to determine which procedures must be
performed and their correct sequence.
(Cont'd)

Doc. No. MM-3047612-0101 6 - 119 (308)

 Flow Chart of Procedures for Changing the DeviceNet Point I/O Adapter

Change the DeviceNet Point I/O

adapter
(Cont'd)

6 - 120 (308)
6.2 Distributed I/O

No No No
New adapter with New adapter with New adapter with New adapter with a
same series and same series and old same series and new series and new
same firmware firmware new firmware firmware

Yes Yes Yes Yes

Fit the new adapter, see Change Fit the new adapter, see Change Fit the new adapter, see Change Fit the new adapter, see Change
the DeviceNet Point I/O Adapter the DeviceNet Point I/O Adapter the DeviceNet Point I/O Adapter the DeviceNet Point I/O Adapter
on page 6-121 on page 6-121 on page 6-121 on page 6-121

Set the node address, see Set the node address, see Set the node address, see Set the node address, see
6.2.2-2 DeviceNet Point I/O 6.2.2-2 DeviceNet Point I/O 6.2.2-2 DeviceNet Point I/O 6.2.2-2 DeviceNet Point I/O
Adapter - Set Node Address on Adapter - Set Node Address on Adapter - Set Node Address on Adapter - Set Node Address on

Doc. No. MM-3047612-0101

page 6-123 page 6-123 page 6-123 page 6-123

Load the scanner program, see Load the scanner program, see Load the scanner program, see Load the scanner program, see
6.2.2-3 DeviceNet Point I/O 6.2.2-3 DeviceNet Point I/O 6.2.2-3 DeviceNet Point I/O 6.2.2-3 DeviceNet Point I/O
Adapter - Download Program on Adapter - Download Program on Adapter - Download Program on Adapter - Download Program on
page 6-124 page 6-124 page 6-124 page 6-124

(Cont'd)
6 Electrical System

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 6 Electrical System 6.2 Distributed I/O

(Cont'd)
Change the DeviceNet Point I/O Adapter
a) Remove the power connector (1).
b) Remove the cable connector (2).
c) Remove the first point I/O slice (3).
TechPub_2614345_0107 - 0601_3057044_01.fm

2 1
1 Power connector
2 Cable connector
3 Point I/O slice

(Cont'd)

Doc. No. MM-3047612-0101 6 - 121 (308)

6.2 Distributed I/O 6 Electrical System

(Cont'd)
d) Turn the screw (4) to release the Point I/O adapter (5) and slide out the
adapter. Discard the Point I/O adapter (5).
e) Remove the blank connectors and the cover plate from the new adapter.
f) Fit the new adapter and turn the screw (4).
g) Fit the point I/O slice (3).
h) Fit the cable connector (2).
i) Fit the power connector (1).
j) Continue with the necessary procedures as described in Flow Chart of
Procedures for Changing the DeviceNet Point I/O Adapter on
page 6-120.

TechPub_2614345_0107 - 0601_3057044_01.fm
5

4 1 3

1 Power connector 4 Screw

2 2 Cable connector 5 Point I/O module
3 Point I/O slice

6 - 122 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

6.2.2-2 DeviceNet Point I/O Adapter - Set Node Address

Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 90459-2494

Note! For this type of adapter the baud rate is set automatically.
Use the push buttons (1) to set the node address at 01, for the Point I/O
adapter.

1
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1 Push button

Doc. No. MM-3047612-0101 6 - 123 (308)

6.2 Distributed I/O 6 Electrical System

6.2.2-3 DeviceNet Point I/O Adapter - Download Program

Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with CD Drive
Ethernet communication cable, TP No. 351501-0100
Program CD TP No. 2886185-0XXX
SPC Reference 90459-2494

Note! Before starting, check the current version of Software installed, see
the Software - Installation List on page 6-248, included in the chapter
6.7.2-1 HMI Installation List - Check Version of Software and Firmware
Installed.
Note! To connect to the CPU module using an ethernet communication
cable, the PC must first be configured for this type of communication. See
6.1.1-1 Preparation for PLC Communication - Configure PC Network
Communications on page 6-7 and 6.1.1-2 Preparations for PLC
Communication - Configure RSLinx on page 6-17 for more details.
(Cont'd)

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6 - 124 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)
a) Set the node address for the DeviceNet Point I/O adapter, see 6.2.2-2
DeviceNet Point I/O Adapter - Set Node Address on page 6-123.
b) Connect the ethernet communication cable between a vacant connection
port on the ethernet switch (1) and the PC (2).
Note! The DeviceNet scanner module must not be in RUN position for the
program load.
c) Turn the key on the CPU module to the PROG mode position.
d) Insert the program CD into the PC CD drive.
e) Browse to the CD drive and copy the program file included in the folder
2886192-1XXX to the PC desktop.

1
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1 Ethernet switch
2 PC

(Cont'd)

Doc. No. MM-3047612-0101 6 - 125 (308)

6.2 Distributed I/O 6 Electrical System

(Cont'd)
f) Double click on the program file to automatically start the RSNetWorx
program and to open the program file.
g) Select the NETWORK menu (3) and then select ONLINE (4).

3 4

3 Network menu
4 Online

TechPub_2614345_0107 - 0601_3057044_01.fm
(Cont'd)

6 - 126 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)
h) Browse the network and select the DeviceNet SubNetwork (5), then
select the OK button (6).
TechPub_2614345_0107 - 0601_3057044_01.fm

6
5 DeviceNet, SubNetwork
6 OK button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 127 (308)

6.2 Distributed I/O 6 Electrical System

(Cont'd)
i) If the FIRMWARE MISMATCH symbol (7) appears on some modules, as
indicated below with arrows, then perform the instructions Solve
Firmware Mismatch on page 6-129, otherwise continue with the
instruction:
• Download Program - Procedure for Output Point I/O Slices on
page 6-132, only if one or more Output Point I/O Slices have been
replaced
or
• Download Program - Standard Procedure on page 6-139.

TechPub_2614345_0107 - 0601_3057044_01.fm
7 Firmware mismatch symbol

(Cont'd)

6 - 128 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)
Solve Firmware Mismatch
If any of the modules has a Firmware release, that differs from the project
online, the FIRMWARE MISMATCH symbol (1) appears on the module, and
the Identity Mismatch message for the node is displayed.
In this case the module configuration (i.e. parameters, settings and in case of
ADN scanner also the scan list) are not downloaded to the module, until the
mismatch is solved and a new download is performed.
Note! In case a Firmware mismatch is detected on the ADN, then it is
MANDATORY to solve it, before solving any of the other Firmware
mismatches eventually detected on the Point I/O slices.
a) Solve the Firmware mismatch for each module, by repeating the
following instructions:
• double click on the FIRMWARE MISMATCH symbol (1) of a module

1
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1 Firmware mismatch symbol

(Cont'd)

Doc. No. MM-3047612-0101 6 - 129 (308)

6.2 Distributed I/O 6 Electrical System

(Cont'd)
• when the DEVICE MISMATCH DIALOG window (2) appears, read
carefully what reported and follow the instructions, then select the OK
button (3)
Note! If a module has a Firmware release (RSNetworx reports online the
Firmware release), that is older than the Firmware release in the project
(Offline Firmware release), then it is strongly recommended to substitute the
module with one having the latest Firmware release.

TechPub_2614345_0107 - 0601_3057044_01.fm
3
2 Device mismatch dialog window
3 OK button

(Cont'd)

6 - 130 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)
• when the DEVICE window (4) appears, select the OK button (5).
b) Continue with the instruction:
• Download Program - Procedure for Output Point I/O Slices on the next
page, only if one or more Output Point I/O Slices have been replaced
or
• Download Program - Standard Procedure on page 6-139.

4
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5
4 Device window
5 OK button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 131 (308)

6.2 Distributed I/O 6 Electrical System

(Cont'd)
Download Program - Procedure for Output Point I/O Slices
Note! Perform these instructions, only if one or more Output Point I/O Slices
have been replaced.
a) Highlight the DeviceNet Point I/O adapter (1) and right click the PC
mouse, then select CLASS INSTANCE EDITOR (2).
b) When the dialogue box (3) appears, select the YES button (4) to
continue.

TechPub_2614345_0107 - 0601_3057044_01.fm
3

1 DeviceNet Point I/O adapter

2 Class instance editor
3 Dialogue box
4
4 Yes button

(Cont'd)

6 - 132 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)
c) Scroll and select RESET (5).

5
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5 Reset

(Cont'd)

Doc. No. MM-3047612-0101 6 - 133 (308)

6.2 Distributed I/O 6 Electrical System

(Cont'd)
d) Select the EXECUTE button (6).

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6 Execute button

(Cont'd)

6 - 134 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)
e) Do not care about the message displayed and select the CLOSE
button (7).
TechPub_2614345_0107 - 0601_3057044_01.fm

7
7 Close button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 135 (308)

6.2 Distributed I/O 6 Electrical System

(Cont'd)
f) Repeat the following instructions for each Output Point I/O Slice that
has been replaced:
• highlight the Output Point I/O Slice (8) and right click the PC mouse,
then select DOWNLOAD TO DEVICE (9) to start the download
procedure
• when the dialogue box (10) appears, select the YES button (11) to
continue.

TechPub_2614345_0107 - 0601_3057044_01.fm
10 9

8 Output Point I/O slice

9 Download to device
10 Dialogue box 11
11 Yes button

(Cont'd)

6 - 136 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)
g) From the FILE menu (12), select EXIT (13).
h) In the dialogue box (14), select the NO button (15).

12

13
TechPub_2614345_0107 - 0601_3057044_01.fm

14

12 File menu
13 Exit
14 Dialogue box 15
15 NO button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 137 (308)

6.2 Distributed I/O 6 Electrical System

(Cont'd)
i) Double click on the program file to automatically start the RSNetWorx
program and to open the program file.
j) Select the NETWORK menu (16) and then select ONLINE (17).
k) Continue with Download Program - Standard Procedure on the next
page.

16 17

16 Network menu

TechPub_2614345_0107 - 0601_3057044_01.fm
17 Online

(Cont'd)

6 - 138 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)
Download Program - Standard Procedure
a) Highlight the DeviceNet Point I/O adapter (1) and right click the PC
mouse, then select DOWNLOAD TO DEVICE (2) to start the download
procedure.
b) When the dialogue box (3) appears, select the YES button (4) to
continue.
c) When the download is complete, close the RSNetWorx program.
d) Turn the key on the CPU module to the RUN mode position and then to
the REM mode position.

1
TechPub_2614345_0107 - 0601_3057044_01.fm

2 3

1 DeviceNet Point I/O adapter

2 Download to device
4
3 Dialogue box
4 Yes button

Doc. No. MM-3047612-0101 6 - 139 (308)

6.2 Distributed I/O 6 Electrical System

6.2.2-4 DeviceNet Point I/O Adapter - LED Description

Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 90459-2494

LED Colour Description

Adapter Off No power is applied to the device.
status (1) Solid green Device is operating normally.
Flashing green Device needs to be commissioned because
configuration is missing, incomplete or incorrect.
Flashing red Recoverable fault is present.
Solid red Unrecoverable fault may require the adapter to
be changed.
Flashing red/ Device is in self-test
green

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1 Adapter status LED

(Cont'd)

6 - 140 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)

LED Colour Description

DeviceNet Off Device is not online:
status (2) - the device is autobauding.
- the device has not completed the dup_MAC_id
test.
Check the adapter status indicator to determine
if more time is required to complete the
dup_MAC_id test or if power is required at the
module.
Solid green Device is online and has connections in the
established state
Flashing green Device is online but has no connections in the
established state
Flashing red 1 or more I/O connections are in a timed-out
state.
Determine the cause of the time-out. An
increase in packet rate may be required.
Solid red Critical link failure - communication device failed.
Device detected error that prevents it from
communicating on the network.
Make sure the device is using the correct MAC
ID and baud rate.
TechPub_2614345_0107 - 0601_3057044_01.fm

2 DeviceNet status LED

(Cont'd)

Doc. No. MM-3047612-0101 6 - 141 (308)

6.2 Distributed I/O 6 Electrical System

(Cont'd)

LED Colour Description

PointBus Off Device is not online:
status (3) - the device is autobauding.
- the device has not completed the dup_MAC_id
test.
Check the adapter status indicator to determine
if more time is required to complete the
dup_MAC_id test or if power is required at the
module.
Solid green Device is online and has connections in the
established state
Flashing green Device is online but has no connections in the
established state
Flashing red No scan list is available. I/O module is missing.
Make sure all I/O modules are connecting and
using the correct MAC ID’s.
Check the “Cycling Node Status” parameter in
RSNetWorx for DeviceNet.
Solid red Critical link failure - communication device failed.
Device detected error that prevents it from
communicating on the network.
Make sure an I/O module is not using the MAC

TechPub_2614345_0107 - 0601_3057044_01.fm
ID = 0. Make sure all backplane modules are
connecting at the correct baud rate.

3 PointBus status LED

(Cont'd)

6 - 142 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)

LED Colour Description

System Off Field power is OFF. DC-DC converter problem.
power (4) Check adapter configuration. Turn the Field
power ON.
Solid green System power is ON. DC-DC converter is
active (5V)
Field Off Check adapter configuration. Turn the Field
power (5) power ON.
Solid green Power is ON with 24V present.

4
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4 System power
5 Field power

Doc. No. MM-3047612-0101 6 - 143 (308)

6.2 Distributed I/O 6 Electrical System

6.2.3 DeviceNet Point I/O Module

6.2.3-1 DeviceNet Point I/O Module - Change
Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with CD Drive
Ethernet communication cable, TP No. 351501-0100
SPC Reference 90459-2503 (Input)
90459-2505 (Output)
90459-2512 (Thermocouple)

Note! The DeviceNet Point I/O modules are not supposed to be flashed.
Note! The firmware revision of the new DeviceNet Point I/O module may be
equal to, or newer than the firmware revision of the old DeviceNet Point I/O
modules. Using a newer firmware revision may create errors when going
online, such as unrecognized device or device mismatch, if the PC does not
contain the very latest EDS files.
Note! The functionality of the application is not verified when the new
DeviceNet Point I/O modules have a different series and of consequence
they have a different 90000 TP part number. Contact the Machine System
Liaison for more information.

TechPub_2614345_0107 - 0601_3057044_01.fm
Preparation
Before changing the DeviceNet Point I/O modules:
• Use the RSLinx Classic program to verify and record the firmware
version of the DeviceNet Point I/O modules.
• Verify and record the node address of the DeviceNet Point I/O modules.
• Use the Flow Chart of Procedures for Changing the DeviceNet Point I/O
Module on the next page to determine which procedures must be
performed and their correct sequence.
(Cont'd)

6 - 144 (308) Doc. No. MM-3047612-0101

 TechPub_2614345_0107 - 0601_3057044_01.fm

Flow Chart of Procedures for Changing the DeviceNet Point I/O Module

Change the DeviceNet Point I/O

module
(Cont'd)
6 Electrical System

No No No
New module with New module with New module with New module with a
same series and same series and old same series and new series and new
same firmware firmware new firmware firmware

Yes Yes Yes Yes

Fit the new module, see Fit the new module, see Fit the new module, see Fit the new module, see
Change the DeviceNet Point Change the DeviceNet Point Change the DeviceNet Point Change the DeviceNet Point
I/O Module on page 6-146 I/O Module on page 6-146 I/O Module on page 6-146 I/O Module on page 6-146

Doc. No. MM-3047612-0101

(Cont'd)

6 - 145 (308)
6.2 Distributed I/O
6.2 Distributed I/O 6 Electrical System

(Cont'd)
Change the DeviceNet Point I/O Module
Lower the locking tab (1) of the power connector (2) in order to remove and
replace the point I/O module (3).

TechPub_2614345_0107 - 0601_3057044_01.fm
1

2 3
1 Locking tab
2 Power connector
3 Point I/O module

6 - 146 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

6.2.3-2 DeviceNet Point I/O Module - LED Description

Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 90459-2503 (Input)
90459-2505 (Output)
90459-2512 (Thermocouple)

Note! The module and network status LED descriptions are the same for all
types of DeviceNet Point I/O modules, see the following pages for module
specific LED descriptions.
Module and Network Status LEDS
LED Colour Description
Module Green Device operating normally
status (1) Flashing Device needs commissioning due to
Green configuration missing, incomplete or incorrect
Flashing Red Recoverable fault
Red Unrecoverable fault may require device
replacement
Flashing Red/ Device is in self-test
Green
TechPub_2614345_0107 - 0601_3057044_01.fm

1 Module status LED

(Cont'd)

Doc. No. MM-3047612-0101 6 - 147 (308)

6.2 Distributed I/O 6 Electrical System

(Cont'd)

LED Colour Description

Network Off Device is not on-line
status (2) - Device has not completed dup_MAC_id test.
- Device not powered - check module status
indicator
Flashing Device is on-line but has no connections in the
Green established state
Green Device on-line and has connections in the
established state
Flashing Red One or more I/O connections in timed-out state
Red Critical link failure - failed communication device.
Device detected error that prevents it
communicating on the network
Flashing Red/ Communication faulted device - the device has
Green detected a network access error and is in
communication faulted state. Device has
received and accepted an Identify
Communication Faulted Request - long protocol
message

TechPub_2614345_0107 - 0601_3057044_01.fm
2

2 Network status LED

(Cont'd)

6 - 148 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)
Digital Input Module
LED Colour Description
Input Off Input is in the off-state
status (1) Yellow Input is in the on-state

1
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1 Input status LED

(Cont'd)

Doc. No. MM-3047612-0101 6 - 149 (308)

6.2 Distributed I/O 6 Electrical System

(Cont'd)
Digital Output Module
LED Colour Description
Output Off All outputs are inactive
status (1) Yellow One or more output is active and under control
Flashing red Open circuit detected - no load (Off-state only).
Connect load or disable no load detection
Solid Red Short circuit detected (On-state only). Remove
short or overloaded circuit

TechPub_2614345_0107 - 0601_3057044_01.fm
1

1 Output Status LED

(Cont'd)

6 - 150 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)
Thermocouple Module
LED Colour Description
Thermocouple Off Module in CAL mode
input Solid Green Normal (channel scanning inputs)
status (1)
Flashing Channel being calibrated
Green
Solid Red Major channel fault
Flashing Red Channel at end of range (over or under)
TechPub_2614345_0107 - 0601_3057044_01.fm

1 Thermocouple input status LED

Doc. No. MM-3047612-0101 6 - 151 (308)

6.2 Distributed I/O 6 Electrical System

6.2.4 DeviceNet PowerFlex Adapter

6.2.4-1 DeviceNet PowerFlex Adapter - Change
Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with CD Drive
Ethernet communication cable, TP No. 351501-0100
SPC Reference 90459-2614

Note! The DeviceNet PowerFlex adapters are not supposed to be flashed.

Note! The firmware revision of the new DeviceNet PowerFlex adapter may
be equal to, or newer than the firmware revision of the old DeviceNet
PowerFlex adapter. Using a newer firmware revision may create errors
when going online, such as unrecognized device or device mismatch, if the
PC does not contain the very latest EDS files.
Note! The functionality of the application is not verified when the new
DeviceNet PowerFlex adapters have a different series and of consequence
they have a different 90000 TP part number. Contact the Machine System
Liaison for more information.
Preparation

TechPub_2614345_0107 - 0601_3057044_01.fm
Before changing the DeviceNet PowerFlex adapter:
• Use the RSLinx Classic program to verify and record the firmware
version of the DeviceNet PowerFlex adapter.
• Verify and record the node address of the DeviceNet PowerFlex adapter.
• Use the Flow Chart of Procedures for Changing the DeviceNet
PowerFlex Adapter on the next page to determine which procedures
must be performed and their correct sequence.
(Cont'd)

6 - 152 (308) Doc. No. MM-3047612-0101

 TechPub_2614345_0107 - 0601_3057044_01.fm

Flow Chart of Procedures for Changing the DeviceNet PowerFlex Adapter

Change the DeviceNet PowerFlex

adapter
(Cont'd)
6 Electrical System

No No No
New adapter with New adapter with New adapter with New adapter with a
same series and same series and old same series and new series and new
same firmware firmware new firmware firmware

Yes Yes Yes Yes

Fit the new adapter, see Change Fit the new adapter, see Change Fit the new adapter, see Change Fit the new adapter, see Change
the DeviceNet PowerFlex the DeviceNet PowerFlex the DeviceNet PowerFlex the DeviceNet PowerFlex
Adapter on page 6-154 Adapter on page 6-154 Adapter on page 6-154 Adapter on page 6-154

Set the node address, see Set the node address, see Set the node address, see Set the node address, see
6.2.4-2 DeviceNet PowerFlex 6.2.4-2 DeviceNet PowerFlex 6.2.4-2 DeviceNet PowerFlex 6.2.4-2 DeviceNet PowerFlex

Doc. No. MM-3047612-0101

Adapter - Set on page 6-155 Adapter - Set on page 6-155 Adapter - Set on page 6-155 Adapter - Set on page 6-155

(Cont'd)

6 - 153 (308)
6.2 Distributed I/O
6.2 Distributed I/O 6 Electrical System

(Cont'd)
Change the DeviceNet PowerFlex Adapter
a) Remove the cover (1) from the front of the PowerFlex drive (2).
b) Disconnect the devicenet cable (3) and the internal interface cable (4)
from the adapter (5).
c) Press the clips (6) and pull out the adapter (5) from the cover (1).
d) Fit the new adapter and assemble in the reverse order.
e) Continue with the necessary procedures as described in Flow Chart of
Procedures for Changing the DeviceNet PowerFlex Adapter on
page 6-153.

TechPub_2614345_0107 - 0601_3057044_01.fm
1

1 Cover
2 PowerFlex drive 4 6
3 DeviceNet cable
4 Internal interface cable
5 Adapter 5
6 Clip
3

6 - 154 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

6.2.4-2 DeviceNet PowerFlex Adapter - Set

Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 90459-2614

For each adapter from (1) to (7), corresponds a node address and a function,
according to the table below:

Adapter Node address Function

Position (1) 20 Infeed conveyor
Position (2) 21 Infeed belt brake
Position (3) 22 Divider conveyor
Position (4) 23 Accumulation conveyor
Position (5) 24 Grouping conveyor
Position (6) 26 Feeder belt
Position (7) 27 External discharge conveyor
TechPub_2614345_0107 - 0601_3057044_01.fm

1
3
4
5
6
7

1 Adapter (Node 20)

2 Adapter (Node 21)
3 Adapter (Node 22)
4 Adapter (Node 23)
5 Adapter (Node 24)
6 Adapter (Node 26)
7 Adapter (Node 27)
2
(Cont'd)

Doc. No. MM-3047612-0101 6 - 155 (308)

6.2 Distributed I/O 6 Electrical System

(Cont'd)
Set Node Address and Baud Rate
The F/C switches (9) under each frequency converter front cover (8) are used
to set the node address and the baud rate of the DeviceNet PowerFlex
adapter.

The F/C switches 1-6 determine the node address and the F/C switches 7
and 8 determine the baud rate.
Note! See the previous page, for the location of the adapters from (1) to (7).
Set the F/C switches (9) for all the adapters according to the table below:

Adapter Switch Switch Switch Switch Switch Switch Switch Switch

No. 1 No. 2 No. 3 No. 4 No. 5 No. 6 No. 7 No. 8
Position (1) DOWN DOWN UP DOWN UP DOWN DOWN UP
Position (2) UP DOWN UP DOWN UP DOWN DOWN UP
Position (3) DOWN UP UP DOWN UP DOWN DOWN UP
Position (4) UP UP UP DOWN UP DOWN DOWN UP
Position (5) DOWN DOWN DOWN UP UP DOWN DOWN UP
Position (6) DOWN UP DOWN UP UP DOWN DOWN UP
Position (7) UP UP DOWN UP UP DOWN DOWN UP

TechPub_2614345_0107 - 0601_3057044_01.fm
9

8 Front cover
9 F/C switch

8
(Cont'd)

6 - 156 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)
Set Operating Mode
The jumper (10) on the connector (11) determines the operating mode of the
adapter. For each adapter, set the jumper (10) to the right has shown below,
to select the SINGLE DRIVE mode.

10

11
TechPub_2614345_0107 - 0601_3057044_01.fm

10 Jumper
11 Connector

Doc. No. MM-3047612-0101 6 - 157 (308)

6.2 Distributed I/O 6 Electrical System

6.2.4-3 DeviceNet PowerFlex Adapter - LED Description

Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 90459-2614

LED Colour Description

PORT (1) Off The adapter is not powered or connected
correctly to the drive. Check the ribbon cable
connecting the adapter is securely fitted to the
drive. Apply power to the adapter.
Solid green The adapter is properly connected and is
communicating with the drive.
Flashing green The adapter is establishing an I/O connection to
the drive or (DSI I/O Config) is configured for all
I/O disabled. The LED will turn GREEN or RED.
Check the setting of parameter 15 (DSI I/O
Config). The adapter is operating normally if no
DSI I/O is enabled.

TechPub_2614345_0107 - 0601_3057044_01.fm
1

1 PORT LED 2
2 MOD LED
3 NET A LED 3

(Cont'd)

6 - 158 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)

LED Colour Description

PORT (1) Flashing red The adapter is not receiving communications
from a drive, a connected drive has failed or a
drive is missing. Clear any drive faults, Check
that all cables are securely connected. Cycle
power to the drive.
Solid red The drive has refused an I/O connection from
the adapter. Another DSI peripheral is using the
same DSI port as the adapter. Check that all DSI
cables are securely connected and undamaged.
If necessary, replace any damaged cable.
Solid orange Daisy-chained devices in the Multi-Drive mode
are not of the correct type. Install the correct
modules.
TechPub_2614345_0107 - 0601_3057044_01.fm

1 PORT LED 2
2 MOD LED
3 NET A LED 3

(Cont'd)

Doc. No. MM-3047612-0101 6 - 159 (308)

6.2 Distributed I/O 6 Electrical System

(Cont'd)

LED Colour Description

MOD (2) Off The adapter is not powered or connected
correctly to the drive. Check the ribbon cable
connecting the adapter is securely fitted to the
drive. Apply power to the adapter.
Solid green The adapter is operational and transferring I/O
data.
Flashing green The adapter is operational but is not transferring
I/O data. Put the scanner in the RUN mode.
Program the controller to recognize and transmit
I/O data to the adapter. Configure the adapter for
the program in the controller. The adapter is
operating normally if no DSI I/O is enabled.

TechPub_2614345_0107 - 0601_3057044_01.fm
1

1 PORT LED 2
2 MOD LED
3 NET A LED 3

(Cont'd)

6 - 160 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)

LED Colour Description

MOD (2) Flashing red The adapter has failed the firmware test, a
connected drive has failed or a drive is missing.
Clear any drive faults. Cycle power to the drive.
If cycling power does not correct the problem,
the parameter settings may have been
corrupted. Restore default values reconfigure
the adapter.
If restoring default values does not correct the
problem, flash the adapter with the latest
firmware release.
Determine which drive is missing or has failed.
Check cabling and configuration settings.
Solid red The adapter has failed the hardware test
Cycle power to the drive. Replace the adapter.
TechPub_2614345_0107 - 0601_3057044_01.fm

1 PORT LED 2
2 MOD LED
3 NET A LED 3

(Cont'd)

Doc. No. MM-3047612-0101 6 - 161 (308)

6.2 Distributed I/O 6 Electrical System

(Cont'd)

LED Colour Description

NET A (3) Off The adapter and/or the network is not powered
or the adapter is not connected correctly to the
network. Check that the ribbon cable is securely
connected to the adapter and to the drive. Check
that the DeviceNet cable is correctly connected.
Apply power to the adapter and the network.
Solid green The adapter is properly connected and is
communicating with devices on the network.
Flashing green The adapter is properly connected but is not
communicating with any devices on the network.
Put the scanner in the RUN mode, or apply
power to the peer device that will send I/O data.
Configure a controller or peer device to
recognize and transmit I/O to the adapter.
Configure the adapter for the program in the
controller or the I/O from the peer device.

TechPub_2614345_0107 - 0601_3057044_01.fm
1

1 PORT LED 2
2 MOD LED
3 NET A LED
3

(Cont'd)

6 - 162 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.2 Distributed I/O

(Cont'd)

LED Colour Description

NET A (3) Flashing red A DeviceNet I/O connection has timed out.
Put the scanner in the RUN mode, or apply
power to the peer device that will send I/O data.
Check the amount of traffic on the network.
Solid red Failed duplicate node detection test or bus off
condition exists.

1
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1 PORT LED 2
2 MOD LED
3 NET A LED 3

Doc. No. MM-3047612-0101 6 - 163 (308)

6.3 Servo System 6 Electrical System

6.3 Servo System

SPC Reference 2867994-0100
2869029-0100

6.3-1 Servo System - Description

SPC Reference 2867994-0100
2869029-0100

The servo system is managed by the PLC module (1) which communicates
with the Sercos module (2) through the backplane of the PLC rack (3). The
Sercos module (2) communicates through an optical fiber network (4) with
the two servo racks (5) containing the IAM (Integrated Axis Modules) (6)
and the AM (Axis Module) servo drives (7).

TechPub_2614345_0107 - 0601_3057045_01.fm
4
1
5

1 CPU module
2 Sercos module
7 3 PLC rack
4 Optical fiber network
6 5 Servo rack
6 Integrated axis module (IAM)
7 7 Axis module (AM)
6
(Cont'd)

6 - 164 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.3 Servo System

(Cont'd)
Each servo drive rack contains an IAM (6) and the AM servo drives (7).
Each servo drive rack is powered with 400 V/AC via the power
connector (8) on the top of the IAM (6) and control power 240V/AC to the
AM drives (7), is supplied through the control power connector (9) on top of
the IAM. A DC bus through the servo drive rack backplane provides the
drives with DC power.
The IAM (6) provides power to the AM servo drives (7) in the servo drive
rack (5) and also functions as a servo drive for one servo motor. Each rack
has a base node number, which is set by the plus and minus switches (10) on
the IAM.

7
7
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6
5
9 10

5 Servo Rack
6 Integrated axis module (IAM)
7 Axis module (AM)
8 Power connector
9 Control power connector
10 Switch

(Cont'd)

Doc. No. MM-3047612-0101 6 - 165 (308)

6.3 Servo System 6 Electrical System

(Cont'd)
The AM servo drives each have a node number which is determined by the
base node number set on the IAM and by the rack slot in which the drive is
located.
The fault/status display (11) on the AM servo drive indicates the current
system status, when the:
• LED segments are displayed alternatively in a rotating pattern, this
indicates the system is checking for a closed optical ring
• digit “1” is displayed, this indicates that the optical ring has been
checked and that the physical communication is in place. The system is
now checking for active nodes
• digit “2” is displayed, this indicates that all nodes in the optical ring are
active. The system is now checking the configuration of the nodes
• digit “3” is displayed, this indicates that all nodes are configured
according to the application software. The system is now checking for
motor types
• digit “4” is displayed, this indicates that the motor type matching for all
axis is complete and the system is running
• letter “E” is displayed, this indicate an error, see section 6.3.2-5 Servo

TechPub_2614345_0107 - 0601_3057045_01.fm
Drive - Error Codes on page 6-187.

11

11 Fault/status display

(Cont'd)

6 - 166 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.3 Servo System

(Cont'd)
On the front of each AM servo drive are three D-sub connectors:
• connector (12) is for I/O communications
• connector (13) is for position feedback from the servo motor
• connector (14) is for auxiliary position feedback.

The AM servo drives (7) are connected to the servo motors with
uninterrupted cabling which is used to:
• supply power to the servo motors
• receive signals with position indicator feedback
• activate and deactivate if fitted, the servo motors mechanical brake.

The connectors for servo motor power (15) and power to the mechanical
brake of the motor (16) are located on top of the drive.

15 16
12 13 14

7
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7 Axis module (AM)

12 Connector for I/O communication
13 Connector for position feedback
14 Connector for auxiliary position feedback
15 Motor power
16 Brake power

Doc. No. MM-3047612-0101 6 - 167 (308)

6.3 Servo System 6 Electrical System

6.3.1 Sercos Module

6.3.1-1 Sercos Module - Change
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 90459-2481

Note! The firmware of a Sercos module is locked with the ControlLogix

application project.
Note! The functionality of the application is not verified when the new
Sercos modules have a different firmware revision. Contact the Machine
System Liaison for more information. The correct firmware revision must be
installed to the Sercos modules.
Note! The firmware revision of the new Sercos module may be equal to, or
newer than the firmware revision of the old Sercos module. Using a newer
firmware revision may create errors when going online, such as
unrecognized device or device mismatch, if the PC does not contain the
very latest EDS files.
Note! The functionality of the application is not verified when the new
Sercos modules have a different series and of consequence they have a

TechPub_2614345_0107 - 0601_3057045_01.fm
different 90000 TP part number. Contact the Machine System Liaison for
more information.
Note! If the EtherNet/IP modules have still the MAC address programmed
as a factory setting, or if they have a different IP address setting, then
perform the 6.1.3-2 EtherNet/IP Module - Set IP Address on page 6-65.
Preparation
Before changing the Sercos module:
• Use the RSLinx Classic program to verify and record the firmware
version of the existing Sercos module.
• Use the Flow Chart of Procedures for Changing the Sercos Module on
the next page to determine which procedures must be performed and
their correct sequence.
(Cont'd)

6 - 168 (308) Doc. No. MM-3047612-0101

 TechPub_2614345_0107 - 0601_3057045_01.fm

Flow Chart of Procedures for Changing the Sercos Module

Change the Sercos module

(Cont'd)
6 Electrical System

No No No
New module with New module with New module with New module with a
same series and same series and old same series and new series and new
same firmware firmware new firmware firmware

Yes Yes Yes Yes

Fit the new module, see Change Fit the new module, see Change Fit the new module, see Change It is NOT RECOMMENDED to fit
the Sercos Module on the Sercos Module on the Sercos Module on a Sercos module with a different
page 6-170 page 6-170 page 6-170 series. The machine functionality
is only verified with the existing
EtherNet/IP module series.

Upgrade the firmware to the Downgrade the firmware to the

Doc. No. MM-3047612-0101

same revision as the old module, same revision as the old module,
see 6.3.1-2 Sercos Module - see 6.3.1-2 Sercos Module -
Load Firmware on page 6-172 Load Firmware on page 6-172
6.3 Servo System

(Cont'd)

6 - 169 (308)
6.3 Servo System 6 Electrical System

(Cont'd)
Change the Sercos Module
a) Mark the receive connector (1) and the transmit connector (2) and
remove the connectors from the Sercos module (3).
b) Push in and hold the top and bottom locking tabs on the Sercos
module (3).
c) Slide the Sercos module (3) out of the chassis.

TechPub_2614345_0107 - 0601_3057045_01.fm
1
2
1 Receive connector, Rx
2 Transmit connector, Tx
3 Sercos module

(Cont'd)

6 - 170 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.3 Servo System

(Cont'd)
d) Align the new Sercos module (3) with the top and the bottom guides in
the chassis.
e) Slide the Sercos module (3) into the chassis. Make sure it is flush with
the other modules and the top and bottom latches are engaged.
f) Connect the receive connector (1) and the transmit connector (2) to
the Sercos module (3).
g) Continue with the necessary procedures as described in Flow Chart of
Procedures for Changing the Sercos Module on page 6-169.

3
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1
2
1 Receive connector, Rx
2 Transmit connector, Tx
3 Sercos module

Doc. No. MM-3047612-0101 6 - 171 (308)

6.3 Servo System 6 Electrical System

6.3.1-2 Sercos Module - Load Firmware

Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with CD Drive
Ethernet communication cable, TP No. 351501-0100
Program CD TP No. 2886185-0XXX
SPC Reference 90459-2481

Follow the instructions in 6.1.2-2 CPU Module - Load Firmware on

page 6-36, to load the firmware for the Sercos module.

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6 - 172 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.3 Servo System

6.3.1-3 Sercos Module - LED Description

Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 90459-2481

The Sercos module has three LEDs indicating the state of the system.
• The CP LED (Sercos communication) (1) displays the status of the
communication phases
• The Sercos ring LED (2) displays the status of the Sercos network
• The OK LED (3) indicates the status of the module and the
communication.
During power up, the module completes a self test that includes an indicator
test. All LEDs go red for one second, green for one second and OFF for one
second.

LED Colour Description

CP (1) Solid Orange In Phase -1: Autobaud detection in progress.
Off In Phase 0: looking for a closed ring.
Flashing Red In Phase 1: looking for active nodes.
TechPub_2614345_0107 - 0601_3057045_01.fm

Alternating In Phase 2: configuration of nodes for communication.

Red/Green
Flashing In Phase 3: configuration of device specific
Green parameters
Solid Green In Phase 4: configured and active.

3
1

1 Sercos communication LED

2 Sercos ring LED
3 OK LED

(Cont'd)

Doc. No. MM-3047612-0101 6 - 173 (308)

6.3 Servo System 6 Electrical System

(Cont'd)

LED Colour Description

Sercos Solid Green The ring, drive, and axes are configured and are actively
ring (2) communicating through to the nodes on the ring.
Flashing Red The module has detected a setup or configuration fault
with the ring. Check the configuration as follows:
- Ensure drive and axes addresses are correct
- Remove excess axes from ring
- Make sure application program has selected the proper
ring cycle period and baud rate.
Solid Red The module has detected a hardware or installation fault
with the ring. Check as follows:
- Make sure all cables are properly installed
- Make sure the cable is of the correct type and length
- Make sure application program has configured the ring
transmit level of the module to high when using specified
cables
- Make sure the transmit levels of the drive are set
appropriately
- Inspect cables for damage
- Inspect the drives for any faults
Off The module has detected no ring data on its receiver or
has not successfully completed phase 2.

TechPub_2614345_0107 - 0601_3057045_01.fm
Check as follows:
- Make sure all cables are properly installed
- Inspect cable for wear and damage
- Inspect drives for faults.
Flashing The ring, drive, or axes are not configured but, at least
Green one has been identified. Not a problem if the system has
not been configured. If you are having configuration
problems with the ring, drive, and axes, make sure that
the application program is setup properly for the
equipment in use.

2 Sercos ring LED

(Cont'd)

6 - 174 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.3 Servo System

(Cont'd)

OK (3) Off The module is not operating. Apply chassis power.

Verify the module is completely inserted into the chassis
and backplane.
Flashing The module has passed internal diagnostics, but
Green has not established active communications.
Steady Green Data is being exchanged and the module is in the
normal operating state.
Flashing Red A major recoverable failure has occurred or an firmware
upgrade is in progress. If an firmware upgrade is in
progress, complete the upgrade.
If a firmware upgrade is not in progress, cycle the power.
Solid Red A potential non-recoverable fault has occurred. Cycle the
power to the module. If the solid red persists, replace the
module.

3
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3 OK LED

Doc. No. MM-3047612-0101 6 - 175 (308)

6.3 Servo System 6 Electrical System

6.3.2 Servo Drive

6.3.2-1 Servo Drive - Change
Machine Status Mains Power OFF
Air OFF
Water OFF
Special Equipment Torque Wrench min. 2 Nm
SPC Reference 2867994-0100
2869029-0100

Note! The firmware of a Servo drive is locked with the ControlLogix

application project.
Note! The functionality of the application is not verified when the new Servo
drives have a different firmware revision. Contact the Machine System
Liaison for more information. The correct firmware revision must be installed
to the Servo drives.
Note! The firmware revision of the new Servo drive may be equal to, or
newer than the firmware revision of the old Servo drive. Using a newer
firmware revision may create errors when going online, such as
unrecognized device or device mismatch, if the PC does not contain the
very latest EDS files.

TechPub_2614345_0107 - 0601_3057045_01.fm
Note! The functionality of the application is not verified when the new Servo
drives have a different series and of consequence they have a different
90000 TP part number. Contact the Machine System Liaison for more
information.
Note! If the EtherNet/IP modules have still the MAC address programmed
as a factory setting, or if they have a different IP address setting, then
perform the 6.1.3-2 EtherNet/IP Module - Set IP Address on page 6-65.
Preparation
Before changing the servo drive:
• Use the RSLinx Classic program to verify and record the firmware
version of the servo drive.
• Use the Flow Chart of Procedures for Changing an IAM or AM Drive on
the next page, to determine which procedures must be performed and
their correct sequence.
(Cont'd)

6 - 176 (308) Doc. No. MM-3047612-0101

 TechPub_2614345_0107 - 0601_3057045_01.fm

Flow Chart of Procedures for Changing an IAM or AM Drive

Change the IAM or AM Drive

(Cont'd)
6 Electrical System

No No No
New drive with New drive with New drive with New drive with a
same series and same series and old same series and new series and new
same firmware firmware newer firmware firmware

Yes Yes Yes Yes

Fit the new drive, see Change Fit the new drive, see Change Fit the new drive, see Change It is NOT RECOMMENDED to fit
the IAM or AM Drive on page the IAM or AM Drive on page the IAM or AM Drive on page an IAM or AM drive with a
6-178 6-178 6-178 different series. The PLC
program and machine
functionality is only verified to
work with the existing drive
series.
Perform the referencing Upgrade the firmware to the Downgrade the firmware to the
procedure of the servomotor, same revision as the old drive, same revision as the old drive,

Doc. No. MM-3047612-0101

that corresponds to the new see 6.3.2-3 Servo Drive - Load see 6.3.2-3 Servo Drive - Load
drive. Firmware on Firmware on
page 6-184 page 6-184

Perform the referencing Perform the referencing

procedure of the servomotor, procedure of the servomotor,
that corresponds to the new that corresponds to the new
drive. drive.
6.3 Servo System

(Cont'd)

6 - 177 (308)
6.3 Servo System 6 Electrical System

(Cont'd)

WARNING
Hazardous voltage.
Make sure that all control and input power has been removed from the servo
system. Wait five minutes for the DC bus to completely discharge before
proceeding.
Change the IAM or AM Drive
a) Mark and record the position of all connectors from the servo drive and
then remove the connectors.
b) Use a screwdriver in the slot indicated with an arrow, to remove the
motor cable (1) from the cable shield clamp (2).

1 2

TechPub_2614345_0107 - 0601_3057045_01.fm
1 Motor cable
2 Clamp

(Cont'd)

6 - 178 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.3 Servo System

(Cont'd)
c) Loosen the screw (3).
d) Grip the top and bottom of the servo drive (4) and gently pull the servo
drive away from the connectors enough to clear the guide pins (5) (the
servo drive will pivot on the top bracket). Lift the bracket out of the
power rail slot (6) and remove the servo drive from the power rail.
e) If the servo drive to be changed is an IAM module, record the node
address (7) and baud rate settings (8).

6
TechPub_2614345_0107 - 0601_3057045_01.fm

4 7

5 3

5
3 Screw 6 Power rail slot
4 Servo drive 7 Node address
5 Guide pin 8 Baud rate

(Cont'd)

Doc. No. MM-3047612-0101 6 - 179 (308)

6.3 Servo System 6 Electrical System

(Cont'd)

CAUTION
Risk of damage to the equipment.
Make sure the guide pins (5) are correctly seated.
f) Attach the new servo drive mounting bracket (9) to the slot (10) in the
power rail (11).
Note! The IAM has two power rail connectors and guide pins (5), all other
servo drives have only one connector and one guide pin (5).
g) Align the guide pins (5) on the power rail with the guide pin holes in the
back of the servo drive (4).

10

TechPub_2614345_0107 - 0601_3057045_01.fm
4
11

4 Servo drive
5 Guide pin 5
9 Mounting bracket
10 Slot
11 Power rail
5

(Cont'd)

6 - 180 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.3 Servo System

(Cont'd)
h) Tighten the screw (3) to a torque of 2.26 Nm.
i) If the servo drive is an IAM, set the node address (7) and the baud
rate (8) according to the setting recorded previously.
j) Connect the servo drive connectors and apply power to the system.
k) Check that the system is operating properly, see 6.3.2-4 Servo Drive -
LED Description on page 6-185.
l) Continue with the necessary procedures as described in Flow Chart of
Procedures for Changing an IAM or AM Drive on page 6-177.

8
TechPub_2614345_0107 - 0601_3057045_01.fm

3 7

3 Screw
7 Node address
8 Baud rate

Doc. No. MM-3047612-0101 6 - 181 (308)

6.3 Servo System 6 Electrical System

6.3.2-2 Servo Drive - Set

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2867994-0100
2869029-0100

Set Baud Rate

Set the DIP switches for the IAM and AM drives according to the table and
the illustration below.

Dip switch Setting

Optical power (1) On
Baud rate LSB (2) On
Baud rate MSB (3) Off

ON
OFF

TechPub_2614345_0107 - 0601_3057045_01.fm
3 2 1
The illustration shows an
Integrated Axis Module (IAM)

1 DIP switch optical power

2 DIP switch baud rate LSB
3 DIP switch baud rate MSB

(Cont'd)

6 - 182 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.3 Servo System

(Cont'd)
Set Node Address
Use the push buttons (3) to set the node address, for the IAM drives (1)
and (2) according to the table below.

IAM drive Node address

Position (1) 01
Position (2) 09
TechPub_2614345_0107 - 0601_3057045_01.fm

2
3

1
1 IAM drive
2 IAM drive
3 Push button

Doc. No. MM-3047612-0101 6 - 183 (308)

6.3 Servo System 6 Electrical System

6.3.2-3 Servo Drive - Load Firmware

Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with CD Drive
Ethernet communication cable, TP No. 351501-0100
Program CD TP No. 2886185-0XXX
SPC Reference 2867994-0100
2869029-0100

CAUTION
Risk of damage to the equipment.
To avoid injury or damage to the equipment due to unpredictable motor
activity, do not apply AC input power or establish communications with the
SERCOS module.
Note! After a firmware download, perform the referencing procedure of the
corresponding servomotor.
Follow the instructions in 6.1.2-2 CPU Module - Load Firmware on
page 6-36, to load the firmware for the servo drive.

TechPub_2614345_0107 - 0601_3057045_01.fm

6 - 184 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.3 Servo System

6.3.2-4 Servo Drive - LED Description

Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 2867994-0100
2869029-0100

LED Colour Status Action

Drive Off Normal, no faults
Status (1) Solid Drive faulted Read the error code in the Fault
red status display and see the section
Error codes
Comm Off No communication Check for loose fiber optic
Status (2) connection or damaged fiber optic
cable. Check that the fiber optic
cables are not cross-connected.
Flashing Establishing System is still in the process of
green communication establishing SERCOS
communication.
Solid Communication No faults or failures
green ready
TechPub_2614345_0107 - 0601_3057045_01.fm

1 Drive status LED

2 Comm status LED

(Cont'd)

Doc. No. MM-3047612-0101 6 - 185 (308)

6.3 Servo System 6 Electrical System

(Cont'd)

LED Colour Status Action

Bus Off Bus power not
Status (3) present
Flashing Power is present, Normal when:
green axis enabled. 24V is not applied to
No faults or failures. Hardware Enable Input (IOD-2).
or
MSO instruction is
not commanded in RSLogix 5000
software.
Solid Power is present, Normal when:
green axis enabled. 24V is applied to Hardware
No faults or failures. Enable Input (IOD-2).
or
MSO instruction is
commanded in RSLogix 5000
software.

TechPub_2614345_0107 - 0601_3057045_01.fm
3

3 Bus status LED

6 - 186 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.3 Servo System

6.3.2-5 Servo Drive - Error Codes

Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 2867994-0100
2869029-0100

When an error occurs, the fault/status LED on the front of the servo drive
will display the letter E followed by a two-digit error code, one digit at a
time. Refer to the error codes table below to identify error codes and the
corrective actions.

Error Fault message Problem Description Action

code RSLogix (HIM)
Power indicator No AC power or auxiliary logic Verify AC control power is
not ON. power. applied to the Kinetix 6000.
Internal power supply Change the module.
malfunction.
Motor jumps when Motor wiring error. Check motor wiring.
first enabled. Run Hookup test in RSLogix
5000.
TechPub_2614345_0107 - 0601_3057045_01.fm

Incorrect motor chosen. Verify the proper motor is

selected.
Digital I/O not I/O power supply Verify connections and I/O
working correctly. disconnected. power source.
E00 BusUndervoltage A blown fuse was Blown fuse. Call your Allen-Bradley
Fault detected on the representative to return module
(Blown fuse) inverter PCB. for repair.
E04 MotorOvertemp Motor thermal High motor ambient Operate within (not above) the
Fault switch tripped. temperature and/or excessive continuous torque rating for the
(Motor Overtemp) current. ambient temperature (40°C
maximum).
Lower ambient temperature,
increase motor cooling.
Motor wiring error. Check motor wiring at MF
connector on the IAM/AM.
Incorrect motor selection. Verify the proper motor has
been selected.

Doc. No. MM-3047612-0101 6 - 187 (308)

6.3 Servo System 6 Electrical System

Error Fault message Problem Description Action

code RSLogix (HIM)
E05 DriveOvercurrent Self-protection of Motor cables short circuit. Verify continuity of motor
Fault the Intelligent power cable and connector.
(Power Fault) Power Module Motor winding internal short Disconnect motor power
(IPM) is indicating circuit internally. cables from the motor. If the
a major power motor is difficult to turn by
related fault hand, it may need to be
condition. replaced.
Kinetix 6000 temperature too Check for clogged vents or
high. defective fan.
Ensure cooling is not restricted
by insufficient space around
the unit.
Operation above continuous Verify ambient temperature is
power rating and/or product not too high.
environmental ratings. Operate within the continuous
power rating.
Reduce acceleration rates.
Kinetix 6000 has a short Remove all power and motor
circuit, overcurrent, or failed connections, and preform a
component. continuity check from the DC
bus to the U, V, and W motor
outputs. If a continuity exists,

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check for wire fibers between
terminals, or send drive in for
repair.
E06 HardOvertravel Axis moved Dedicated over travel input is Check wiring.
Fault beyond the inactive. Verify motion profile.
(+/- Hard physical travel Verify axis configuration in
Overtravel) limits in the software
positive/negative
direction.
E07 MotFeedbackFault The feedback wiring is open, has a short circuit, or Check motor encoder wiring.
(Motor Feedback missing. Run Hookup test in RSLogix
Loss) 5000.
E09 BusUndervoltage With three-phase DC bus voltage for 460V Verify voltage level of the
Fault power present, system is below 275V. incoming AC power.
(Bus Undervoltage) the DC bus DC bus voltage for 230V Check AC power source for
voltage is below system is below 137V. glitches or line drop.
limits. Install an uninterrupted power
supply (UPS) on your AC input.
DC bus voltage Disable follower axis before
fell below the removing power.
undervoltage limit
while an axis on
the follower power
rail was enabled.

6 - 188 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.3 Servo System

Error Fault message Problem Description Action

code RSLogix (HIM)
E10 DriveOvervoltage The DC bus Excessive regeneration of Change the deceleration or
Fault voltage is above power. motion profile.
(Bus Overvoltage) limits. When the motor is driven by Use a larger system (motor
an external mechanical power and Kinetix 6000).
source, it may regenerate too Install shunt module.
much peak energy through
the Kinetix 6000’s power
supply.
The system faults to save
itself from an overload.
DC bus voltage for 460V Verify input is within
system is over 820V. specifications.
DC bus voltage for 230V
system is over 410V.
E11 MotFeedbackFault State of Hall Bad connections. Verify the Hall wiring at the MF
(Illegal Hall State) feedback inputs is connector on the IAM/AM.
incorrect. Verify 5V power supply to the
encoder.
E16 Softovertravel Axis position exceeded maximum software setting. Verify motion profile.
Fault Verify over-travel settings are
(+/- Software appropriate.
Overtravel)
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E17 ExcessiveAverage The drive was The peak current is due to the Verify that there are no
CurrentFault working for a too fact that the axis has impediments to motion.
(Fault Condition) long time at the encountered a resistance to Reduce friction.
peak current. motion.
E18 OverSpeedFault Motor speed has exceeded 150% of maximum Check cables for noise.
(Overspeed Fault) rated speed. The 100% trip point is dictated by the Check tuning.
lesser of the user velocity limits or the motor rated
base speed.
E19 PositionErrorFault Position error limit was exceeded. Increase the feed forward gain.
(Follow Error) Increase following error limit or
time.
Check position loop tuning.
Verify sizing of system.
Verify mechanical integrity of
system within specification
limits.
E20 MotFeedbackFault Motor Encoder The motor encoder Use shielded cables with
(Mtr Fdbk AQB) State Error. encountered an illegal twisted pair wires.
transition. Route the feedback away from
potential noise sources.
Check the system grounds.
Replace the motor/encoder.
E21 AuxFeedback Communication was not established with an Verify auxiliary encoder wiring.
Fault intelligent encoder.
(Aux Feedback
Comm)
E30 MotFeedbackFault Communication was not established with an Verify motor selection.
(Motor Feedback intelligent encoder. Verify the motor supports
Comm) automatic identification.
Verify motor encoder wiring.

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6.3 Servo System 6 Electrical System

Error Fault message Problem Description Action

code RSLogix (HIM)
E34 GroundShortFault Excessive ground Wiring error. Check motor power wiring.
(Ground Fault) current in the Check input power wiring (refer
converter was to Kinetix 6000 Installation
detected. Manual, publication 2094-
IN001x-EN-P, regarding use of
isolation transformer).
Motor internal ground short. Replace motor.
Internal malfunction. Disconnect motor power cable
from drive and enable drive
with current limit set to 0.
If fault clears, then a wiring
error or motor internal problem
exists. If fault remains, call your
A-B representative.
Grounded control power Remove ground from control
terminal (applies to 230V power input.
systems only). Source control power from
three phase input power.
Add isolation transformer for
control power.
E35 DriveUndervoltage Converter pre- Low AC input voltage. Check input AC voltage on all
Fault charge cycle phases.

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(Precharge Fault) failed. Internal malfunction. Call your A-B representative.
E36 DriveOvertemp Converter thermal Excessive heat exists in the Reduce acceleration rates.
Fault switch tripped. power circuitry. Reduce duty cycle (ON/OFF)
(System of commanded motion.
Overtemperature) Increase time permitted for
motion.
Use larger Kinetix 6000
converter.
Check for clogged vents or
defective fan.
Ensure cooling is not restricted
by insufficient space around
the unit.
E37 PowerPhaseLoss One or more phases of the input AC power is Check input AC voltage on all
Fault missing. phases.
(Phase Loss Flt) Axis was enabled when main (3-phase) power was Disable axis before removing
removed. power.
Common bus follower axis was enabled when DC
bus power was removed.
E38 SERCOSFault The SERCOS ring Cable disconnected. Check that the fiber optic cable
(SERCOS Ring Flt) is not active after is present and connected
being active and properly.
operational.
E39 DriveHardFault Self-sensing Motion required for self- Verify that there are no
(Self Sense Flt) Commutation sensing start-up commutation impediments to motion at
Startup Error. was obstructed. startup, such as hard limits.
Increase self-sensing current if
high friction or load conditions
exist.
Check motor or encoder wiring
using wiring diagnostics.

6 - 190 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.3 Servo System

Error Fault message Problem Description Action

code RSLogix (HIM)
E43 DriveEnableInput Missing Drive An attempt was made to Disable the Drive Enable Input
Fault Enable Input enable the axis through fault.
(Drive Enable Flt) Signal. software while the Drive Verify that Drive Enable
Enable hardware input was hardware input is active
inactive. whenever the drive is enabled
The Drive Enable input through software.
changed from active to
inactive while the axis was
enabled.
E49 DriveHardFault Safe-off function Loose wiring at SO connector. Verify wire terminations, cable/
(Safe-Off HW Flt) mismatch. Drive Cable/header not seated header connections, and +24V.
will not allow properly in SO connector. Reset error and run proof test.
motion. Safe-off circuit missing +24V If error persists, return the drive
DC. to Allen-Bradley.
E50 SERCOSFault Duplicate node address detected on SERCOS Verify that each SERCOS drive
(SERCOS Same ring. is assigned an unique node
ADDR) address.
E54 DriveHardFault Current feedback hardware fault detected. Replace the module.
(Ifbk HW Fault)
E60 DriveHardFault Illegal ID bits detected. Replace the module.
(Unknown Axis)
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E61 AuxFeedback Auxiliary Encoder The auxiliary encoder Use shielded cables with
Fault State Error. encountered an illegal twisted pair wires.
(Aux Fdbk AQB) transition. Route the feedback away from
potential noise sources.
Check the system grounds.
Replace the motor/encoder.
E62 AuxFeedback The feedback wiring is open, has a short circuit, or Check the motor feedback
Fault missing. cable connectors/wiring to the
(Aux Fdbk Loss) IAM/AM and motor.
E63 AuxFeedback Noise on auxiliary Recommended grounding, Verify grounding.
Noise feedback cable. per installation instructions, Route feedback cable away
(Aux Fdbk Noise) has not been followed. from noise sources.
E64 MotorFeedback Noise on motor Refer to System Design for
Noise feedback cable. Control of Electrical Noise
(Mtr Fdbk Noise) Reference Manual (publication
GMC-RM001).
E65 No Fault Message Hookup Motor or feedback device Check motor power/feedback
(condition indicated procedure failed malfunction. wiring.
by on-screen Refer to on-screen message
message) for resolution.
(Hookup Fault)
E66 No Fault Message Autotune Motor or feedback device Check motor power/feedback
(condition indicated procedure failed. malfunction. wiring.
by on-screen Refer to on-screen message
message) solution.
(Atune Flt) Perform Hookup in RSLogix
5000.
Consult RSLogix 5000 for help
screen.
E67 DriveHardFault Operation system Software initalization fault Cycle power.
(Task init) failed. detected due to hardware If fault persists, replace
failure. module.

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6.3 Servo System 6 Electrical System

Error Fault message Problem Description Action

code RSLogix (HIM)
E68 DriveHardFault DPI The DPI device or cable is Check DPI connections.
(SCANport Comm) communication faulty.
failed.
E69 HardDriveFault Non-volatile memory is corrupt due to control Load default parameters, save
(Objects Init) board hardware failure. to non-volatile memory, and
recycle power or reset the
drive.
E70 DriveHardFault Non-volatile memory is corrupt due to control Load default parameters, save
(NV Mem Init) board software error. to non-volatile memory, and
recycle power or reset the
drive
E71 DriveHardFault RAM or flash memory validation failure. Cycle power.
(Memory Init) If fault persists, replace
module.
E72 DriveOvertemp Inverter thermal The fan on the IAM or an AM Replace the failed module.
Fault switch tripped. failed.
(Drive Overtemp) The cabinet ambient Check the cabinet
temperature is above rating. temperature.
The machine duty cycle Change the command profile
requires an RMS current to reduce speed or increase
exceeding the continuous time.

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rating of the module.
The airflow access to the Check airflow and re-route
Kinetix 6000 is limited or cables away from the Kinetix
blocked. 6000.
E73 Communicate Power rail CAN communications failed. Check module for proper
(Backplane Comm) mount.
Power rail connection has a short circuit or is Check power rail and module
open. for foreign objects.
E74 DriveOvercurrent DC link current Motor or transmission Check for proper motor sizing.
Fault exceeds rating. malfunction. Check/replace transmission
(BusOverCurrent) device.
Check/replace motor.
IAM not properly sized. Check for proper IAM sizing.
Install larger kW rated IAM.
E75 DriveOvervoltage The IAM or AM has exceeded its shunt resistor Use properly sized shunt or
Fault continuous rating. modify duty cycle of the
(Shunt Time Out) application.
System uses internal shunt
and requires external shunt for
additional capacity.
E76 DriveHardFault DPI hardware Control board hardware Reset system.
(Can Init) initialization fault failure. If fault persists, replace system
detected. module.
E77 DriveHardFault Either 230V AM is installed on power rail with 460V Replace mismatched module.
(Module Mismatch) IAM, or 460V AM is installed on power rail with
230V IAM.
E78 DriveHardFault Control hardware fault detected. Cycle power.
(SERCOS Init) If fault persists, replace
module.

6 - 192 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.3 Servo System

Error Fault message Problem Description Action

code RSLogix (HIM)
E79 DriveOvervoltage SM Temperature Fault LED status is solid Red. Refer to Temperature Fault
Fault LED description.
(Shunt Module Flt) SM Shunt Fault LED status is solid Red. Refer to Shunt Fault LED
description.
Module missing from power rail. Install missing module on
power rail.
Fill empty slot with slot filler
module.
E80 HardwareFault Control hardware fault detected. Replace module.
(CPLD FLT)
E81 DriveHardFault Follower IAM detected AC input power being Remove AC input power
(Common Bus FLT) applied. connections from Follower
IAM.
E90 DriveHardFault Pre-charge resistor power exceeds the resistor Allow resistor to cool.
(Pre-charge Timeout rating.
FLT)
All RESERVED Call your local Allen-Bradley
others representative.
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Doc. No. MM-3047612-0101 6 - 193 (308)

6.4 Safety System 6 Electrical System

6.4 Safety System

SPC Reference 2867990-0100

6.4-1 Safety System - Description

SPC Reference 2867990-0100

The safety system of the machine is managed by the a Pluto Safety PLC
module. To increase the number of input and output possibilities, the
modules are assisted by two expansion relays.
The pluto system monitors the:
– emergency stop buttons
– door safety switches
– pressure switch of the pneumatic circuit
– contactors for AC motor driven units
– modules for the servo controlled units.
When an emergency stop button is pushed, a door is opened or a cover is
removed, an emergency stop signal is sent to the CPU module which then
takes the necessary actions to stop the machine.

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When the emergency stop button is released or the door is closed, a reset
signal is generated by the CPU module when the alarm is reset on the TPOP.

6 - 194 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.4 Safety System

6.4-2 Safety System - Troubleshooting

Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 2867990-0100

Note! The PLC only monitors the channel with constant +24V DC.
Safety Relay Disengaged
When the SAFETY RELAY DISENGAGED symbol (1) appears on the
TPOP, this indicates that the PLC has received an input that a door has been
opened or an emergency stop button has been pressed.
Make sure to close all the doors, if necessary twist and release the emergency
stop button that has been previously activated, then press the RESET
button (2) to engage the SAFETY RELAY and touch the ALARM
AKNOWLEDGE button (3) to make disappear the SAFETY RELAY
DISENGAGED symbol (1).
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1 2 3

1 Safety relay disengaged symbol (yellow)

2 Reset button
3 Alarm aknowledge button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 195 (308)

6.4 Safety System 6 Electrical System

(Cont'd)
Safety Relay Fault
When the SAFETY RELAY FAULT symbol (1) appears on the TPOP, there
are two types of faults that may cause this condition: two channel fault and
feedback fault; see the table below, to identify the fault type and the relevant
actions that should be taken, then press the RESET button (2) to engage the
SAFETY RELAY and touch the ALARM AKNOWLEDGE button (3) to make
disappear the SAFETY RELAY FAULT symbol (1).

1 2 3
1 Safety relay fault symbol (red)
2 Reset button
3 Alarm aknowledge button

Two Channel Fault

Problem Description Action

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The system will trip but it will One of the channels (inputs) Open and close both
not automatically reset when may have been temporarily channels (for example by
the input is OK again. interrupted but is now OK. opening and closing a door in
The LED associated with the the affected circuit) and reset
faulty input will flash as will the alarm.
the information output to the
PLC.
The system will trip and One or both channels are Repair the faulty circuit, open
cannot be reset. permanently off. The LED and close both channels (for
associated with the faulty example by opening and
input is OFF. closing a door in the affected
circuit) and reset the alarm.
Feedback Fault
Problem Description Action
The system cannot be reset. One of the feedback circuits Repair the faulty circuit or
has not been closed when the contactor and reset the alarm.
output has tripped. The LED
associated with the faulty
input (feedback circuit) is OFF
and the information output to
the PLC will be ON.

6 - 196 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.4 Safety System

6.4.1 Pluto Module

6.4.1-1 Pluto Module - Load Program
Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with CD drive and Pluto Manager
Pluto Communication Cable TP No. 90459-6033
Program CD TP No. 2886185-0XXX
SPC Reference 90459-6692

Note! Before starting, check the current version of Software installed, see
the Software - Installation List on page 6-248, included in the chapter
6.7.2-1 HMI Installation List - Check Version of Software and Firmware
Installed.
Note! The program must be compiled before it can be loaded. A fault
message is shown if the program is not compiled.
a) Connect the PC (1) to the Pluto module (2).
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2
1

1 PC
2 Pluto module, F09K0000

(Cont'd)

Doc. No. MM-3047612-0101 6 - 197 (308)

6.4 Safety System 6 Electrical System

(Cont'd)
b) Insert the program CD into the PC CD drive.
c) Browse to the CD drive and copy the program file included in the folder
2886194-1XXX to the PC desktop.
d) Open the START menu (3) on the PC, then select PROGRAMS (4),
PLUTO MANAGER (5) and then PLUTO MANAGER program (6).

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3
3 Start menu
4 Programs
5 Pluto manager
6 Pluto manager program

(Cont'd)

6 - 198 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.4 Safety System

(Cont'd)
e) The JOKAB SAFETY window (7) appears when the program is not
registered, in this case select the REGISTER KEY button (8), otherwise
continue from item h) on the next page.
f) In the ENTER REGISTRATION CODE window (9), type your own
registration code or the word “mute”, then select the OK button (10).
g) The message window (11) appears, if the word “mute” has been
previously introduced, select the OK button (12).

7
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9
10
7 Jokab safety window
8 Register key button
9 Enter registration code
10 OK button
11 11 Message window
12 OK button
12
(Cont'd)

Doc. No. MM-3047612-0101 6 - 199 (308)

6.4 Safety System 6 Electrical System

(Cont'd)
h) In the PLUTO MANAGER window, select PROJECTS (13) and then
select OPEN icon (14).

14

13

13 Projects
14 Open icon

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(Cont'd)

6 - 200 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.4 Safety System

(Cont'd)
Note! The project number shown in the illustration is an example.
i) Select the required PROJECT (15) and then select the OPEN button (16).

15
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16

15 Project
16 Open button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 201 (308)

6.4 Safety System 6 Electrical System

(Cont'd)
j) In the window that appears, click on the PLUTO 24 icon (17), then
select the DOWNLOAD icon (18).

18

17

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17 Pluto 24 icon
18 Download icon

(Cont'd)

6 - 202 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.4 Safety System

(Cont'd)
k) If the Pluto module is assigned with a password, a dialogue box appears
asking for the password.
l) Type the password “abc80” in the PASSWORD field (19).
m) Select the OK button (20).

19
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20
19 Password field
20 OK button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 203 (308)

6.4 Safety System 6 Electrical System

(Cont'd)
Note! If the fault message COULDN’T ESTABLISH CONNECTION appears
there is no connection with the Pluto module. Check the communication
cable is correctly connected.
Note! If the fault message CONNECTION TIME OUT appears the
communication has been interrupted. Check the communication cable is
correctly connected.
n) When the download is complete the dialogue box appears, select the
YES button (21).

Note! A warning is given if the program project is for several Pluto modules
and all modules are not connected to the bus.

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21
21 Yes button

6 - 204 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.4 Safety System

6.4.1-2 Pluto Module - LED Description

Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with Pluto Manager
Pluto Communication Cable TP No. 90459-6033
SPC Reference 90459-6692

Pluto Module F09K0000

LED Description
I0 Reserve
I1 Reserve
I2 Reserve
I3 Feedback air pressure
I4 Feedback emergency stops (L21, L22)
I5 Feedback doors zone 1 (L31, L34, L37)
I6 Feedback doors zone 2 (L32, L35, L38)
I7 Feedback options (L32, L35, L38)
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CH I1 I3 I6 IQ10 Q2

CL I0 I2 I4 I5 I7 IQ11 Q3

PLUTO B20
K

IQ12 IQ14 IQ16 Q0 Q1

IQ13 IQ15 IQ17 ID 0V +24V

(Cont'd)

Doc. No. MM-3047612-0101 6 - 205 (308)

6.4 Safety System 6 Electrical System

(Cont'd)

LED Description
Q0 Safety line (L21)
Q1 Safety line (L22)
Q2 Safety line doors zone 1 (L31, L34)
Q3 Safety line doors zone 2 (L32, L35)
IQ10 A-pulse (L36)
IQ11 Emergency stops zone 1
IQ12 Emergency stops zone 2
IQ13 Doors zone 1
IQ14 Doors zone 2
IQ15 Reset
IQ16 Pressure switch
IQ17 Error message
ID Identifier on the CAN bus
0V 0V
+24V +24V DC (L12)

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CH I1 I3 I6 IQ10 Q2

CL I0 I2 I4 I5 I7 IQ11 Q3

PLUTO B20
K

IQ12 IQ14 IQ16 Q0 Q1

IQ13 IQ15 IQ17 ID 0V +24V

6 - 206 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.4 Safety System

6.4.1-3 Pluto Module - Configure in an Existing Application

Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with Pluto Manager
Pluto Communication Cable TP No. 90459-6033
SPC Reference 90459-6692

The safety system comprises of a Pluto module.

If a new Pluto module belonging to a program project is connected to the bus
that is already connected to one or more Pluto modules, two situations may
arise depending upon the status of the new Pluto module:
• The new Pluto does not contain a PLC program (error code E20) but it is
fitted with the correct IDFIX circuit. When this is the case the new Pluto
can be programmed using its self programming function. To do this
proceed as follows:
– Press the K button (1) on the Pluto front panel for two seconds. The
display flashes L indicating that the system is ready for self
programming.
– Press the K button (1) again.
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– The program load is started. This is indicated by a steady ‘L’ on the

display.

CH I1 I3 I6 IQ10 Q2

CL I0 I2 I4 I5 I7 IQ11 Q3

PLUTO B20
K

1 IQ12 IQ14 IQ16 Q0 Q1

IQ13 IQ15 IQ17 ID 0V +24V

1 K button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 207 (308)

6.4 Safety System 6 Electrical System

(Cont'd)
• The new Pluto is fitted with correct ID-fix circuit but loaded with wrong
version of the program.
When this is the situation, all Pluto modules of the project will display
the error code E27 indicating that the new Pluto module with the
incorrect software has been detected. The modules will run the PLC
program, but will not accept I/O data from the new Pluto module.
To correct this situation, download the correct version of the module, see
6.4.1-1 Pluto Module - Load Program on page 6-197.

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6 - 208 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.4 Safety System

6.4.1-4 Pluto Module - Set ID-FIX Address after Replacing an

ID-FIX
Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with Pluto Manager
Pluto Communication Cable TP No. 90459-6033
SPC Reference 90459-6692

Connect ID-FIX
To enable the PLC to identify a Pluto module, an ID code must be given to
the module. This is done by connecting an ID-FIX (1), between the ID
terminal (2) and the 0V terminal (3) at the front of the Pluto module (4). The
unique code associated with the ID-FIX must then be entered in the PLC
program.

4
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1 ID-FIX
2 ID terminal
1
3 0V terminal
4 Pluto module

(Cont'd)

Doc. No. MM-3047612-0101 6 - 209 (308)

6.4 Safety System 6 Electrical System

(Cont'd)
Set ID-FIX Address
a) Connect the PC (1) to the Pluto module (2).

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1

1 PC
2 Pluto module

(Cont'd)

6 - 210 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.4 Safety System

(Cont'd)
b) Open the START menu (3) on the PC, then select PROGRAMS (4),
PLUTO MANAGER (5) and then PLUTO MANAGER program (6).

4
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3 Start menu
4 Programs
5 Pluto manager
6 Pluto manager program

(Cont'd)

Doc. No. MM-3047612-0101 6 - 211 (308)

6.4 Safety System 6 Electrical System

(Cont'd)
c) The JOKAB SAFETY window (7) appears when the program is not
registered, in this case select the REGISTER KEY button (8), otherwise
continue from item f) on the next page.
d) In the ENTER REGISTRATION CODE window (9), type your own
registration code or the word “mute”, then select the OK button (10).
e) The message window (11) appears, if the word “mute” has been
previously introduced, select the OK button (12).

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8

9
10
7 Jokab safety window
8 Register key button
9 Enter registration code
10 OK button
11 Message window
11 12 OK button
12
(Cont'd)

6 - 212 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.4 Safety System

(Cont'd)
f) In the PLUTO MANAGER window, select PROJECTS (13) and then
select the OPEN icon (14).

14

13

13 Projects
14 Open icon
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(Cont'd)

Doc. No. MM-3047612-0101 6 - 213 (308)

6.4 Safety System 6 Electrical System

(Cont'd)
Note! The project number shown in the illustration is an example.
g) Select the required PROJECT (15) and then select the OPEN button (16).

15

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16

15 Project
16 Open button

(Cont'd)

6 - 214 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.4 Safety System

(Cont'd)
h) In the window that appears, click on the PLUTO 24 icon (17).

17
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17 Pluto 24 icon

(Cont'd)

Doc. No. MM-3047612-0101 6 - 215 (308)

6.4 Safety System 6 Electrical System

(Cont'd)
i) Select the TOOLS menu (18) and then select WRITE IDFIX (19).

18

19

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18 Tools menu
19 Write IDFIX

(Cont'd)

6 - 216 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.4 Safety System

(Cont'd)

CAUTION
Risk of damage to the equipment.
Do not select the ERASE PROTECT ID checkbox (20), otherwise no further
IDFIX changes are allowed.
Note! Do not press the SUGGEST UNIQUE ID button (21). The ID number
must be inserted following the instructions below.
j) According to the table below, write the IDFIX code in the ID NUMBER
field (22), then select the WRITE ID CIRCUIT button (23).

Unit ID number
F09K0000 24000009F000

k) Select the CLOSE button (24).

21
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22

20

23 24

20 Erase protect ID checkbox

21 Suggest unique ID button
22 ID number field
23 Write ID circuit button
24 Close button

Doc. No. MM-3047612-0101 6 - 217 (308)

6.4 Safety System 6 Electrical System

6.4.1-5 Pluto Module - Error Codes

Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with Pluto Manager
Pluto Communication Cable TP No. 90459-6033
SPC Reference 90459-6692

General Status Messages

Message Description
- Power up
n Run mode for station number 0-9. (n = station number)
P nn Run mode for station number 10-31. (nn = station number)
L Program load mode state.
Flashing ‘L’, ready for self programming (program found in other unit).
H Program execution stopped from PC computer.

(Cont'd)

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6 - 218 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.4 Safety System

(Cont'd)
Error Codes
Faults
Error Code Fault and Possible Reason Reset Action
E10 Dynamic output short circuited to Remedy of fault
foreign voltage
E11 IQ_for illuminated push button Remedy of fault
function. Missing diode
E12 Short circuit between two Remedy of fault
dynamic inputs
E13 Static output Q10...Q17 short Reset button, power off/on
circuited to 0V or Q2-Q3
overloaded
E14 Static output Q10...Q17 short Remedy of fault
circuited to 24V
E15 Power supply below 18V Reset button, power off/on
E16 Power supply above 30V Reset button, power off/on
E17
E18 CAN-bus fault. Remedy of fault+ reset button
(Short circuit, termination
resistor, etc.)
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E19 Other unit same station ID on

CAN-bus.
E20 PLC program not loaded Load the program
E21 PLC program CRC error Re-load with valid PLC-program
E22 Identifier problem. External Power off/on
identifier can not be read.
E23 Unmatched ID. Identifier does Exchange of identifiers or re-
not match declaration in declaration of identifier in
program. program
E24 Erroneous PLC code. Invalid Reload with valid code
PLC instructions.
E25 For version A16. Non existing
output used in program.
E26 Baud rate conflict. Unit Cycle the power to the unit or
programmed for other baud rate reset with pluto manager to
than current bus baud rate. reboot the unit and start with
programmed baud rate.
E27 Wrong checksum for unit Reprogramming or reboot
member in common program.

(Cont'd)

Doc. No. MM-3047612-0101 6 - 219 (308)

6.4 Safety System 6 Electrical System

(Cont'd)

I/O Faults
Error Code Fault and Possible Reason Reset Action
E40 Error output Q0-Q3 Remedy of fault + reset button
E41 Error output Q2 or Q3. Overload Remedy of fault + reset button
or foreign voltage.
E42 Error output Q0 or Q1. (No Remedy of fault + reset button
answer from relay monitoring)
E43 Error output Q0 or Q1. (Self test Power off/on
of transistors)
E45 Analogue functions not System must be calibrated
calibrated.
E49 Error calibration values, Recalibration
analogue functions

CPU Faults
Error Code Fault and Possible Reason Reset Action
E50 a/b twin input data diff Power off/on
E51 a/b twin output data diff Power off/on
E59 Calibration analogue functions Power off/on

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CRC fault
E60 Twin self test monitoring Power off/on
E61 Timer IRQ monitoring Power off/on
E62 Internal serial communication Power off/on
E63 Boot-flash CRC Power off/on
E64 OS-flash CRC Power off/on
E65 PLC-flash CRC Power off/on
E66 5 volt under/over voltage Power off/on
monitoring
E67 CPU-test error Power off/on
E68 Ram-test error Power off/on
E69 Scan cycle time over run Power off/on
E70 System, sum of system and Power off/on
stack monitoring
E71 Pluto used for IDFIX writing. Power off/on
Normal operation ceased
E80 Undefined self-test error Power off/on

(Cont'd)

6 - 220 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.4 Safety System

(Cont'd)

User Error
Error Code Fault and Possible Reason Reset Action
UE23 Malfunction feedback air
pressure guard
UE24 Missing feedback, Input I4 (L21) Power off/on
UE25 Missing feedback, Input I5 Power off/on
(L31, L34 and L37)
UE26 Missing feedback, Input I6
(L32, L35 and L38)
UE27 Missing feedback options, Power off/on
Input I7 (L32, L35 and L38)
UE35 Reset signal constant high
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Doc. No. MM-3047612-0101 6 - 221 (308)

6.5 Frequency Converters 6 Electrical System

6.5 Frequency Converters

SPC Reference 2867993-0100
2870440-0100

6.5-1 Frequency Converters - Change

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 90459-3442

Note! Make sure that the machine has been switched OFF.
Note! The Frequency Converters are not supposed to be flashed.
Note! The firmware revision of the new Frequency Converter may be equal
to, or newer than the firmware revision of the old Frequency Converter.
Using a newer firmware revision may create errors when going online, such
as unrecognized device or device mismatch, if the PC does not contain the
very latest EDS files.
Note! The functionality of the application is not verified when the new
Frequency Converters have a different series and of consequence they
have a different 90000 TP part number. Contact the Machine System
Liaison for more information.

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(Cont'd)

6 - 222 (308) Doc. No. MM-3047612-0101

 TechPub_2614345_0107 - 0601_3057047_01.fm

Flow Chart of Procedures for Changing the Frequency Converter

Change the frequency converter

(Cont'd)
6 Electrical System

No No No
New converter with New converter with New converter with New converter with
same series and no same series and old same series and a new series and
firmware firmware new firmware new firmware

Yes Yes Yes Yes

Fit the new converter, see Fit the new converter, see Fit the new converter, see Fit the new converter, see
Change the Frequency Change the Frequency Change the Frequency Change the Frequency
Converter on page 6-224 Converter on page 6-224 Converter on page 6-224 Converter on page 6-224

Doc. No. MM-3047612-0101

(Cont'd)

6 - 223 (308)
6.5 Frequency Converters
6.5 Frequency Converters 6 Electrical System

(Cont'd)
Change the Frequency Converter
a) Remove the cover (1) from the front of the PowerFlex drive (2).
b) Disconnect the devicenet cable (3) and the internal interface cable (4)
from the adapter (5) and the PowerFlex drive (2).
c) Press the clips (6) and pull out the adapter (5) from the cover (1).

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1 Cover
2 PowerFlex drive 4 6
3 DeviceNet cable
4 Internal interface cable
5 Adapter 5
6 Clip 3
(Cont'd)

6 - 224 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.5 Frequency Converters

(Cont'd)
d) Make a note of the electrical connections (7) at the base of the
PowerFlex drive (2) and then disconnect all of the cables and wires.

7
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2 PowerFlex drive
7 Electrical connections

(Cont'd)

Doc. No. MM-3047612-0101 6 - 225 (308)

6.5 Frequency Converters 6 Electrical System

(Cont'd)
e) Remove the screws (8) and the PowerFlex drive (2). Discard the
PowerFlex drive (2).

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2 PowerFlex drive
8 Screw

(Cont'd)

6 - 226 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.5 Frequency Converters

(Cont'd)
Note! Make sure that the sink/source switch of the new PowerFlex drive, is
set to the SRC position.
f) Fit the new PowerFlex drive in the reverse order.
Note! The setting values will be automatically uploaded in the new
PowerFlex drive installed, only when the machine will be switched ON and
then stepped up with all the doors closed.

SNK

SRC
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Doc. No. MM-3047612-0101 6 - 227 (308)

6.5 Frequency Converters 6 Electrical System

6.5-2 Frequency Converters - Parameters

Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 90459-3442

The frequency converter parameter sets are stored in the program loaded in
the CPU. Each time that: the machine is powered up, the power is applied to
a frequency converter and the communication is established with the
DeviceNet scanner module, the parameters set are written into the frequency
converter.
As a consequence, manual changes to the parameters set will be overwritten
with parameters stored in the PLC program. It is not recommended to make
manual changes to the parameter.
(Cont'd)

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6 - 228 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.5 Frequency Converters

(Cont'd)
For each frequency converter from (1) to (7), corresponds a function,
according to the table below:

Frequency Reference Function

Converter Designation
Position (1) W30T2000 Infeed conveyor
Position (2) W30T3000 Infeed belt brake
Position (3) W30T4000 Divider conveyor
Position (4) C35T1000 Accumulation conveyor
Position (5) X40T3000 Grouping conveyor
Position (6) C45T3000 Feeder belt
Position (7) W50T4000 External discharge conveyor

1
3 4
5 6
7
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1 Frequency converter, W30T2000

2 Frequency converter, W30T3000
3 Frequency converter, W30T4000
4 Frequency converter, C35T1000
5 Frequency converter, X40T3000
2 6 Frequency converter, C45T3000
7 Frequency converter, W50T4000

Doc. No. MM-3047612-0101 6 - 229 (308)

6.5 Frequency Converters 6 Electrical System

6.5-3 Frequency Converters - Error Codes

Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 90459-3442

To clear a fault, press the Stop key, cycle power or set A100 (Fault clear) to 1
or 2.

No. Fault Description

F2 Auxiliary Input (*) Check remote wiring.
F3 Power Loss Monitor the incoming AC line for low voltage or line
power interruption.
F4 UnderVoltage (*) Monitor the incoming AC line for low voltage or line
power interruption.
F5 OverVoltage (*) Monitor the AC line for high voltage or transient
conditions.
Bus overvoltage can also be caused by motor
regeneration.
Extend the decel time or install dynamic brake
option.

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F6 Motor Stalled (*) Increase [Accel Time x] or reduce load so drive
output current does not exceed the current set by
parameter A089 [Current Limit].
F7 Motor Overload (*) An excessive motor load exists. Reduce load so
drive output current does not exceed the current set
by parameter P033 [Motor OL Current].
F8 Heatsink OvrTmp Check for blocked or dirty heat sink fins. Verify that
(*) ambient temperature has not exceeded 40ºC
(140ºF) for IP 30/NEMA 1/UL Type 1 installations or
50ºC (122ºF) for Open type installations. Check fan.
F12 HW OverCurrent Check programming. Check for excess load,
improper DC boost setting, DC brake volts set too
high or other causes of excess current.
F13 Ground Fault Check the motor and external wiring to the drive
output terminals for a grounded conditions.
F29 Analog Input Loss An analog input is configured to fault on signal loss.
(*) A signal loss has occurred
F33 Auto Rstrt Tries Correct the cause of the fault and manually clear.
F38 Phase U to Gnd Check the wiring between the drive and motor.
F39 Phase V to Gnd Check motor for grounded phase. Replace drive if
fault cannot be cleared.
F40 Phase W to Gnd

(*) Auto-Reset/Run type fault. Configure with parameters A092 and A093.
(Cont'd)

6 - 230 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.5 Frequency Converters

(Cont'd)

No. Fault Description

F41 Phase UV Short Check the motor and drive output terminal wiring for
F42 Phase UW Short a shorted condition. Replace drive if fault cannot be
cleared.
F43 Phase VW Short
F48 Params Defaulted The drive was commanded to write default values
to EEPROM. Clear the fault or cycle power to the
drive. Program the drive parameters as needed.
F63 SW OverCurrent (*) Check load requirements and A098 [SW Current
Trip] setting.
F64 Drive Overload Reduce load or extend Accel Time.
F70 Power Unit Cycle Power. Replace drive if fault cannot be
cleared.
F71 Net Loss The communication network has faulted.
F80 SVC Autotune The autotune function was either cancelled by the
user of failed.
F81 Comm Loss If adapter was not intentionally disconnected, check
wiring to the port. Replace wiring, port expander,
adapters or complete drive as required. Check
connection. An adapter was intentionally
disconnected. Turn off using A105 [Comm Loss
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Action].
F100 Parameter Restore factory defaults.
Checksum
F122 I/O Board Fail Cycle Power. Replace drive if fault cannot be
cleared.

(*) Auto-Reset/Run type fault. Configure with parameters A092 and A093.

Doc. No. MM-3047612-0101 6 - 231 (308)

6.6 Power Supply 6 Electrical System

6.6 Power Supply

SPC Reference 2867990-0100
2867991-0100

6.6.1 Fuses
6.6.1-1 Fuses - Rated Current
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2867990-0100
2867991-0100

A01F2010 A01F2020 A01F2030 A01F4000

4A 4A 4A 4A

A01F7000 A01F6100 A01F3000 A01F1030 A01F1050 A01F2000

10 A 2A 4A 6A 6A 6A

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2 3
4

5 6
7 8
9 10

1 24 VDC power supply, A01F2010 7 PLC, TPOP and DeviceNet power supply,
2 24 VDC power supply, A01F2020 A01F3000
3 24 VDC power supply, A01F2030 8 Electronic power servo system 1, A01F1030
4 TPOP panel power supply, A01F4000 9 Electronic power servo system 2, A01F1050
5 Machine and cabinet lighting, A01F7000 10 24 VCC power supply, A01F2000
6 Fan electrical cabinet cooling, A01F6100

6 - 232 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.6 Power Supply

6.6.2 Overload Protection

6.6.2-1 Overload Protection - Set
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2867990-0100
2867991-0100

Set the overload protections according to the tables below:

A01F1020 A01F1040 A01F6000 V01F5000 W30F2000 W30F3000
20 A 20 A 2.7 A 17.5 A 8A 8A

W30F4000 C35F1000 X40F3000 C45F3000 W50F4000 V60F3000

8A 8A 8A 8A 8A 0.63 A

1
2
3 4
5 6
7 8
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9 10
11

12

1 Main power servo system 1, A01F1020 7 Divider conveyor, W30F4000

2 Main power servo system 2, A01F1040 8 Accumulation conveyor, C35F1000
3 Electrical cabinet cooling circulation, A01F6000 9 Grouping conveyor, X40F3000
4 Hotmelt unit, V01F5000 10 Feeder belt, C45F3000
5 Infeed conveyor, W30F2000 11 External discharge conveyor, W50F4000
6 Infeed belt brake, W30F3000 12 Wrap lift, V60F3000

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6.6 Power Supply 6 Electrical System

6.6.3 Residual Current Device (RCD)

6.6.3-1 Residual Current Device (RCD) - Check
Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 2867991-0100

DANGER
Hazardous voltage.
Can shock, burn or cause death. Change the RCD (2) if it does not trip
immediately.
Note! The RCD (2) must be tested monthly and always before using the
socket outlet (1), as follows.
a) Make sure that the switch (3) is in the ON position.
b) Press the TEST button (4).
c) The RCD (2) must trip immediately and the switch (3) must jump to the
OFF position. If the switch (3) does not jump to the OFF position,
change the RCD (2).

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d) Set the switch (3) to the ON position.

1 Socket outlet 3 Switch (ON position)

2 RCD (residual current device) 4 Test button
4 3

6 - 234 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.7 HMI and PLMS

6.7 HMI and PLMS

SPC Reference 90600-0980

6.7.1 HMI User Management

6.7.1-1 HMI User Management - Description
SPC Reference 90600-0980

The HMI includes certain sections which have restricted access and are
password protected. Access is permitted and defined by the user profile and
the password used to log on, see the table below for a description of each of
the available user profiles and the corresponding level of access.
Note! The default machine operator has no user log on profile or access to
the restricted areas of the HMI.

User Profile User Name Password Access Description

TP service tptechnician not provided Access to:
technician - production control settings and
functions
- maintenance control settings
and functions
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- create and delete recipes

- software installation and
configuration
- shutdown
- diagnostic
- full access to the configuration
window

(Cont'd)

Doc. No. MM-3047612-0101 6 - 235 (308)

6.7 HMI and PLMS 6 Electrical System

(Cont'd)

User Profile User Name Password Access Description

Supervisor supervisor shiftsup Access to:
- user administration
- production control settings and
functions
- maintenance control settings
and functions
- create and delete recipes
- software installation and
configuration
- shutdown
- diagnostic
- partial access to the
configuration window
Service technician technician custtech Access to:
- production control settings and
functions
- maintenance control settings
and functions
- create and delete recipes
- software installation and
configuration
- partial access to the

TechPub_2614345_0107 - 0601_3057049_01.fm
configuration window
Power operator pwroperator expertop Access to:
- production control settings and
functions
Operator (default - - Access to:
user with no log - production control settings and
on) functions
- alarm management
- basic recipe management

6 - 236 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.7 HMI and PLMS

6.7.1-2 HMI User Management - Log On as a User

Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 90600-0980

This procedure describes how to log on to the HMI and to access the
restricted password protected sections of the HMI. The level of access
permitted is defined by the user profile, see 6.7.1-1 HMI User Management -
Description on page 6-235.
Note! After 5 minutes of HMI inactivity the user is automatically logged out,
but it is always recommended to log out using the LOG OFF button (3), at
the end of the operation.
To log on to the HMI proceed as described below:
a) On the TPOP, touch the SYSTEM SETUP button (1).
b) In the SYSTEM SETUP window, touch the USER MANAGEMENT
button (2).
c) In the USER MANAGEMENT window, touch the LOG ON button (4) to
display the LOGIN window (5).
TechPub_2614345_0107 - 0601_3057049_01.fm

1 2 3 4 5

1 System setup button 4 Log on button

2 User management button 5 Login window
3 Log off button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 237 (308)

6.7 HMI and PLMS 6 Electrical System

(Cont'd)
d) Touch the USER button (6) to display the keyboard (7).
e) Use the keyboard (7) to type your user name, then touch the ENTER
button (8).

TechPub_2614345_0107 - 0601_3057049_01.fm
8

6 User button
7 Keyboard
8 Enter button

(Cont'd)

6 - 238 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.7 HMI and PLMS

(Cont'd)
f) Touch the PASSWORD button (9) to display the keyboard (7).
g) Use the keyboard (7) to type your password, then touch the ENTER
button (8).
h) Touch the ENTER button (10) to confirm the data entry.
The user is now logged on to the HMI with the corresponding level of
access.

10

9
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7 Keyboard
8 Enter button
9 Password button
10 Enter button

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6.7 HMI and PLMS 6 Electrical System

6.7.1-3 HMI User Management - Change User Password

Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 90600-0980

CAUTION
Risk of unplanned machine stoppage.
If the default passwords are changed and subsequently forgotten, the HMI
software must be reinstalled. Perform 5.2.1-6 Touch Screen - Download
Program see on page 5-56, in order to restore the default passwords and
have the access to the restricted sections of the HMI.
The user with the profile “supervisor” has the authority to set and change the
passwords for the user profiles of “technician” and “pwroperator”. To change
the password of either the user profiles proceed as follows:
a) Log on to the HMI as the user profile “supervisor”, see 6.7.1-2 HMI
User Management - Log On as a User on page 6-237.
b) In the USER MANAGEMENT window, touch either the:
– ENABLE PWROPERATOR CHANGE PASSWORD button (1) for the
user profile “pwroperator”

TechPub_2614345_0107 - 0601_3057049_01.fm
– ENABLE TECHNICIAN CHANGE PASSWORD button (2) for the
user profile “technician”.

1 2
1 Enable pwroperator change password button
2 Enable technician change password button

(Cont'd)

6 - 240 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.7 HMI and PLMS

(Cont'd)
c) Touch the LOG OFF button (3).
d) Log on to the HMI using the user profile chosen in item b), see 6.7.1-2
HMI User Management - Log On as a User on page 6-237.
e) The CHANGE PASSWORD button (4) is now enabled in the USER
MANAGEMENT window, touch the CHANGE PASSWORD button (4) to
display the CHANGE PASSWORD window (5).
Note! An old password, can be reused only if the password has been
changed at least for 5 times, or if the HMI software has been reinstalled.

3 4 5
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3 Log off button

4 Change password button
5 Change password window

(Cont'd)

Doc. No. MM-3047612-0101 6 - 241 (308)

6.7 HMI and PLMS 6 Electrical System

(Cont'd)
f) Touch the OLD PASSWORD button (6) to display the keyboard (8).
g) Use the keyboard (8) to type the current password, then touch the
ENTER button (9).
h) Touch the NEW PASSWORD button (7) to display the keyboard (8).
i) Use the keyboard (8) to type the new password, then touch the ENTER
button (9).

TechPub_2614345_0107 - 0601_3057049_01.fm
8

6 Old password button 8 Keyboard

7 New password button 9 Enter button

(Cont'd)

6 - 242 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.7 HMI and PLMS

(Cont'd)
j) Touch the CONFIRM PASSWORD button (10) to display the
keyboard (8).
k) Use the keyboard (8) to type and repeat the new password, then touch
the ENTER button (9).

10
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8 Keyboard
9 Enter button
10 Confirm password button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 243 (308)

6.7 HMI and PLMS 6 Electrical System

(Cont'd)
l) Touch the ENTER button (11) to finalise the password change procedure.

If necessary repeat the procedure to change the password for the other user
profile. The password for the user profile “supervisor” can be changed by
logging on as the “supervisor” and selecting the CHANGE PASSWORD
button in the USER MANAGEMENT window.

11

11 Enter button

TechPub_2614345_0107 - 0601_3057049_01.fm
(Cont'd)

6 - 244 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.7 HMI and PLMS

(Cont'd)
Note! If the ENABLE CHANGE PASSWORD buttons are not deselected by the
“supervisor” profile, the CHANGE PASSWORD button remains visible and
accessible in the profiles for the “pwroperator” and “technician”.
m) Touch the LOG OFF button (3).
n) Log on to the HMI using the user profile “supervisor”, see 6.7.1-2 HMI
User Management - Log On as a User on page 6-237.
o) In the USER MANAGEMENT window, depending on which button was
selected in item b) on page 6-240, deselect the:
– ENABLE PWROPERATOR CHANGE PASSWORD button (1) for the
user profile “pwroperator”
– ENABLE TECHNICIAN CHANGE PASSWORD button (2) for the
user profile “technician”.
If necessary repeat the procedure to change the password for the other user
profile. The password for the user profile “supervisor” can be changed by
logging on as the “supervisor” and selecting the CHANGE PASSWORD
button in the USER MANAGEMENT window.

3 1 2
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1 Enable pwroperator change password button

2 Enable technician change password button
3 Log off button

Doc. No. MM-3047612-0101 6 - 245 (308)

6.7 HMI and PLMS 6 Electrical System

6.7.1-4 HMI User Management - Enable/Disable Operator

Settings
Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 90600-0980

The user with the profile “supervisor”, has the authority to enable or disable
some settings for the profiles “power operator” and “operator”. When this
function is disabled, the icons for the settings involved will not be displayed
on the HMI, see the OM for more information.
a) Log on to the HMI as the user profile “supervisor”, see 6.7.1-2 HMI
User Management - Log On as a User on page 6-237.
b) In the USER MANAGEMENT window touch the button (1) to enable or
disable the operator settings. An open padlock (2) over the button (1),
means that all the settings will be available for the operators, while a
closed padlock (3) means that some settings will not be available for the
operators.

TechPub_2614345_0107 - 0601_3057049_01.fm
1

3
1 Operator settings button
2 Open padlock (operator settings enabled)
3 Closed padlock (operator settings disabled)

6 - 246 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.7 HMI and PLMS

6.7.2 HMI Installation List

6.7.2-1 HMI Installation List - Check Version of Software and
Firmware Installed
Machine Status Mains Power ON
Air OFF
Water OFF
SPC Reference 90600-0980

This procedure allows to check for each device that requires a software or a
firmware installation, if the current version installed on the device matches
the compatible version displayed on the HMI.
a) On the TPOP, touch the SYSTEM SETUP button (1).
b) In the SYSTEM SETUP window, touch the INSTALLATION LIST
button (2), then navigate as follows:
• touch the SINGLE ARROW buttons (3) or the DOUBLE ARROW
buttons (4) to scroll and select the list of devices
• touch the NEXT WINDOW button (5) to display the Firmware -
Installation List see page 6-251
TechPub_2614345_0107 - 0601_3057049_01.fm

• touch the PREVIOUS WINDOW button (6) to display the Software -

Installation List see the next page.

1 2 3 4

1 System setup button

2 Installation list button
3 Single arrow button
4 Double arrow button
5 Next window button
6 Previous window button
5 6
(Cont'd)

Doc. No. MM-3047612-0101 6 - 247 (308)

6.7 HMI and PLMS 6 Electrical System

(Cont'd)
Software - Installation List
Note! For each device (1) of the installation list, make sure that the current
version of software installed (2) and all the compatible versions of
software (3) displayed on the HMI, are equal. The pictures shown below and
on the next pages are only indicative and represent a machine with the
Genius Communication Unit (OE) installed and activated.
PLC Motion

1 3

TechPub_2614345_0107 - 0601_3057049_01.fm
1 Device
2 Version of software installed
3 Version of software compatible

HMI

(Cont'd)

6 - 248 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.7 HMI and PLMS

(Cont'd)
PLC Safety
Note! For some devices it is not possible to detect the current version of
software installed, in this cases is reported the reference designation (4) of
the device, so that it is necessary a connection online to the device, in order
to verify the current version of software installed.

4
4 Reference designation
TechPub_2614345_0107 - 0601_3057049_01.fm

DeviceNet Config

(Cont'd)

Doc. No. MM-3047612-0101 6 - 249 (308)

6.7 HMI and PLMS 6 Electrical System

(Cont'd)
PLC Genius

PLMS Config

TechPub_2614345_0107 - 0601_3057049_01.fm
(Cont'd)

6 - 250 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.7 HMI and PLMS

(Cont'd)
Firmware - Installation List
Note! For each device (1) of the installation list, are reported the reference
designation (2) and the current version of firmware installed (3) on the
components. The pictures shown below and on the next pages are only
indicative and represent a machine with the Genius Communication Unit
(OE) installed and activated.
PLC Main Rack

2 3
1 Device
2 Reference designation
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3 Version of firmware installed

Kinetix 6000
Note! The kinetix V60T1000 (4) is valid only for machines equipped with the
WA Unit (OE).

4 Kinetix V60T1000
4

(Cont'd)

Doc. No. MM-3047612-0101 6 - 251 (308)

6.7 HMI and PLMS 6 Electrical System

(Cont'd)
Cabinet Point I/O

Frequency Converter PF40 and DeviceNet Adapter 22COMD

TechPub_2614345_0107 - 0601_3057049_01.fm
Armorblock

(Cont'd)

6 - 252 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.7 HMI and PLMS

(Cont'd)
TPOP Panel

PLC Genius
TechPub_2614345_0107 - 0601_3057049_01.fm

Doc. No. MM-3047612-0101 6 - 253 (308)

6.7 HMI and PLMS 6 Electrical System

6.7.3 HMI
6.7.3-1 HMI - Enable/Disable Languages
Machine Status IDLE (STEP ZERO)
SPC Reference 90600-0980

a) On the TPOP, log on as: “tptechnician”, see 6.7.1-2 HMI User

Management - Log On as a User on page 6-237.
b) With the machine in IDLE, touch the SYSTEM SETUP button (1).
c) In the SYSTEM SETUP window, touch the LANGUAGE button (2) to
display the dialogue window, at the first access will be displayed only
the ENGLISH button (3).
d) Touch the AVAILABLE LANGUAGE button (4) to display all the others
languages.

TechPub_2614345_0107 - 0601_3057049_01.fm
3 1 2 4

1 System setup button

2 Language button
3 English button
4 Available language button

(Cont'd)

6 - 254 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.7 HMI and PLMS

(Cont'd)
e) Touch any of the buttons (5) to enable the various languages.
f) Touch the AVAILABLE LANGUAGES button (4) to eliminate all the
other buttons (6) for the not enabled languages.

5 5 5 5 5 5

6 6 6 6
TechPub_2614345_0107 - 0601_3057049_01.fm

4 Available language button

5 Button (enabled language)
6 Button (not enabled language) 4

g) To upload a new language on the TPOP, touch a button of the available

languages.
h) Touch the EXIT button (7).

7 Exit button
7

Doc. No. MM-3047612-0101 6 - 255 (308)

6.7 HMI and PLMS 6 Electrical System

6.7.3-2 HMI - Set Machine Capacity

Machine Status PREHEATING
SPC Reference 90600-0980

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

see 6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) With the machine in PREHEATING, touch the MAINTENANCE
button (1) and the SERVICE PARTS button (2), or touch the SERVICE
PARTS tab (3).
c) Touch the MACHINE CAPACITY icon (4) to display the dialogue
window.

1 2 4

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1 Maintenance button
2 Service parts button
3 Service parts tab
4 Machine capacity icon

(Cont'd)

6 - 256 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.7 HMI and PLMS

(Cont'd)
d) In the dialogue window are displayed:
– the CURRENT CAPACITY DETECTED (5), this value can not be
modified and it depends by the percentage of extra capacity that is
added to the nominal capacity or to the overcapacity, as described in
the Machine Capacity Setting Values chapter of the OM
– the MEDIUM CURRENT CAPACITY (6) measured during the last
2.5 seconds
– the OVER CAPACITY (7) and the NOMINAL CAPACITY (8), for
machines installed in lines with Line Controller the values can be
modified only from the Line Controller control panel, otherwise
change the values as follows on the next page.

6 7
TechPub_2614345_0107 - 0601_3057049_01.fm

5 8
5 Current capacity detected
6 Medium current capacity
7 Over capacity
8 Nominal capacity

(Cont'd)

Doc. No. MM-3047612-0101 6 - 257 (308)

6.7 HMI and PLMS 6 Electrical System

(Cont'd)
Note! When setting a new value remember that: the over capacity must be
bigger than the nominal capacity and of consequence the nominal capacity
must be smaller than the over capacity.
e) Touch the OVER CAPACITY icon (9) or the NOMINAL CAPACITY
icon (10) then set the new value as follows:
• the new value set is displayed in the SETTING VALUE field (11)
• touch the FACTORY button (15) to display the factory value
• touch the DOUBLE-ARROW buttons (12) to increase or decrease the
value of 1000 package/hour
• touch the SINGLE-ARROW buttons (13) to increase or decrease the
value of 100 package/hour
• touch the KEYBOARD button (14) to display the numeric keyboard, then
type the value
• touch the CONFIRMATION button (16) to confirm the new value set
f) Touch the EXIT button (17).

TechPub_2614345_0107 - 0601_3057049_01.fm
9 17

15 16
10

11

12 13 12 14
9 Over capacity icon 14 Keyboard button
10 Nominal capacity icon 15 Factory button
11 Setting value field 16 Confirmation button
12 Double-arrow button 17 Exit button
13 Single-arrow button

6 - 258 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.7 HMI and PLMS

6.7.4 PLMS NRG

6.7.4-1 PLMS NRG - Install Software
Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with CD Drive
Program CD TP No. 2886185-0XXX

If the machine is installed in a line with a filling machine with PLMS NRG,
then refer to the MM of the filling machine, for the instructions regarding the
software installation, in order to install the PLMS Logger Config.
The PLMS Logger Config is filed as SETUP.EXE in the program CD and it
is also included in the folder 2886197-1XXX.
TechPub_2614345_0107 - 0601_3057049_01.fm

Doc. No. MM-3047612-0101 6 - 259 (308)

6.7 HMI and PLMS 6 Electrical System

6.7.5 PLMS NRG Configurator

6.7.5-1 PLMS NRG Configurator - Set Machine ID
Machine Status IDLE (STEP ZERO)

Note! Perform this setting at the first start up of the machine.

a) On the TPOP, log on as a “tptechnician”, see 6.7.1-2 HMI User
Management - Log On as a User on page 6-237.
b) With the machine in IDLE, touch the MACHINE CONFIGURATION
button (1).
c) In the MACHINE CONFIGURATION window, touch the MACHINE
NUMBER icon (2).

1 2

75723 00000

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1 Machine configuration button
2 Machine number icon

(Cont'd)

6 - 260 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.7 HMI and PLMS

(Cont'd)
Note! The machine serial number is stamped on the Machine Plate see
page i-11 for the location.
d) According to the machine serial number of your machine, touch the first
part button (3) or the second part button (4) and display the SETTING
window (5) in order to set the second part of the machine serial number.

75723/99999

5
3

75723

99999
TechPub_2614345_0107 - 0601_3057049_01.fm

3 First part button

4 Second part button
5 Setting window

(Cont'd)

Doc. No. MM-3047612-0101 6 - 261 (308)

6.7 HMI and PLMS 6 Electrical System

(Cont'd)
e) When the SETTING window (5) is displayed, proceed as follows:
• touch the FACTORY button (6) to display the factory setting
• touch the DOUBLE-ARROW buttons (7) to increase or decrease the value
of 10 units
• touch the SINGLE-ARROW buttons (8) to increase or decrease the value
of 1 unit
• touch the KEYPAD button (9) to display a KEYPAD (10), type the value,
then touch the CONFIRMATION button (11), or the CLEAR button (12),
or the EXIT button (13)
• at the end touch the CONFIRMATION button (14) to confirm the value
displayed in the field (15).
f) Touch the EXIT button (16).

16 17 5 6

14

TechPub_2614345_0107 - 0601_3057049_01.fm
9

5 Setting window
6 Factory button 7 8 7 10
7 Double-arrow button
8 Single-arrow button
9 Keypad button
10 Keypad
11 Confirmation button 11
12 Clear button
13 Exit button
14 Confirmation button
12
15 Field
16 Exit button 13

6 - 262 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.8 Cooling Unit

6.8 Cooling Unit

SPC Reference 2867998-0100

6.8-1 Cooling Unit - Clean Filter

Machine Status Mains Power ON
Air ON
Water ON
SPC Reference 2867998-0100

WARNING
Refrigerant gas.
Cooling media R134A. Carefully follow the supplier’s instructions.

CAUTION
Risk of damage to the equipment.
Only the procedures described may be performed by Tetra Pak or Tetra Pak
trained customer technicians. In all other cases contact Tetra Pak.
(Cont'd)
TechPub_2614345_0107 - 0601_3057050_01.fm

Doc. No. MM-3047612-0101 6 - 263 (308)

6.8 Cooling Unit 6 Electrical System

(Cont'd)
a) Remove the screws (1).
b) Remove the cover (2) and the filter (3).
c) Clean the filter (3) with compressed air.
d) Assemble in the reverse order.

TechPub_2614345_0107 - 0601_3057050_01.fm
1 Screw
2 Cover
3 Filter

6 - 264 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.8 Cooling Unit

6.8-2 Cooling Unit - Change Filter

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2867998-0100

WARNING
Refrigerant gas.
Cooling media R134A. Carefully follow the supplier’s instructions.

CAUTION
Risk of damage to the equipment.
Only the procedures described may be performed by Tetra Pak or Tetra Pak
trained customer technicians. In all other cases contact Tetra Pak.
(Cont'd)
TechPub_2614345_0107 - 0601_3057050_01.fm

Doc. No. MM-3047612-0101 6 - 265 (308)

6.8 Cooling Unit 6 Electrical System

(Cont'd)
a) Remove the screws (1).
b) Remove the cover (2) and the filter (3).
c) Change the filter (3).
d) Assemble in the reverse order.

TechPub_2614345_0107 - 0601_3057050_01.fm
1 Screw
2 Cover
3 Filter

6 - 266 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.8 Cooling Unit

6.8-3 Cooling Unit - Check

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2867998-0100

DANGER
Hazardous voltage.
Will shock, burn or cause death. Follow the lockout procedure before
performing this procedure.

CAUTION
Risk of damage to the equipment.
Only the procedures described may be performed by Tetra Pak or Tetra Pak
trained customer technicians. In all other cases contact Tetra Pak.
a) Remove the screws (1) and the cover (2).
b) Clean the condenser unit (3) with compressed air, blow the compressed
air through the inner side of the condenser unit (3) through to the outside
of the cooling unit.
TechPub_2614345_0107 - 0601_3057050_01.fm

c) Clean any build up of dirt from the fan blades (4).

2 1 4

1 Screw 3 Condenser unit

2 Cover 4 Fan blade

(Cont'd)

Doc. No. MM-3047612-0101 6 - 267 (308)

6.8 Cooling Unit 6 Electrical System

(Cont'd)
d) Check for:
• oil leakages on the copper pipe connections, if oil is leaking from the
pipe connections, contact Tetra Pak
• that the compressor (5) is securely fastened to the cooling unit base
• that the fans (6) are securely fixed and there is not excessive radial play.
To change the fans, see 6.8-4 Cooling Unit - Overhaul on page 6-269.
e) Assemble in the reverse order.

TechPub_2614345_0107 - 0601_3057050_01.fm
5 Compressor
6 Fan

6 - 268 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.8 Cooling Unit

6.8-4 Cooling Unit - Overhaul

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2867998-0100

DANGER
Hazardous voltage.
Will shock, burn or cause death. Follow the lockout procedure before
performing this procedure.

WARNING
Refrigerant gas.
Cooling media R134A. Carefully follow the supplier’s instructions.

CAUTION
Risk of damage to the equipment.
Only the procedures described may be performed by Tetra Pak or Tetra Pak
trained customer technicians. In all other cases contact Tetra Pak.
Note! If the cooling unit is removed from the electrical cabinet it is advisable
TechPub_2614345_0107 - 0601_3057050_01.fm

to fit a new gasket to ensure a sufficient seal between the electrical cabinet
and the cooling unit. Apply the self adhesive side of the new gasket to the
cooling unit base.
(Cont'd)

Doc. No. MM-3047612-0101 6 - 269 (308)

6.8 Cooling Unit 6 Electrical System

(Cont'd)
Preparation
Remove the screws (1) and the cover (2).

2 1

TechPub_2614345_0107 - 0601_3057050_01.fm
1 Screw
2 Cover

(Cont'd)

6 - 270 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.8 Cooling Unit

(Cont'd)
Change the Condenser Fan M0002
a) Disconnect the electrical cable W0009 (1) from the electrical connection
box X1710 (2).
b) Remove the screws (3) and the bracket (4).
c) Remove the screws (5) and the fan (6).
d) Assemble in the reverse order.

6 4

2
TechPub_2614345_0107 - 0601_3057050_01.fm

1 5
1 Electrical cable, W0009 4 Bracket
2 Connection box, X1710 5 Screw
3 Screw 6 Fan, M0002

(Cont'd)

Doc. No. MM-3047612-0101 6 - 271 (308)

6.8 Cooling Unit 6 Electrical System

(Cont'd)

CAUTION
Risk of damage to the equipment.
Take care to fit the fan (6) with the correct screws (5), the screws (3) may
damage the fan.
Change the Evaporator Fan M0003
a) Disconnect the electrical cable W0010 (1) from the electrical connection
box X1710 (2).
Note! If necessary cut the plastic ties securing the earth cable to the
screws (3).
b) Remove the screws (3) and the cover (4).
c) Remove the screws (5) and the fan (6).
d) Assemble in the reverse order.

6 4

TechPub_2614345_0107 - 0601_3057050_01.fm
2

5
1 Electrical cable, W0010 3
2 Connection box, X1710
3 Screw
4 Bracket
5 Screw
6 Fan, M0003

(Cont'd)

6 - 272 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.8 Cooling Unit

(Cont'd)
Change the Anti-freeze Thermostat B0006
a) Cut the thermostat tubing (1) where necessary and remove the
thermostat tubing (1) from the cooling unit (2).
b) Remove the thermostat sensor (3) from the evaporator unit (4).

4
TechPub_2614345_0107 - 0601_3057050_01.fm

1
1

1 Thermostat tube
2 Cooling unit
3 Thermostat sensor
4 Evaporator unit

(Cont'd)

Doc. No. MM-3047612-0101 6 - 273 (308)

6.8 Cooling Unit 6 Electrical System

(Cont'd)
c) Remove the electrical connections (5) from the thermostat (6).
d) Remove the screws (7) and the thermostat (6).
e) Fit the new thermostat sensor (8) into the evaporator (4).
f) Thread the thermostat tube through the cooling unit following the path of
the old thermostat tube.
Note! Secure the thermostat tube where necessary with plastic ties and coil
any excess tube around the bracket (9) before fitting the thermostat (6).
g) Assemble in the reverse order.

TechPub_2614345_0107 - 0601_3057050_01.fm
5

9
7
4 Evaporator 7 Screw
5 Electrical connection 8 Thermostat sensor
6 Thermostat 9 Bracket

6 - 274 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.8 Cooling Unit

6.8-5 Cooling Unit - Troubleshooting

Machine Status Mains Power ON
Air ON
Water ON
SPC Reference 2867998-0100

CAUTION
Risk of damage to the equipment.
Only the procedures described may be performed by Tetra Pak or Tetra Pak
trained customer technicians. In all other cases contact Tetra Pak.
If the cooling unit fails to operate or is operating insufficiently use the table
below to determine the possible cause and actions to be taken.

Description Possible Cause Action

The cooling unit will not No mains power supply to Check the circuit breaker
start. the cooling unit. and connections to the
mains power supply.
Only the inside fan The electrical cabinet Check the electrical
runs. Practically no internal thermostat has cabinet internal
electric consumption tripped or is wrongly set. The thermostat and if
freeze thermostat has necessary set to 35°C.
TechPub_2614345_0107 - 0601_3057050_01.fm

tripped.
Normal operation. Condenser coil or filter dirty. Check coil and air filter.
Insufficient cooling. Faulty condenser fan. Check the fans. Remove
High electric Electric panel not properly any obstacles. Close the
consumption sealed. cabinet doors.
The fan runs but the Compressor internal Contact Tetra Pak.
compressor does not protection has tripped
run. Low electric probably due to too many
consumption frequent start ups or
insufficient refrigerant gas
Normal operation. Low Insufficient or complete lack Contact Tetra Pak.
electric consumption of refrigerant gas.
and compressor very
hot.
Compressor never Check that the thermostat Replace the necessary
stops. contacts or any switch faulty part.
contacts are not stuck.
During operation a lot Cabinet not sealed Improve the cabinet
of condensation forms sufficiently. Cabinet doors sealing. Close the
and is drained off. open. Holes in cabinet walls. cabinet doors. Fill any
holes in the cabinet.

Doc. No. MM-3047612-0101 6 - 275 (308)

6.9 Signal Exchange 6 Electrical System

6.9 Signal Exchange

6.9.1-1 Signal Exchange - Select Line Automation
Machine Status IDLE (STEP ZERO)

Note! Perform this setting at the first start up of the machine.

There are three type of solution: with LC (Line Controller), with Genius or
with Photocell (that means without Line Automation, no LC and no Genius).
a) On the TPOP, log on as: “tptechnician” or “supervisor” or “technician”,
see 6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) With the machine in IDLE, touch the MACHINE CONFIGURATION
button (1)
c) In the MACHINE CONFIGURATION window, check if the solution
displayed in the CURRENT SELECTION field (2) is correct for your
line, if not touch the OPTION LINE AUTOMATION icon (3) and
change it as follows:
• the new solution selected is displayed in the SELECTION field (4)
• touch the SINGLE-ARROW buttons (5) to change the selection
• touch the CONFIRMATION button (6) to confirm the selection
d) Touch the EXIT button (7).

TechPub_2614345_0107 - 0601_3057051_01.fm
3 4

1 2

1 Machine configuration button

6
2 Current selection field
3 Option line automation icon 4
4 Selection field
5 Single-arrow button
6 Confirmation button
7 Exit button

5 7

6 - 276 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.9 Signal Exchange

6.9.2.2 PLC Power Supply

6.9.2.2-1 PLC Power Supply - Change
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 90031-0068

DANGER
Hazardous voltage.
Will cause shock, burns or even death. Perform the lockout procedure
before starting any work in the electrical cabinet and wait five minutes to let
all power dissipate.
(Cont'd)
TechPub_2614345_0107 - 0601_3057051_01.fm

Doc. No. MM-3047612-0101 6 - 277 (308)

6.9 Signal Exchange 6 Electrical System

(Cont'd)
Note! Note and record the position of the electrical connectors.
a) Open the plastic cover of the PLC power supply (1) and disconnect the
electrical connectors:
– earth connection (2)
– two blue input connections (3)
– two black input connections (4).
Note! Lift up the PLC power supply (1) to disengage the hook (6).
b) Press the release catch (5) underneath the PLC power supply (1) then
remove unit from the back plane (7).
c) Make sure that the connector on the back plane is not damaged.
d) Assemble in the reverse order.

PROGRAMMABLE CONTROLLER
BATT
RUN
PWR

OK

POWER SUPPLY
HIGH CAPACITY
GE Fanuc
SERIES 90 - 30

TechPub_2614345_0107 - 0601_3057051_01.fm
50/60 Hz 100VA
125 VDC 50W
100-240 VAC

0.8 A MAX.
OUTPUT
INPUT

+ 24 VDC

B
A

R
E

Y
T
T
5

4 3 2
7 1 PLC power supply
2 Earth connection
3 Input connection (blue)
6 4 Input connection (black)
5 Release catch
1 6 Hook
7 Back plane

6 - 278 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.9 Signal Exchange

6.9.2.2-2 PLC Power Supply - Download Program

Machine Status Mains Power ON
Air OFF
Water OFF
Special Equipment PC with CD Drive
Serial communication cable RS-232, TP No. 90031-0300
Program CD TP No. 2886185-0XXX
SPC Reference 90031-0068
Note! Before starting, check the current version of Software installed, see
the Software - Installation List on page 6-248, included in the chapter
6.7.2-1 HMI Installation List - Check Version of Software and Firmware
Installed.
a) Connect the serial communication cable (1) between the PC and the PLC
connector (2) of the power supply unit.

2
TechPub_2614345_0107 - 0601_3057051_01.fm

BATT
PWR

RUN

PROGRAMMABLE CONTROLLER
OK

POWER SUPPLY
SERIES 90 30
GE Fanuc

STANDARD

50/60HZ 90 VA

125 VDC, 50W

100 240 VAC

0.8A MAX.
OUTPUT
24 VDC
INPUT

R
B
A

Y
T
T

1 Serial communication cable

2 PLC connector

(Cont'd)

Doc. No. MM-3047612-0101 6 - 279 (308)

6.9 Signal Exchange 6 Electrical System

(Cont'd)
b) Insert the program CD into the PC CD drive.
c) Browse to the CD drive and copy the folder 2886195-1XXX to the PC
desktop.
d) Open the START menu (3) on the PC, then select PROGRAMS (4), GE
FANUC (5), PROFICY MACHINE EDITION (6) and then PROFICY
MACHINE EDITION program (6).

5 6 7

TechPub_2614345_0107 - 0601_3057051_01.fm
3
3 Start menu
4 Programs
5 GE fanuc
6 Proficy machine edition
7 Proficy machine edition program

(Cont'd)

6 - 280 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.9 Signal Exchange

(Cont'd)
e) Select the CANCEL button (8) in the MACHINE EDITION window (9).

9
TechPub_2614345_0107 - 0601_3057051_01.fm

8 Cancel button
9 Machine edition window

(Cont'd)

Doc. No. MM-3047612-0101 6 - 281 (308)

6.9 Signal Exchange 6 Electrical System

(Cont'd)
f) From the FILE menu (10), select RESTORE PROJECT (11).

10

11

TechPub_2614345_0107 - 0601_3057051_01.fm
10 File menu
11 Restore project

(Cont'd)

6 - 282 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.9 Signal Exchange

(Cont'd)
g) When the RESTORE window (12) appears, select Proficy Machine
Edition (*.SwxCF) in the FILES OF TYPE window (13).
h) Browse and select the program file included in the folder
2886195-1XXX, then select the OPEN button (14).

12

13
TechPub_2614345_0107 - 0601_3057051_01.fm

14

12 Restore window
13 Files of type window
14 Open button

(Cont'd)

Doc. No. MM-3047612-0101 6 - 283 (308)

6.9 Signal Exchange 6 Electrical System

(Cont'd)
i) Select the target program (15).
j) Select the ONLINE/OFFLINE icon (16) and the TOGGLE ONLINE
MODE icon (17).

16

17

15

TechPub_2614345_0107 - 0601_3057051_01.fm
15 Target program
16 Online/Offline icon
17 Toggle online mode icon

(Cont'd)

6 - 284 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.9 Signal Exchange

(Cont'd)
k) Right click the PC mouse, then select ONLINE COMMANDS (18) and
STOP PLC... (19).
TechPub_2614345_0107 - 0601_3057051_01.fm

18 19
18 Online commands
19 Stop PLC...

(Cont'd)

Doc. No. MM-3047612-0101 6 - 285 (308)

6.9 Signal Exchange 6 Electrical System

(Cont'd)
l) Select the OUTPUTS DISABLED checkbox (20) in the STOP PLC
window (21), then select the OK button (22).
m) Right click the PC mouse, then select DOWNLOAD TO PLC... (23).

20
21

22

TechPub_2614345_0107 - 0601_3057051_01.fm
23

20 Outputs disabled checkbox

21 Stop PLC window
22 OK button
23 Download to PLC...

(Cont'd)

6 - 286 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.9 Signal Exchange

(Cont'd)
n) In the DOWNLOAD TO PLC window (24), make sure that all the
checkboxes indicated with arrows are selected, then select the OK
button (25).
o) Right click the PC mouse, then select ONLINE COMMANDS (26) and
START PLC... (27).

24
25
TechPub_2614345_0107 - 0601_3057051_01.fm

26
24 Download to PLC... window
25 OK button
27 26 Online commands
27 Start PLC...

(Cont'd)

Doc. No. MM-3047612-0101 6 - 287 (308)

6.9 Signal Exchange 6 Electrical System

(Cont'd)
p) In the START PLC window (28) select the OK button (29).
q) Reset the CPU module of the Rockwell PLC, by turning the key to the
PROG mode position, then to the RUN mode position and finally to the
REM mode position.

28

29
28 Start PLC... window
29 OK button

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6 - 288 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.9 Signal Exchange

6.9.2.2-3 PLC Power Supply - Change Battery

Machine Status Mains Power ON
Air ON
Water ON
SPC Reference 90031-0301

Note! The replacement of the battery (4) must be completed within 20

minutes otherwise the RAM memory might be erased.
When the battery signal lamp (1) lights up, the battery (4) must be changed.
a) Remove the battery cover (2).
b) Insert the cable connector (8) of the new battery (9) on the unused
contact (7).
c) Remove the old battery (4) from the mounting clips (3).
d) Firmly attach the new battery (9) to the clips (3).

WARNING
Dispose of batteries in a safe way.
Batteries must not be disposed of with regular waste. Hand in the old battery
to the nearest recycle centre. Do not burn or attempt to recharge lithium
batteries.
TechPub_2614345_0107 - 0601_3057051_01.fm

e) Disconnect the cable connector (5) from the contact (6) and discard the
old battery (4).
f) Fit back the battery cover (2).

1 Lamp
2 Battery cover 9 8
3 Mounting clip
4 Battery 7
5 Cable connector
6 Contact
7 Contact
8 Cable connector
9 Battery
2 3 4 5 6

Doc. No. MM-3047612-0101 6 - 289 (308)

6.9 Signal Exchange 6 Electrical System

6.9.2.3 DeviceNet Slave Module

6.9.2.3-1 DeviceNet Slave Module - Reset Genius
Communication
Machine Status Mains Power ON
Air ON
Water ON
SPC Reference 90459-4234

After the start up of the machine, sometimes the error 78 on the node 62 is
displayed on the DeviceNet Scanner Module of the PLC Rockwell (see
6.2.1-6 DeviceNet Scanner Module - Error Codes on page 6-116), in this
case, remove and re-insert the DeviceNet Slave Module (1) to reset the
Genius communication.

TechPub_2614345_0107 - 0601_3057051_01.fm
1

1 DeviceNet Slave Module

6 - 290 (308) Doc. No. MM-3047612-0101

 6 Electrical System 6.10 Box

6.10 Box
SPC Reference 2870442-0100

6.10.1 Overvoltage Protector

6.10.1-1 Overvoltage Protector - Change
Machine Status Mains Power OFF
Air ON
Water ON
SPC Reference 90082-0013

The overvoltage protector (1) protects the machine when one or more of the
phases are subject to an overvoltage. This is indicated by the
OVERVOLTAGE TRIPPED alarm (3) on the TPOP.
When a fuse has tripped, the colour in that indication window (2) will change
from green to red.
Change all tripped fuses, otherwise the machine will not be protected for the
next overvoltage event.

1
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1 Overvoltage protector, A01F1010

2 Indication window
3 Overvoltage tripped alarm (blue)

Doc. No. MM-3047612-0101 6 - 291 (308)

6.11 Electrical Components on the
Machine 6 Electrical System

6.11 Electrical Components on the Machine

6.11.1 Photocells
6.11.1-1 Photocells - Set Sensitivity
Machine Status Mains Power ON
Air ON
Water ON
SPC Reference 90459-2986 (Reflection)
90459-5530 (Sender)
90459-5531 (Receiver)

WARNING
Risk of personal injury.
Watch your fingers when working in this area. Moving parts can cause
serious injuries. In case of accident, use Emergency stop.

CAUTION
Laser radiation, do not stare into beam.
Class 2 laser product.

TechPub_2614345_0107 - 0601_3057053_01.fm
There are two different types of photocells installed on the machine
described in the following paragraphs:
• Reflection Photocells - Set on the next page
and
• Transmitter/Receiver Photocells (Through-Beam) - Set on page 6-296.
(Cont'd)

6 - 292 (308) Doc. No. MM-3047612-0101

 6.11 Electrical Components on the
6 Electrical System Machine

(Cont'd)
Reflection Photocells - Set
a) Make sure that the photocell is positioned, so that the object can be
detected by the photocell.
b) Set the operation selector (1), according to the Setting Tables for
Reflection Photocells on the next page.
c) Set the sensitivity as follows:
• without any object to detect, turn the distance adjuster (4) clockwise to
max, until the green LED (3) and the orange LED (2) are ON
• turn the distance adjuster (4) anti-clockwise to min, until the orange
LED (2) goes OFF, then to secure the setting turn the distance
adjuster (4) just a little bit anti-clockwise
• place the object to be detected in front of the photocell, and check that
the orange LED (2) goes ON, whilst the green LED (3) is ON.

1
3
2
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1 Operation selector (Dark/Light)

2 Operation indicator (Orange LED)
3 Stability indicator (Green LED)
4 Distance adjuster

(Cont'd)

Doc. No. MM-3047612-0101 6 - 293 (308)

6.11 Electrical Components on the
Machine 6 Electrical System

(Cont'd)
Setting Tables for Reflection Photocells
In the following tables are indicated the setting position of the operation
selector (1) (see the previous page for the location), for each reflection
photocell installed on the machine.
Note! With the operation selector (1) set on L position, the signal will be sent
when the object is detected by the photocell; while if it is set on D position,
the signal will be sent when no object is detected by the photocell.

Reference Machine Group Function Description Operation Electrical Function

Designation selector (1)
C35B1100 Accumulation unit Max queue lane 1 L 0=no packages
1=packages detected
C35B1110 Accumulation unit Max queue lane 2 L 0=no packages
1=packages detected
C35B1120 Accumulation unit Max queue lane 3 L 0=no packages
1=packages detected
C35B1130 Accumulation unit Max queue lane 4 L 0=no packages
1=packages detected
C35B1140 Accumulation unit Max queue lane 5 L 0=no packages
1=packages detected

TechPub_2614345_0107 - 0601_3057053_01.fm
C35B1150 Accumulation unit Max queue lane 6 L 0=no packages
1=packages detected
C35B1160 Accumulation unit Max queue lane 7 L 0=no packages
1=packages detected
C35B1170 Accumulation unit Max queue lane 8 L 0=no packages
1=packages detected
C35B1180 Accumulation unit Max queue lane 9 L 0=no packages
1=packages detected
C35B1190 Accumulation unit Max queue lane 10 L 0=no packages
1=packages detected
C35B1200 Accumulation unit Max queue lane 11 L 0=no packages
(only for TBA 125S) 1=packages detected

(Cont'd)

6 - 294 (308) Doc. No. MM-3047612-0101

 6.11 Electrical Components on the
6 Electrical System Machine

(Cont'd)

Reference Machine Group Function Description Operation Electrical Function

Designation selector (1)
W50B1140 Feed unit Blank in feed unit L 0=no blank
1=blank detected
W50B3100 Feed unit Unit in hotmelt position L 0=no blank
1=blank detected
W50B1120 Feed unit Outfeed congestion L 0=no blank
1=blank detected
C45B1100 Magazine unit Low level L 0=no blank
1=blank detected
C45B1110 Magazine unit Very low level L 0=no blank
1=blank detected
C45B2100 Magazine unit Blank pull down L 0=no blank
1=blank detected
V60B4210 (*) Magazine unit Wrap glue control L 0=no blank
1=blank detected

(*) The reflection photocell has to be used only for machines running with
WA unit (OE).
(Cont'd)
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Doc. No. MM-3047612-0101 6 - 295 (308)

6.11 Electrical Components on the
Machine 6 Electrical System

(Cont'd)
Transmitter/Receiver Photocells (Through-Beam) - Set
a) The transmitter photocell (1) and the receiver photocell (2) must be
positioned opposite each other as shown below.
b) Set the operation selector (3) on the receiver photocell (2), according to
the Setting Tables for Receiver Photocells on the next page.
c) Set the sensitivity on the receiver photocell (2) as follows:
• without any object to detect, turn the distance adjuster (6) clockwise to
max, until the green LED (5) and the orange LED (4) are ON
• turn the distance adjuster (6) anti-clockwise to min, until the orange
LED (4) goes OFF, then to secure the setting turn the distance
adjuster (6) just a bit anti-clockwise
• place the object to be detected between the photocells (1) and (2), and
check that the orange LED (4) goes ON, whilst the green LED (5) is ON.

6
4

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5

1 Transmitter photocell
2 Receiver photocell
3 Operation selector (Dark/Light)
4 Operation indicator (Orange LED)
5 Stability indicator (Green LED)
6 Distance adjuster

(Cont'd)

6 - 296 (308) Doc. No. MM-3047612-0101

 6.11 Electrical Components on the
6 Electrical System Machine

(Cont'd)
Setting Tables for Receiver Photocells
In the following tables are indicated the setting position of the operation
selector (1) (see the previous page for the location), for each receiver
photocell (2) installed on the machine.
Note! With the operation selector (1) set on L position, the signal will be sent
when no object is detected between the photocells; while if it is set on D
position, the signal will be sent when the object is detected between the
photocells.

Reference Machine Group Function Description Operation Electrical Function

Designation selector (1)
W30B1160 (*) Infeed unit Overflow/Package coming D 0=no packages
1=packages detected
W30B2120 Infeed unit Infeed fallen packages lower D 0=no packages
1=packages detected
W30B2160 Infeed unit Infeed fallen packages upper D 0=no packages
trailing (**) 1=packages detected
W30B2140 Infeed unit Infeed fallen packages upper D 0=no packages
leading (**) 1=packages detected
A01B4010 Infeed unit PLMS package in L 0=packages detected
1=no packages
TechPub_2614345_0107 - 0601_3057053_01.fm

W30B4120 Infeed unit Divider congestion D 0=no packages

1=packages detected
W30B6120 Infeed unit Trailing counter (**) D 0=no packages
1=packages detected
W30B6100 Infeed unit Leading counter (**) D 0=no packages
1=packages detected

(*) Disconnect the receiver photocell indicated and the corresponding

transmitter photocells if they are not used in your production line, otherwise
the machine will never stop in stand by. They will function as overflow in
line with LC and as package coming in the other lines.
(**) The Leading photocells are placed downstream, respect the Trailing
photocells that are placed upstream.
(Cont'd)

Doc. No. MM-3047612-0101 6 - 297 (308)

6.11 Electrical Components on the
Machine 6 Electrical System

(Cont'd)

Reference Machine Group Function Description Operation Electrical Function

Designation selector (1)
X40B1100 Grouping unit Min queue accumulation L 0=flag detected
1=no flag
X40B1120 Grouping unit Index fallen package L 0=flag detected
1=no flag
X40B2120 Grouping unit Flight bar crash D 0=no packages
1=packages detected
X40B3100 Grouping unit Unit leaving grouping D 0=no packages
1=packages detected
W50B4100 Feed unit Queue after the machine L 0=box detected
1=no box
X40B3200 Grouping unit Fallen package D 0=no packages
1=packages detected

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6 - 298 (308) Doc. No. MM-3047612-0101

 6.11 Electrical Components on the
6 Electrical System Machine

6.11.1-2 Photocells - Check and Clean

Machine Status Mains Power ON
Air ON
Water ON
SPC Reference 90459-2986 (Reflection)
90459-5530 (Sender)
90459-5531 (Receiver)

WARNING
Risk of personal injury.
Watch your fingers when working in this area. Moving parts can cause
serious injuries. In case of accident, use Emergency stop.

CAUTION
Laser radiation, do not stare into beam.
Class 2 laser product.
Reflection Photocells - Check/Clean
a) Make sure that the green LED (1) is ON, then place the object to be
detected in front of the photocell and check that the orange LED (2) goes
ON, if not fine adjust the sensitivity of the photocell, see Reflection
TechPub_2614345_0107 - 0601_3057053_01.fm

Photocells - Set on page 6-293.

b) If required clean the optical lens (3) of the photocells with a cloth.

1
2

1 Operation indicator (Green LED)

2 Stability indicator (Orange LED)
3 Optical lens

(Cont'd)

Doc. No. MM-3047612-0101 6 - 299 (308)

6.11 Electrical Components on the
Machine 6 Electrical System

(Cont'd)
Transmitter/Receiver Photocells - Check/Clean
a) On the receiver photocell (2), make sure that the green LED (3) is ON,
then place the object to be detected, between the photocell (1) and (2)
and check that the orange LED (4) goes ON, if not fine adjust the
sensitivity of the receiver photocell (2), see Transmitter/Receiver
Photocells (Through-Beam) - Set on page 6-296.
b) If required clean the optical lens (5) of both photocells (1) and (2) with a
cloth.

4 3

1 2

TechPub_2614345_0107 - 0601_3057053_01.fm
1 Transmitter photocell
2 Receiver photocell
3 Stability indicator (Green LED)
4 Operation indicator (Orange LED)
5 Optical lens

6 - 300 (308) Doc. No. MM-3047612-0101

 6.11 Electrical Components on the
6 Electrical System Machine

6.11.2 Armorblocks
6.11.2-1 Armorblocks - Set the Node Address

Machine Status Mains Power OFF

Air OFF
Water OFF
SPC Reference 90459-6062

CAUTION
This equipment is sensitive to electrostatic discharge, which can
cause internal damage and affect normal operation.

Follow these guidelines when you handle this equipment:

• Touch a grounded object to discharge potential static.
• Wear an approved grounding wriststrap.
• Do not touch connectors or pins on component boards.
• Do not touch circuit components inside the equipment.
• If available, use a static-safe workstation.
TechPub_2614345_0107 - 0601_3057053_01.fm

• When not in use, store the equipment in appropriate static-safe

packaging.

(Cont'd)

Doc. No. MM-3047612-0101 6 - 301 (308)

6.11 Electrical Components on the
Machine 6 Electrical System

(Cont'd)
Note! Only the node addresses from 00 up to 63 are valid. For this machine
are used the node addresses from 40 up to 61.
a) Set the node address according to the EM.
b) Each new module is set as default with the node address 63. Remove the
caps on the front of the module to access the two switches:
• Switch (1) most significant digit - LH side on the module
• Switch (2) least significant digit - RH side on the module
c) Reset the node address, using a screwdriver to rotate the switches (1)
and (2), until they are lined up with the node address number as
represented on the circuit diagram.
d) Power when all the modules have been set.

0
0.1 +24 S hield 2
0.4 +24V 4
0.3 0V 0V 1
CAN_H 5
CAN_L 3
1

1.1 +24
1.4 S hield 2

TechPub_2614345_0107 - 0601_3057053_01.fm
1.3 0V +24V 4
The picture shows an example of 0V 1
node address, as represented on CAN_H 5
2 CAN_L
the circuit diagram, see the EM. 3
2
2.1 +24
2.4
2.3 0V 1
Node No
The picture above shows the
3 node address set at 41.
3.1 +24
1
3.4 4
3.3 0V

1
4 2
4.1 +24
4.4
4.3 0V

1 Switch, X10
2 Switch, X1

(Cont'd)

6 - 302 (308) Doc. No. MM-3047612-0101

 6.11 Electrical Components on the
6 Electrical System Machine

(Cont'd)
The rotary switches (1) and (2) are read periodically. If the switches have
been changed since the last time they were read and they no longer match the
on line address, a minor fault will occur, which is indicated by a flashing red
MOD LED (3). Settings between 64 and 99 force the module to use the last
valid node address stored internally (for example: the last setting internally
was 40; if a change is made to 68, and then the module is power up, the
address will become 40).
The module is equipped with AutoBaud detect. AutoBaud lets the module
read the settings already in use on the DeviceNet network and automatically
adjusts to follow those settings.

This picture shows the default

node address set at 63.
3

1
TechPub_2614345_0107 - 0601_3057053_01.fm

1 Switch, X10
2 Switch, X1
3 MOD LED (red)
2

Doc. No. MM-3047612-0101 6 - 303 (308)

6.11 Electrical Components on the
Machine 6 Electrical System

6.11.2-2 Armorblocks - LED Description

Machine Status Mains Power ON

Air OFF
Water OFF
SPC Reference 90459-6062

The Armorblock module has four different types of LEDs indicating the state
of the system. See the tables on the next pages for the description of the
status of each LED.

1 2
MOD NET
Network

4 X10 X1

4
0

TechPub_2614345_0107 - 0601_3057053_01.fm
1

4
2

4
3

4
4

4
5

4
6

3
1 MOD LED 7

2 NET LED
3 I/O LED AUX POWER

4 AUX POWER

(Cont'd)

6 - 304 (308) Doc. No. MM-3047612-0101

 6.11 Electrical Components on the
6 Electrical System Machine

(Cont'd)

LED Colour Status Description Action

MOD (1) OFF No power There is no power Apply power to the
applied to the module.
module.
GREEN Module The module is None
operational operating
normally.
FLASHING Module needs The module needs Check the
GREEN commissioning commissioning configuration and
due to missing, cycle power.
incomplete or an
incorrect
configuration.
FLASHING Minor fault The module has a Check the
RED recoverable fault. configuration and
cycle power.
RED Critical fault Watchdog timeout Cycle power to the
or the module has module. If this not
an unrecoverable solve the problem
fault. contact the Tetra
Pak service desk.
The module may
TechPub_2614345_0107 - 0601_3057053_01.fm

need to be
changed.

(Cont'd)

Doc. No. MM-3047612-0101 6 - 305 (308)

6.11 Electrical Components on the
Machine 6 Electrical System

(Cont'd)

LED Colour Status Description Action

Net (2) OFF No power or The module is not Wait until module
not on line online. has completed the
dup_MAC_id test or
power the module.
GREEN Online Device is operating None
Connected normally and is
online with
connections
established.
FLASHING Online but not The module is Establish
GREEN connected online with connections to other
connections nodes.
established.
RED Critical link Failed Check the
failure communication communication and
module. cycle power.
FLASHING Connection An I/O connection Cycle power to the
RED time out has timed out module.

(Cont'd)

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6 - 306 (308) Doc. No. MM-3047612-0101

 6.11 Electrical Components on the
6 Electrical System Machine

(Cont'd)

LED Colour Status Description Action

aux OFF No auxiliary There is no Apply auxiliary
power (3) power auxiliary power power to the
applied to the module.
module.
GREEN Auxiliary There is auxiliary None
power present power applied to
the module.
i/o (4) OFF Output not Output is not None
energised or energised or input
no valid input not valid.
YELLOW Output Output is energised None
energised or or input is valid.
valid input
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Doc. No. MM-3047612-0101 6 - 307 (308)

6.11 Electrical Components on the
Machine 6 Electrical System

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6 - 308 (308) Doc. No. MM-3047612-0101

 7 Wrap Around Unit
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Doc. No. MM-3047612-0101 7 - 1 (64)

 7 Wrap Around Unit

Wrap Around Unit - Description

SPC Reference 663110-0200
Note! If not indicated in a different way, all the pictures used in the chapter
show the Wrap Around Unit for a machine with Magazine Unit on the RH
side.

7.4

7.5

7.3

TechPub_2614345_0107 - 0701_3057054_01.fm
7.6 7.2 7.1
7.1 Wrap Around Unit
7.2 Side Adjuster
7.3 Folding Unit
7.4 Spindle Guide
7.5 Gun Holder
7.6 Motor Unit

7 - 2 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit Table of Contents

7 Wrap Around Unit . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5

7-1 Wrap Around Unit - Functional Description . . . . 7 - 5
7-2 Wrap Around Unit- Setting Sequence, Type I . . . 7 - 6
7-3 Wrap Around Unit - Setting Sequence, Type II . . 7 - 7
7-4 Wrap Around Unit - Setting Sequence, Type III . 7 - 7

7.1 Wrap Around Unit . . . . . . . . . . . . . . . . . . . . . . . . 7 - 8

7.1-1 Wrap Around Unit - Set Software Installation . . . 7 - 8
7.1-2 Wrap Around Unit - Basic Setting . . . . . . . . . . . 7 - 10
7.1-3 Wrap Around Unit - Centre Unit . . . . . . . . . . . . 7 - 16
7.1-4 Wrap Around Unit - Set Height Position . . . . . . 7 - 17
7.1-5 Wrap Around Unit - Lift/Lower Unit . . . . . . . . . 7 - 18
7.1-6 Wrap Around Unit - Set Pressure Guides and
Fingers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 19
7.1-7 Wrap Around Unit - Referencing . . . . . . . . . . . . 7 - 34
TechPub_2614345_0107 - 0701_3057054_01.fm

7.1.1 Chain Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 41

7.1.1-1 Chain Unit - Set Tension . . . . . . . . . . . . . . . . . . 7 - 41
7.1.1-2 Chain Unit - Check . . . . . . . . . . . . . . . . . . . . . . . 7 - 42
7.1.1-3 Chain Unit - Change . . . . . . . . . . . . . . . . . . . . . . 7 - 43
7.1.2 Pressure Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 45
7.1.2-1 Pressure Unit - Check . . . . . . . . . . . . . . . . . . . . . 7 - 45
7.1.2-2 Pressure Unit - Set Position . . . . . . . . . . . . . . . . 7 - 47
7.1.3 Motor Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 49
7.1.3-1 Motor Bracket - Set Chain Tension . . . . . . . . . . 7 - 49

7.2 Side Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 50

7.2-1 Side Adjuster - Check Timing Belt . . . . . . . . . . 7 - 50

7.3 Folding Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 51

7.3-1 Folding Unit - Basic Settings . . . . . . . . . . . . . . . 7 - 51
7.3-2 Folding Unit - Disable WAIF Alarm Clutch . . . 7 - 54

7.4 Spindle Guide . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 55

7.4-1 Spindle Guide - Check . . . . . . . . . . . . . . . . . . . . 7 - 55

Doc. No. MM-3047612-0101 7 - 3 (64)

Table of Contents 7 Wrap Around Unit

7.5 Gun Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 56

7.5-1 Gun Holder - Set . . . . . . . . . . . . . . . . . . . . . . . . 7 - 56

7.6 Motor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 64

7.6-1 Motor Unit - Check . . . . . . . . . . . . . . . . . . . . . . 7 - 64

TechPub_2614345_0107 - 0701_3057054_01.fm

7 - 4 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7 Wrap Around Unit

7 Wrap Around Unit

7-1 Wrap Around Unit - Functional Description
As optional equipment a WA unit, can be installed in the base unit over the
feed unit. The WA unit is designed to handle different sizes of WASF, WAIF
and TRAY OF cardboard blanks. The unit mainly consists of an electrical
motor (1) used to set the height of the equipment, and a servo motor (2) that
drives three chains: the two outer chains with the pushers (3) and the chain in
the middle with the dolly (4). The WA unit is equipped with a gun holder (5),
in order to apply the glue on the top side of the cardboard box, when it is
transported from the magazine unit into the base unit, and a folding unit (6)
to fold the WAIF cardboard blank.
While the box with the packages is transported on the feed unit, it passes
below the WA unit, where the cover is folded by the pressure guides (7) and
the top side flaps are folded by the pressure guides (8).
The WA unit is controlled by the TPOP and run synchronized with the main
motor of the feed unit.

2
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4
5

1 Electrical motor 5 Gun holder

2 Servo motor 6 Folding unit
3 Pusher 7 Pressure guide
4 Dolly 8 Pressure guide
1 8 7

Doc. No. MM-3047612-0101 7 - 5 (64)

7 Wrap Around Unit 7 Wrap Around Unit

7-2 Wrap Around Unit- Setting Sequence, Type I

Type I settings must be performed in sequence according to the flowchart
below. These settings are performed before the first start-up or
commissioning of the machine.

7.1-1 Wrap Around Unit - Set Software Installation 7.1.1-1 Chain Unit - Set Tension on page 7-41
on page 7-8

7.1-2 Wrap Around Unit - Basic Setting on 7.1-7 Wrap Around Unit - Referencing on
page 7-10 page 7-34

7.1-3 Wrap Around Unit - Centre Unit on page 7-16 7.5-1 Gun Holder - Set on page 7-56

7.1-4 Wrap Around Unit - Set Height Position on In the Feed Unit, check the setting of the Upper

TechPub_2614345_0107 - 0701_3057054_01.fm
page 7-17 Gun Holders, see Set Upper Gun Holders on
page 4-34

7.1-6 Wrap Around Unit - Set Pressure Guides and

Fingers on page 7-19
In the Base Unit, check the setting of the bar, see
5.4.1-1 Bar (for WA Unit) - Set Position on
page 5-97

7.1.2-2 Pressure Unit - Set Position on page 7-47

7 - 6 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7 Wrap Around Unit

7-3 Wrap Around Unit - Setting Sequence, Type II

Type II settings must be performed in sequence according to the flowchart
below. These settings are performed when the production change, in order to
adjust the WA for the cardboard blank in use.

7.1-3 Wrap Around Unit - Centre Unit on 7.5-1 Gun Holder - Set on page 7-56
page 7-16

7.1-4 Wrap Around Unit - Set Height Position on In the Feed Unit, check the setting of the Upper
page 7-17 Gun Holders, see Set Upper Gun Holders on
page 4-34

7.1-6 Wrap Around Unit - Set Pressure Guides and

Fingers on page 7-19
In the Base Unit, check the setting of the bar, see
5.4.1-1 Bar (for WA Unit) - Set Position on
page 5-97
TechPub_2614345_0107 - 0701_3057054_01.fm

7.1.2-2 Pressure Unit - Set Position on page 7-47

7.1.1-1 Chain Unit - Set Tension on page 7-41

7-4 Wrap Around Unit - Setting Sequence, Type III

Type III settings include all the remaining WA setting procedures. These
settings can be performed independently and have no effect on any of the
other WA unit settings.

Doc. No. MM-3047612-0101 7 - 7 (64)

7.1 Wrap Around Unit 7 Wrap Around Unit

7.1 Wrap Around Unit

7.1-1 Wrap Around Unit - Set Software Installation
Machine Status IDLE (STEP ZERO)
SPC Reference 663110-0200

Note! Perform the installation only if the machine is equipped with the WA
unit (OE).
a) On the TPOP, log on as: “tptechnician”, see 6.7.1-2 HMI User
Management - Log On as a User on page 6-237.
b) With the machine in IDLE, touch the MACHINE CONFIGURATION
button (1).
Note! A cross over the WA UNIT icon (2), means that the option has not
been installed.
c) In the MACHINE CONFIGURATION window, touch the WA UNIT
icon (2).

1 2

TechPub_2614345_0107 - 0701_3057055_01.fm
1 Machine configuration button
2 WA unit icon (not installed)

(Cont'd)

7 - 8 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.1 Wrap Around Unit

(Cont'd)
d) Touch the INSTALLATION icon (3).
e) Touch the ON button (4), to select the installation of the WA unit, then
touch the CONFIRMATION button (5) to confirm the installation.
Note! A green dot (7) close to the WA UNIT icon (6), means the WA unit has
been activated. The WA unit is automatically activated, when a recipe that
includes the WA option is selected, see 8.2.1-1 Recipe - Set on page 8-6.
Note! In the MACHINE CONFIGURATION window will disappear the cross
over the WA UNIT icon (6).
f) Touch the EXIT button (8).

3 4 5 6 7
TechPub_2614345_0107 - 0701_3057055_01.fm

3 Installation icon
4 ON button
5 Confirmation button 8
6 WA unit icon (installed)
7 Green dot
8 Exit button

Doc. No. MM-3047612-0101 7 - 9 (64)

7.1 Wrap Around Unit 7 Wrap Around Unit

7.1-2 Wrap Around Unit - Basic Setting

Machine Status Mains Power OFF
Air OFF
Water OFF
Special Equipment Torque Wrench min. 4 Nm
SPC Reference 663110-0200

Pushers - Check
The machine is equipped with two type of pushers: the pushers (1) must be
used for wide boxes and the pushers (2) must be used for narrow boxes,
according to the table below.

Type of Pusher A (mm)

Pusher (1) TP No. 2971545-0000 > 320
Pusher (2) TP No. 2939982-0000 ≤ 320

Measure the width A of the box to produce and check that the pushers
installed on the WA Unit are correct, if necessary change all the six pushers
using the screws (4) and the disc springs (3). Keep the pushers not used in a
safe place.

TechPub_2614345_0107 - 0701_3057055_01.fm
A

1 Pusher
2 Pusher 4 3 2 1
3 Disc ring
4 Screw

(Cont'd)

7 - 10 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.1 Wrap Around Unit

(Cont'd)
Pushers - Alignment
a) Unlock the two sprockets (1) of the outer chains (2) by loosening the six
screws (3).

1
TechPub_2614345_0107 - 0701_3057055_01.fm

3 3
1 Sprocket
2 Outer chain
3 Screw

(Cont'd)

Doc. No. MM-3047612-0101 7 - 11 (64)

7.1 Wrap Around Unit 7 Wrap Around Unit

(Cont'd)
b) Pull backwards or forwards the pusher (4), until the side marked in grey
is aligned to the reference marks (5) existing on both frames (6), then
tighten the screws (3).
c) Keeping the pusher (4) aligned, perform the instruction Folding Unit -
Synchronization on the next page.

6
4
5

TechPub_2614345_0107 - 0701_3057055_01.fm
3 3 5
3 Screw
4 Pusher
5 Reference mark
6 Frame

(Cont'd)

7 - 12 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.1 Wrap Around Unit

(Cont'd)
Folding Unit - Synchronization
Note! The synchronization of the folding unit is necessary only if the
machine runs with WAIF and TRAY OF blanks.
Note! Make sure that the pusher (1) is still aligned to the two reference
marks (2) as shown below and that the torque of the safety clutch (3) is set
correctly, see Safety Clutch - Setting on page 7-51.
a) Unlock the sprocket (4) by loosening the three screws (5).

2
TechPub_2614345_0107 - 0701_3057055_01.fm

1 Pusher
2 Reference mark
3
3 Safety clutch
4 Sprocket
5 Screw

(Cont'd)

Doc. No. MM-3047612-0101 7 - 13 (64)

7.1 Wrap Around Unit 7 Wrap Around Unit

(Cont'd)
b) Synchronize the folding unit as follows:
• make sure that the folder (6) is positioned horizontally as shown below
• with hands slowly rotate the cam (7) in the direction of the arrow
• the synchronization point is reached, when the folder (6) start to turn in
order to fold the top flap of the blank and the roller (8) is positioned over
the cam (7) as shown below.

7 8
6

TechPub_2614345_0107 - 0701_3057055_01.fm
6 Folder
7 Cam 6
8 Roller

(Cont'd)

7 - 14 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.1 Wrap Around Unit

(Cont'd)
c) Tighten the three screws (5) of the sprocket (4).

4
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4 Sprocket
5 Screw

Doc. No. MM-3047612-0101 7 - 15 (64)

7.1 Wrap Around Unit 7 Wrap Around Unit

7.1-3 Wrap Around Unit - Centre Unit

Machine Status Mains Power OFF
Air OFF
Water OFF
Special Equipment Crank TP No. 318820-0105
Shaft TP No. 2728268
SPC Reference 663110-0200
Note! Before starting, make sure that the feed unit has been set correctly.
Centre the WA unit over the feed unit, as follows:
• on both sides, loosen the stop screws of the bearing housings (1)
• apply the crank on the shaft (2), then move the WA unit sideways until it
is centred over the feed unit
• remove the crank and tighten the stop screws.

1 TechPub_2614345_0107 - 0701_3057055_01.fm

2
1
1 Bearing housing
2 Shaft

7 - 16 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.1 Wrap Around Unit

7.1-4 Wrap Around Unit - Set Height Position

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 663110-0200

a) Set both proximity switches (1) and (2) at the distance A from the
plate (3).
b) Measure the height B of a folded cardboard box, then set the height
position of the proximity switch (1), as follows:
• loosen the locking lever (4)
• using the setting scale (6) as reference, move the proximity switch (1),
until the top side of the bracket (5) is aligned to the measure B
• lock the proximity switch (1) in position, with the locking lever (4).
c) Verify that height setting is correct, by following the instruction 7.1-5
Wrap Around Unit - Lift/Lower Unit on page 7-18, if required fine
adjust the position of the proximity switch (1).
TechPub_2614345_0107 - 0701_3057055_01.fm

B
6

A
A = 1 ÷ 2 mm

4
5
1

2 3

1 Proximity switch, V60B3110 4 Locking lever

2 Proximity switch, V60B3100 5 Bracket
3 Plate 6 Setting scale

Doc. No. MM-3047612-0101 7 - 17 (64)

7.1 Wrap Around Unit 7 Wrap Around Unit

7.1-5 Wrap Around Unit - Lift/Lower Unit

Machine Status AIR ON
SPC Reference 663110-0200

a) On the TPOP and with the machine in AIR ON, touch the PRODUCTION
CONTROL button (1) and the WA UNIT button (2), or touch the WA
UNIT tab (3).
b) Touch the WA LIFT MOTOR icon (4) then continue as follows.
• touch the ARROW buttons (5), to move the WA unit at the top or bottom
position
• touch the ARROW buttons (6), to move step by step the WA unit, towards
the top or bottom position
• touch the button (7) to select or deselect the function previously selected
• touch the CONFIRMATION button (8) to move the WA unit.
c) Touch the EXIT button (9).

1 2

TechPub_2614345_0107 - 0701_3057055_01.fm
3

5 8

1 Production control button

2 WA unit button
3 WA unit tab
4 WA lift motor icon
6
5 Arrow
6 Arrow
7 Select/deselect button
8 Confirmation button
9 Exit button
5 7 9

7 - 18 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.1 Wrap Around Unit

7.1-6 Wrap Around Unit - Set Pressure Guides and Fingers

Machine Status Mains Power ON
Air ON
Water ON
SPC Reference 663110-0200

Folding Unit - Preparation

a) The machine is equipped with two type of fingers: the two fingers (1)
must be used with WAIF and WASF boxes, while the finger (2) must be
used only with TRAY OF box. Check the fingers installed and if
necessary change them using the two screws (3). Keep the fingers not
used in a safe place.
b) Only if the machine has to produce WASF box, remove in order: the two
screws (4), the nuts (5), the washers and the folder (6). Keep the parts
removed in a safe place.

4
Setting for
WAIF
3 3
TechPub_2614345_0107 - 0701_3057055_01.fm

1 1
5
Setting for WASF

3
Setting for 6
TRAY OF
1 Finger (for WAIF and WASF)
2 Finger (for TRAY OF)
3 Screw
4 Screw
2 5 Nut
6 Folder (for WAIF and TRAY OF)

(Cont'd)

Doc. No. MM-3047612-0101 7 - 19 (64)

7.1 Wrap Around Unit 7 Wrap Around Unit

(Cont'd)
Top Pressure Guides - Set Position
According to the type of box to produce, the top pressure guides (1) can be
installed in two different positions, using the bearing housings (2) and (3)
existing on both sides of the WA unit, as follows:
• set the top pressure guides (1) in forward position using the bearing
housings (2), for WAIF and WASF boxes
• set the top pressure guides (1) in backward position using the bearing
housings (3), for TRAY OF box.

Setting valid for

WAIF and WASF

TechPub_2614345_0107 - 0701_3057055_01.fm
2 1

Setting valid for

TRAY OF

3 1
1 Top pressure guide
2 Bearing housing
3 Bearing housing

(Cont'd)

7 - 20 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.1 Wrap Around Unit

(Cont'd)
If necessary change the position of the top pressure guides (1) on both sides
of the WA Unit, as follows.
a) Loosen the three screws (4) and pull out the top pressure guide (1).
b) Loosen the two stop screws (8), then adjust the position of the shafts (6)
and (7) on the top pressure guides (1).
c) Fit back the top pressure guides (1), making sure to insert always the
shaft (6) in the bearing housing (5) and the shaft (7) in the bearing
housings (2) or (3), depending by the type of box to produce.
d) According to the type of box to produce, continue by following the
Settings for WAIF and WASF on next page or the Settings for Tray OF
on page 7-28.

4
TechPub_2614345_0107 - 0701_3057055_01.fm

7
2
8
5 6
8

1 Top pressure guide 5 Bearing housing

2 Bearing housing 6 Shaft
3 Bearing housing 7 Shaft
4 Screw 8 Stop screw

(Cont'd)

Doc. No. MM-3047612-0101 7 - 21 (64)

7.1 Wrap Around Unit 7 Wrap Around Unit

(Cont'd)
Settings for WAIF and WASF
As a basic setting and depending on the type of box, set the pressure
guides (2) and (3) on both sides of the WA unit, according to the table below.
.

Box type A (mm) B (mm)

WAIF 300 ±0.5 500 ±0.5
WASF 0 ±0.5 200 ±0.5

a) Loosen the stop screws (4) and set the top pressure guide (2) at the
distance A from the edge of the frame (1), then tighten the stop
screws (4).
b) Loosen the locking levers (5) and set the side pressure guide (3), so that
there is the distance B between the bend of the side pressure guide (3)
and the edge of the frame (1), then tighten the locking levers (5).
Note! During PRODUCTION, check that the cover (6) and the top side
flaps (7) are properly folded and glued, if not fine adjust the position of the
pressure guides (2) and (3).

4 3 2

TechPub_2614345_0107 - 0701_3057055_01.fm
1
A
7
B
1 Frame

6 6 5 2 Top pressure guide

3 Side pressure guide
4 Stop screw
5 Locking lever
WASF WAIF
6 Cover
7 Top side flap

(Cont'd)

7 - 22 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.1 Wrap Around Unit

(Cont'd)
Note! Make sure that the WA unit is centred over the Feed Unit, see 7.1-3
Wrap Around Unit - Centre Unit on page 7-16.
Note! See the instruction 7.1-5 Wrap Around Unit - Lift/Lower Unit on
page 7-18, to lift and lower the WA unit.
c) Lift the WA unit, then fold and place the cardboard box (9) to be
produced on the feed unit. Lower the WA unit.
CAUTION
Risk of damage to the equipment.
Make sure that the pushers (8) can run free without touching the top
pressure guides (2). If necessary change the type of pushers (8), see
Pushers - Check on page 7-10.
d) On both sides, loosen the screws (10) and move sideways the top
pressure guides (2), until they are aligned to the sides of the cardboard
box (9) as shown below, then tighten the screws (10).

10
TechPub_2614345_0107 - 0701_3057055_01.fm

2 8 2

Front view 2 Top pressure guide

8 Pusher
9 Cardboard box
10 Screw

(Cont'd)

Doc. No. MM-3047612-0101 7 - 23 (64)

7.1 Wrap Around Unit 7 Wrap Around Unit

(Cont'd)
Note! Set the side pressure guides (3), so that they press the top sides of
the cardboard box (9) firmly but not hard.
e) On both sides, loosen the screws (12) and move sideways the side
pressure guides (3), until they are aligned to the width of the cardboard
box (9), then tighten the screws (12).
f) On both sides, loosen the locking levers (11) then move up or down the
side pressure guides (3), until they press against the top side flaps (7) in
correspondence of the hotmelt dots (13).
Note! During PRODUCTION, check if the top side flaps (7) are properly
folded and glued, if not fine adjust the position of the side pressure
guides (3).

12

7
WAIF
11

TechPub_2614345_0107 - 0701_3057055_01.fm
3 13
9

7
Front view
WASF

13
3 Side pressure guide 11 Locking lever
7 Top side flap 12 Screw
9 Cardboard box 13 Hotmelt dot

(Cont'd)

7 - 24 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.1 Wrap Around Unit

(Cont'd)
g) Make sure that the steering guides (14), installed on both side pressure
guides (3), are correctly oriented as shown below, if required fine adjust
using the stop screws (15).

14
TechPub_2614345_0107 - 0701_3057055_01.fm

14
3
15
Front view

3 Side pressure guide

14 Steering guides
15 Stop screw

(Cont'd)

Doc. No. MM-3047612-0101 7 - 25 (64)

7.1 Wrap Around Unit 7 Wrap Around Unit

(Cont'd)
h) Make sure that the fingers (18) are parallel to the top of the cardboard
box (9), if required fine adjust using the two screws (16).
i) Loosen the two screws (17) and set both fingers (18) at the distance C,
from the top of the cardboard box (9), then tighten the two screws (17).

17 16

18

17
9

TechPub_2614345_0107 - 0701_3057055_01.fm
C
18
C = 15 ±2 mm Front view
9

Side view

9 Cardboard box
16 Screw
17 Screw
18 Finger

(Cont'd)

7 - 26 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.1 Wrap Around Unit

(Cont'd)
Note! Only for WAIF and during PRODUCTION check that the inside
flap (20) of the cardboard box (9) is folded correctly when the folder (19)
turns, if required fine adjust the height of the folder (19) using the setting
screw (21) and the nut.

21
TechPub_2614345_0107 - 0701_3057055_01.fm

19
20
9

WAIF

Side view

9
9 Cardboard box
19 Folder
20 Inside flap
21 Setting screw

(Cont'd)

Doc. No. MM-3047612-0101 7 - 27 (64)

7.1 Wrap Around Unit 7 Wrap Around Unit

(Cont'd)
Settings for Tray OF
As a basic setting set the pressure guides (3) and (4) on both sides of the WA
unit, according to the table below.
.

Box type A (mm) B (mm)

Tray OF 0 ±0.5 200 ±0.5

a) Loosen the stop screws (5) and set the top pressure guide (3) at the
distance A from the edge of the plate (1), then tighten the stop
screws (5).
b) Loosen the locking levers (6) and set the side pressure guide (4), so that
there is the distance B between the bend of the side pressure guide (4)
and the edge of the frame (2), then tighten the locking levers (6).
Note! During PRODUCTION, check that the top flap (8) and the top side
flaps (7) are properly folded and glued, if not fine adjust the position of the
pressure guides (3) and (4).

5 4 3 2

TechPub_2614345_0107 - 0701_3057055_01.fm
1
8 B
7 6 A

1 Plate 5 Stop screw

2 Frame 6 Locking lever
3 Top pressure guide 7 Top side flap
4 Side pressure guide 8 Top flap
Tray OF

(Cont'd)

7 - 28 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.1 Wrap Around Unit

(Cont'd)
Note! Make sure that the WA unit is centred over the Feed Unit, see 7.1-3
Wrap Around Unit - Centre Unit on page 7-16.
Note! See the instruction 7.1-5 Wrap Around Unit - Lift/Lower Unit on
page 7-18, to lift and lower the WA unit.
c) Lift the WA unit, then fold and place the cardboard box (10) to be
produced on the feed unit. Lower the WA unit.
CAUTION
Risk of damage to the equipment.
Make sure that the pushers (9) can run free without touching the top
pressure guides (3). If necessary change the type of pushers (9), see
Pushers - Check on page 7-10.
d) On both sides, loosen the screws (11) and move sideways the top
pressure guides (3), until they are aligned to the sides of the cardboard
box (10) as shown below, then tighten the screws (11).

11
TechPub_2614345_0107 - 0701_3057055_01.fm

10

3 9 3

Front view 3 Top pressure guide

9 Pusher
10 Cardboard box
11 Screw

(Cont'd)

Doc. No. MM-3047612-0101 7 - 29 (64)

7.1 Wrap Around Unit 7 Wrap Around Unit

(Cont'd)
Note! Set the side pressure guides (4), so that they press the top sides of
the cardboard box (10) firmly but not hard.
e) On both sides, loosen the screws (13) and move sideways the side
pressure guides (4), until they are aligned to the width of the cardboard
box (10), then tighten the screws (13).
f) On both sides, loosen the locking levers (12) then move up or down the
side pressure guides (4), until they press against the top side flaps (7) in
correspondence of the hotmelt dots (14).
Note! During PRODUCTION, check if the top side flaps (7) are properly
folded and glued, if not fine adjust the position of the side pressure
guides (4).

13

TechPub_2614345_0107 - 0701_3057055_01.fm
12
14
Tray OF
4
10

4 Side pressure guide

Front view
7 Top side flap
10 Cardboard box
12 Locking lever
13 Screw
14 Hotmelt dot

(Cont'd)

7 - 30 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.1 Wrap Around Unit

(Cont'd)
g) Make sure that the steering guides (15), installed on both side pressure
guides (4), are correctly oriented as shown below, if required fine adjust
using the stop screws (16).

15
TechPub_2614345_0107 - 0701_3057055_01.fm

15
4
16
Front view

4 Side pressure guide

15 Steering guides
16 Stop screw

(Cont'd)

Doc. No. MM-3047612-0101 7 - 31 (64)

7.1 Wrap Around Unit 7 Wrap Around Unit

(Cont'd)
h) Make sure that the plate (1) is parallel to the top of the cardboard
box (10), if required fine adjust using the two screws (17).
i) Loosen the two screws (18) and set the two fingers (19), until the
plate (1) is placed at the distance C from the top of the cardboard
box (10), then tighten the two screws (18).

18 17

19
1

19 18
10

TechPub_2614345_0107 - 0701_3057055_01.fm
C
1
C = 3 ±1 mm Front view
10

Side view

1 Plate
10 Cardboard box
17 Screw
18 Screw
19 Finger

(Cont'd)

7 - 32 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.1 Wrap Around Unit

(Cont'd)
Note! During PRODUCTION make sure that the top flap (21) of the
cardboard box (10) is folded correctly when the folder (20) turns, if required
fine adjust the height of the folder (20) using the setting screw (22) and the
nut.

22
TechPub_2614345_0107 - 0701_3057055_01.fm

21
20

10

10
Tray OF

Side view

10 Cardboard box
20 Folder
21 Top flap
22 Setting screw

Doc. No. MM-3047612-0101 7 - 33 (64)

7.1 Wrap Around Unit 7 Wrap Around Unit

7.1-7 Wrap Around Unit - Referencing

Machine Status AIR ON
SPC Reference 663110-0200
Note! Perform this setting at the first start up of the machine or after the
replacement of the servo motor.
Note! Before starting make sure to perform the 4-11 Feed Unit - Referencing
on page 4-36.
Preparation
a) On the TPOP, log on as: “tptechnician” or “supervisor” or “technician”,
see6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) Step up the machine to AIR ON then continue by following the
instructions Pushers - Set Homing Position on page 7-36, if the
ABSOLUTE HOMING POSITION LOST alarm (1) appears continue
by following the instructions Absolute Homing Position Lost Alarm -
Reset on page 7-35.

TechPub_2614345_0107 - 0701_3057055_01.fm
1 Absolute homing position lost alarm

(Cont'd)

7 - 34 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.1 Wrap Around Unit

(Cont'd)
Absolute Homing Position Lost Alarm - Reset
a) Press the STEP UP button (1) to step up the machine to PREHEATING.
b) Touch the ALARM AKNOWLEDGE button (2), the alarm does not
disappear.
c) Touch the MAINTENANCE button (3) and the WA UNIT button (4), or
touch the WA UNIT tab (5).
d) Touch the OFFSET icon (6) or the HOME POSITION icon (7).
e) Touch the ON button (8) to select the function.
f) Press the STEP UP button (1) to step up the machine to AIR ON.
g) Continue by following the instructions Pushers - Set Homing Position on
page 7-36.

1 2 3 4

5
TechPub_2614345_0107 - 0701_3057055_01.fm

6 7

1 Step up button
2 Alarm aknowledge button
3 Maintenance button
4 WA unit button
5 WA unit tab
6 Offset icon
8
7 Home position icon
8 ON button

(Cont'd)

Doc. No. MM-3047612-0101 7 - 35 (64)

7.1 Wrap Around Unit 7 Wrap Around Unit

(Cont'd)
Pushers - Set Homing Position
a) With the machine in AIR ON, touch the MAINTENANCE button (1) and
the WA UNIT button (2), or touch the WA UNIT tab (3).
b) Touch the WA MOTOR OFFSET icon (4), in order to display the
dialogue window.
c) Touch the ON button (5) to select the movement function.
d) Touch the OFFSET VALUE icon (6) to display the dialogue window.

4
1 2 3

TechPub_2614345_0107 - 0701_3057055_01.fm
1 Maintenance button 6
2 WA unit button
3 WA unit tab
4 WA motor offset icon
5 ON button
6 Offset value icon

(Cont'd)

7 - 36 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.1 Wrap Around Unit

(Cont'd)
e) The offset value displayed in the SETTING VALUE field (7). Set the
offset value to align the WA pushers to the Feed Unit pushers, when they
are aligned to the reference marks existing on the frames (see the next
page), as follows:
• touch the FACTORY button (10) to display the factory value
• touch the DOUBLE-ARROW buttons (8) to increase or decrease the value
of 10 mm
• touch the SINGLE-ARROW buttons (9) to increase or decrease the value
of 1 mm
• touch the KEYBOARD button (11) to display the numeric keyboard, then
type the value.
f) When the new value is displayed in the OFFSET VALUE field (12),
touch the CONFIRMATION button (13) to move the WA pushers.

7
TechPub_2614345_0107 - 0701_3057055_01.fm

8 9 8 10 11

7 Setting value field

8 Double-arrow button
9 Single-arrow button
10 Factory button 12 13
11 Keyboard button
12 Offset value field
13 Confirmation button

(Cont'd)

Doc. No. MM-3047612-0101 7 - 37 (64)

7.1 Wrap Around Unit 7 Wrap Around Unit

(Cont'd)
g) On both sides, make sure that the pushers (14), are aligned to the
reference marks (15) on the frames, see 4-11 Feed Unit - Referencing on
page 4-36.

14

TechPub_2614345_0107 - 0701_3057055_01.fm
15

15
14 Pusher
15 Reference mark

(Cont'd)

7 - 38 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.1 Wrap Around Unit

(Cont'd)
h) The home position is reached, when the pusher (16) is aligned with the
pushers (14) on both sides of the Feed Unit, check the alignment using a
steel square (17).
Note! In case that the ABSOLUTE HOMING POSITION LOST alarm (18)
has been activated, after opening the door in order to check the alignment,
then continue from item b) on page 7-35.
i) If necessary repeat the instructions from item e) on page 7-37, using a
new offset value until the home position is reached, otherwise confirm
the home position as follows on the next page.

Side view

Infeed direction
TechPub_2614345_0107 - 0701_3057055_01.fm

18

16 14 Pusher
16 Pusher
17 17 Steel square
18 Absolute homing position lost alarm
14

(Cont'd)

Doc. No. MM-3047612-0101 7 - 39 (64)

7.1 Wrap Around Unit 7 Wrap Around Unit

(Cont'd)
j) Confirm the home position as follows:
• touch the OFF button (19) to deselect the movement function
• touch the WA MOTOR ABSOLUTE HOMING icon (20)
• touch the ON button (21) to select the homing function
• touch the CONFIRMATION button (22) to confirm the home position
• touch the EXIT button (23).

19 20

21 22 23

TechPub_2614345_0107 - 0701_3057055_01.fm
19 OFF button
20 WA motor absolute homing icon
21 ON button
22 Confirmation button
23 Exit button

7 - 40 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.1 Wrap Around Unit

7.1.1 Chain Unit

7.1.1-1 Chain Unit - Set Tension
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2751170-0200
Note! Before starting, make sure that the guides (2) are set correctly, see
7.1.2-2 Pressure Unit - Set Position on page 7-47.
In the middle of the WA bottom, check the tension for the three chains (1),
by measuring the distance A between each chain (1) and the guide (2). If
required adjust the chain tension on both sides, with the setting screw (3).
At the end of the setting, make sure that the chain tensioner (6) is horizontal,
by checking on both sides, if there is the same distance B, measured between
the shaft (4) and the frame (5).
TechPub_2614345_0107 - 0701_3057055_01.fm

A = 5 ±0.5 mm
B

A
5
1 2 3 4
1 Chain 4 Shaft
2 Guide 5 Frame
3 Screw 6 Chain tensioner

Doc. No. MM-3047612-0101 7 - 41 (64)

7.1 Wrap Around Unit 7 Wrap Around Unit

7.1.1-2 Chain Unit - Check

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2751170-0200

Check both outer chains (1) and the inner chain (2), making sure that:
• they are not worn or damaged, if required replace them see 7.1.1-3 Chain
Unit - Change on page 7-43
• the chain tension is set correctly, see 7.1.1-1 Chain Unit - Set Tension on
page 7-41.

2
1

TechPub_2614345_0107 - 0701_3057055_01.fm
1 Outer chain
2 Inner chain

7 - 42 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.1 Wrap Around Unit

7.1.1-3 Chain Unit - Change

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2751170-0200
Note! Before starting, release the chain tension, see 7.1.1-1 Chain Unit -
Set Tension on page 7-41.
WA Outer Chains - Replacement
a) Open and remove both outer chains (1) by removing the chain locks (2).
b) Remove the screws (3), the disc springs (4) and the pushers (5).
Note! During the assembling make sure that the pushers (5) are placed in
the correct direction, as shown below.
c) Replace the outer chains (1) and assemble in the reverse order.

5
4
3
TechPub_2614345_0107 - 0701_3057055_01.fm

1
2

1 Outer chain
2 Chain lock
3 Screw
4 Disc spring
5 Pusher

(Cont'd)

Doc. No. MM-3047612-0101 7 - 43 (64)

7.1 Wrap Around Unit 7 Wrap Around Unit

(Cont'd)
WA Inner Chain - Replacement
Note! Before removing the inner chain, it is necessary to remove both outer
chains, see previous page.
a) Open and remove both inner chain (1) by removing the chain lock (2).
b) Remove the screws (3), the disc springs (4) and the plate (5).
Note! During the assembling make sure that the plates (5) are placed in the
correct direction, as shown below.
c) Replace the inner chain (1) and assemble in the reverse order.
Note! At the end reset the chain tension, see 7.1.1-1 Chain Unit - Set
Tension on page 7-41.

3
4
5
1

TechPub_2614345_0107 - 0701_3057055_01.fm
2

1 Inner chain
2 Chain lock
3 Screw
4 Disc spring
5 Plate

7 - 44 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.1 Wrap Around Unit

7.1.2 Pressure Unit

7.1.2-1 Pressure Unit - Check
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2909236-0100

a) If not already done, open and remove both outer chains (1) and the inner
chain (2), see 7.1.1-3 Chain Unit - Change on page 7-43.

2
1
TechPub_2614345_0107 - 0701_3057055_01.fm

1 Outer chain
2 Inner chain

(Cont'd)

Doc. No. MM-3047612-0101 7 - 45 (64)

7.1 Wrap Around Unit 7 Wrap Around Unit

(Cont'd)
b) In the bottom of the WA unit, check that the guides (3) are not worn and
damaged. If required change a guide (3) by removing the screws (4).
c) Fit back the chains previously removed, see 7.1.1-3 Chain Unit - Change
on page 7-43.

TechPub_2614345_0107 - 0701_3057055_01.fm
4

3 Guide
4 Screw

7 - 46 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.1 Wrap Around Unit

7.1.2-2 Pressure Unit - Set Position

Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2909236-0100

According to the type of box to produce, the guides (1) can be set in two
different positions, using the pairs of slots (2) existing on both sides of the
WA unit, as follows:
• set the guides (1) in the upper position for WAIF box,
• set the guides (1) in the lower position for WASF and TRAY OF box.
TechPub_2614345_0107 - 0701_3057055_01.fm

The picture shows the setting

valid for WAIF box

1 Guide
2 Slot
1

(Cont'd)

Doc. No. MM-3047612-0101 7 - 47 (64)

7.1 Wrap Around Unit 7 Wrap Around Unit

(Cont'd)
If required change the position of the guides (1) as follows.
a) If necessary release the tension of the chains on both sides, using the
setting screws (4).
b) On both sides remove the screws (3).
c) Fit the guides (1) in the other two slots (2) with the screws (3).
d) Reset the chain tension, see 7.1.1-1 Chain Unit - Set Tension on
page 7-41.

TechPub_2614345_0107 - 0701_3057055_01.fm
4
3

1 Guide 1
2 Slot
3 Screw
4 Setting screw

7 - 48 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.1 Wrap Around Unit

7.1.3 Motor Bracket

7.1.3-1 Motor Bracket - Set Chain Tension
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2751230-0200

Set the tension of the chain (1) as follows:

• loosen the two screws (2)
• set the chain tensioner (3) so that the sliding profile (4) is placed at the
distance A
• tighten the two screws (2).
TechPub_2614345_0107 - 0701_3057055_01.fm

4 2

A 3
1 Chain
A = 15 ±0.5 mm 2 Screw
3 Chain tensioner
4 Sliding profile

Doc. No. MM-3047612-0101 7 - 49 (64)

7.2 Side Adjuster 7 Wrap Around Unit

7.2 Side Adjuster

7.2-1 Side Adjuster - Check Timing Belt
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2751205-0100

Check the condition of the timing belt (1), if required change it as follows:
• loosen the two stop screws (3) and remove both locking rings (2)
• remove the four screws (4) and the plate (5)
• change the timing belt (1) and assemble in the reverse order.

TechPub_2614345_0107 - 0701_3057056_01.fm
3
2 3

4
2 1 5
1 Timing belt
1 2 Locking ring
3 Stop screw
4 Screw
4 5 5 Plate

7 - 50 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.3 Folding Unit

7.3 Folding Unit

7.3-1 Folding Unit - Basic Settings
Machine Status Mains Power OFF
Air OFF
Water OFF
Special Equipment Torque Wrench 40 Nm
SPC Reference 2827620-0200

Safety Clutch - Setting

a) Make sure that the screw (1) of the safety clutch (2) is tightened at
40 Nm.
b) For a correct functioning, the torque of the safety clutch (2) has to be set
at 13 Nm, check that the reference mark (3) is positioned at the correct
value indicated on the setting scale (5). If required loosen the screw (6)
and turn the adjusting ring (4) until the correct setting value is reached,
then tighten the screw (6).

Front view
TechPub_2614345_0107 - 0701_3057057_01.fm

2
3
1

1 Screw
2 Safety clutch
3 Reference mark
4 Adjusting ring
5 Setting scale
6 Screw 4 5 6

(Cont'd)

Doc. No. MM-3047612-0101 7 - 51 (64)

7.3 Folding Unit 7 Wrap Around Unit

(Cont'd)
Proximity Switch - Setting
a) Set the proximity switch (1) at the distance A from the ring (2) using the
two nuts (3).

1
A = 1 ÷ 2 mm 3
A

TechPub_2614345_0107 - 0701_3057057_01.fm
Front view
2
1 Proximity switch
2 Ring
3 Nut

(Cont'd)

7 - 52 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.3 Folding Unit

(Cont'd)
b) With the folder (6) in horizontal position and the ring (2) engaged, set
the proximity switch (1) at the distance B from the ring (2) using the two
screw (3). In order to avoid false detections during PRODUCTION,
manually move the bracket (4) and verify that the LED (5) is always
OFF, if the LED (5) goes ON slightly increase the distance B.
c) During PRODUCTION when the folder (6) start to close, if an over
torque happens the ring (2) will be disengaged and detected by the
proximity switch (1), the LED (5) must be lit.

1
4

Ring engaged
TechPub_2614345_0107 - 0701_3057057_01.fm

B
2
6
5
B = 0.5 ±0.1 mm

1 Proximity switch
2 Ring
3 Nut
4 Bracket Ring disengaged
5 LED
6 Folder
2

Doc. No. MM-3047612-0101 7 - 53 (64)

7.3 Folding Unit 7 Wrap Around Unit

7.3-2 Folding Unit - Disable WAIF Alarm Clutch

Machine Status Before PRODUCTION
SPC Reference 2827620-0200
Note! The following procedure allows to disable the WAIF alarm clutch, in
order to perform the maintenance operations on the WA unit.
a) On the TPOP, log on as: “tptechnician” or “supervisor” or “technician”,
see6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) With the machine in a program step before PRODUCTION, touch the
MAINTENANCE button (1) and the WA UNIT button (2), or touch the
WA UNIT tab (3).
c) Touch the WAIF ALARM CLUTCH icon (4) to display the dialogue
window.
d) Touch the ON button (5) to select the alarm function.
e) Touch the CONFIRMATION button (6) to activate the alarm disabled
function for the WAIF clutch.
f) Touch the EXIT button (7).

TechPub_2614345_0107 - 0701_3057057_01.fm
1 2 3

1 Maintenance button
2 WA unit button
3 WA unit tab
4 WAIF alarm clutch icon
5 On button
5 6 7
6 Confirmation button
7 Exit button

7 - 54 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.4 Spindle Guide

7.4 Spindle Guide

7.4-1 Spindle Guide - Check
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2871083-0100

Check that the timing belt (1) is not worn or damaged and that it is well
tensioned. If required loosen the fixing screws (2) and move the belt
tensioner (3), in order to replace or tense the timing belt (1), at the end
tighten the fixing screws (2).

2
3
TechPub_2614345_0107 - 0701_3057058_01.fm

1 Timing belt
2 Screw
3 Belt tensioner

Doc. No. MM-3047612-0101 7 - 55 (64)

7.5 Gun Holder 7 Wrap Around Unit

7.5 Gun Holder

7.5-1 Gun Holder - Set
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2827640-0200
Note! The following settings are not necessary if the machine runs with
TRAY OF blanks, but only when it is running with WAIF and WASF blanks.

WARNING
Risk of burns!
During PREHEATING and PRODUCTION the hotmelt gun and the cover
get hot.
Gun Holder - Horizontal Setting
Set the gun holder with the screw (1) until there is the distance A between
the brackets (2) and (3), so that the cardboard blanks are already bent when
they reach the position in front of the grouping unit.

A 2

TechPub_2614345_0107 - 0701_3057059_01.fm
3
1

A = 300 ÷ 305 mm

1 Screw
2 Bracket
Magazine Unit - Side view
3 Bracket

(Cont'd)

7 - 56 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.5 Gun Holder

(Cont'd)
Gun Holder - Vertical Setting
Note! Perform this setting after every change of production that includes a
different WAIF or WASF blank.
Before starting, make sure that the bottom steering (1) is set correctly, see
Bottom Steering - Set Height on page 2-14.
a) Place a cardboard blank (2) fully against the bottom steering (1).
b) Set the height of the gun holder with the two screws (4), so that the top
side of the cardboard blank (2) is aligned to the top side of the steering
rail (3).

A = 0 ±0.1 mm

A
TechPub_2614345_0107 - 0701_3057059_01.fm

3
Magazine Unit - Side view

1 2

1 Bottom steering
2 Cardboard blank
3 Steering rail
4 Screw

(Cont'd)

Doc. No. MM-3047612-0101 7 - 57 (64)

7.5 Gun Holder 7 Wrap Around Unit

(Cont'd)
Gun Holder - Setting of Steering Rails
a) Before starting, make sure that the two guides (1) and (2) are placed as
shown below, if necessary change their positions on the bottom side of
the bracket (3) using the four screws (4).

4
3

TechPub_2614345_0107 - 0701_3057059_01.fm
1 2

1 Guide
2 Guide
3 Bracket
4 Screw

(Cont'd)

7 - 58 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.5 Gun Holder

(Cont'd)
b) Loosen the screw (5), then fine adjust the position of the steering rail (6)
until it is placed at the distance A from the guide (2), so that the steering
rail (6) does not interfere with the nozzle (7) of the hotmelt gun. Tighten
the screw (5).

7
A
6

Front view 2
TechPub_2614345_0107 - 0701_3057059_01.fm

A = 35 ±0.1 mm

6
2 5

2 Guide
5 Screw
6 Steering rail
7 Nozzle

(Cont'd)

Doc. No. MM-3047612-0101 7 - 59 (64)

7.5 Gun Holder 7 Wrap Around Unit

(Cont'd)
c) Loosen the screw (8), then turn the steering rail (9), so that the cardboard
blanks (2) transported towards the grouping unit are well introduced
between the steering rails (6) and (9).

Side view

6
9 8 9

TechPub_2614345_0107 - 0701_3057059_01.fm
2
2 Cardboard blank
6 Steering rail
8 Screw
9 Steering rail

(Cont'd)

7 - 60 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.5 Gun Holder

(Cont'd)
d) In the carton transfer, place a cardboard blank (2) below and in the
middle of the two pressure rollers (10), as shown below.
e) Make sure that the steering rail (9) is placed at least at the distance B
from the side of the cardboard blank (2), so that the steering rail (9) does
not interfere when the cardboard blanks (2) are picked up by the carton
transfer. If required adjust the position of the steering rail (9) then tighten
the screw (8).

8 9
B
TechPub_2614345_0107 - 0701_3057059_01.fm

Side view 9

B = 10 mm

10

Front view
2 Cardboard blank
8 Screw
9 Steering rail
10 Pressure roller

(Cont'd)

Doc. No. MM-3047612-0101 7 - 61 (64)

7.5 Gun Holder 7 Wrap Around Unit

(Cont'd)
f) Make sure that the steering rail (11) turns easily and it is fully extended
as shown below. If required loosen the stop screws (12) then move the
two rings (13) so that both slightly touch the bracket (14).

Top view

TechPub_2614345_0107 - 0701_3057059_01.fm
11 12 13 14 13 12
11 Steering rail
12 Stop screw
13 Ring
14 Bracket

(Cont'd)

7 - 62 (64) Doc. No. MM-3047612-0101

 7 Wrap Around Unit 7.5 Gun Holder

(Cont'd)
g) Fine adjust the steering rail (11) with the screws (15) and (16), so that
the steering rail (11) supports the top side of the cardboard blank (2),
when it is placed in front of the dead plate (17).

15

Side view

11

15
16
TechPub_2614345_0107 - 0701_3057059_01.fm

17 2 17

2 Cardboard blank
11 Steering rail
15 Screw
16 Screw
17 Dead plate

Doc. No. MM-3047612-0101 7 - 63 (64)

7.6 Motor Unit 7 Wrap Around Unit

7.6 Motor Unit

7.6-1 Motor Unit - Check
Machine Status Mains Power OFF
Air OFF
Water OFF
SPC Reference 2838590-0100

Check that the timing belt (1) is not worn or damaged and that it is well
tensioned. If required loosen the four nuts (2) and move the motor unit (3), in
order to replace or tense the timing belt (1), at the end tighten the nuts (2).

TechPub_2614345_0107 - 0701_3057060_01.fm

1 Timing belt
1 2 Nut
3 Motor unit
2 3

7 - 64 (64) Doc. No. MM-3047612-0101

 8 Machine Conversion
TechPub_2614345_0107 - 0801_3057061_01.fm

Doc. No. MM-3047612-0101 8 - 1 (22)

 8 Machine Conversion

Description
This chapter describes how to change the production.

TechPub_2614345_0107 - 0801_3057061_01.fm

8 - 2 (22) Doc. No. MM-3047612-0101

 8 Machine Conversion Table of Contents

8.1 Packing Pattern Definition . . . . . . . . . . . . . . . . . 8 - 5

8.2 Packing Pattern Change . . . . . . . . . . . . . . . . . . . 8 - 6

8.2.1 Recipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 6
8.2.1-1 Recipe - Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 6
TechPub_2614345_0107 - 0801_3057061_01.fm

Doc. No. MM-3047612-0101 8 - 3 (22)

 8 Machine Conversion

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This page intentionally left blank

8 - 4 (22) Doc. No. MM-3047612-0101

 8 Machine Conversion 8.1 Packing Pattern Definition

8.1 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.
TechPub_2614345_0107 - 0801_3057061_01.fm

F
F 3x1

F
3x9 S

1x2

F S
F Face
S
S Side 3x8

Doc. No. MM-3047612-0101 8 - 5 (22)

8.2 Packing Pattern Change 8 Machine Conversion

8.2 Packing Pattern Change

8.2.1 Recipe
8.2.1-1 Recipe - Set
Machine Status IDLE (STEP ZERO)
Note! Perform the setting of the recipe at the first start up of the machine, or
before a change of production.
General Description
The machine can produce only if a recipe has been selected. Each recipe
includes the machine settings necessary for that specific type of production.
a) On the TPOP, log on as: “tptechnician” or “supervisor” or “technician”,
see 6.7.1-2 HMI User Management - Log On as a User on page 6-237.
b) With the machine in IDLE, touch the RECIPE button (1).
c) The CURRENT RECIPE NAME (4) is shown on the top side of the
RECIPE window.

TechPub_2614345_0107 - 0801_3057061_01.fm

1 Recipe button
2 Current recipe name
1
(Cont'd)

8 - 6 (22) Doc. No. MM-3047612-0101

 8 Machine Conversion 8.2 Packing Pattern Change

(Cont'd)
d) The RECIPE window is composed by two windows, in the first window
can be set the following recipe parameters: the PACKAGE TYPE (3), the
INFEED PACKAGE UNIT (4), the OUTFEED PACKING
PATTERN (5), the TURNED/NOT TURNED OPTION (6) and the BOX
TYPE (7).
e) Touch the NEXT WINDOW button (8) to display the second window.

3 4 5 6 7
TechPub_2614345_0107 - 0801_3057061_01.fm

8
3 Package type
4 Infeed package unit
5 Outfeed packing pattern
6 Turned/not turned (option)
7 Box type
8 Next window button

(Cont'd)

Doc. No. MM-3047612-0101 8 - 7 (22)

8.2 Packing Pattern Change 8 Machine Conversion

(Cont'd)
f) In the second window can always be set the following recipe parameters:
the SIDE FLAP WIDTH (9), the NOMINAL CAPACITY (10), the
OVER CAPACITY (11), the DIVIDER OFFSET (12), the CYLINDER
BLANK SUPPLY START POSITION (13), the FEEDER BELT
SPEED OFFSET (14), the BOX LENGTH (15), the INFEED
CONVEYOR SPEED OFFSET (16), the INFEED BELT BRAKE
SPEED OFFSET (17), the DIVIDER CONVEYOR SPEED
OFFSET (18), the QUEUE ALARM ACTIVATION DELAY (19) and
the QUEUE ALARM DEACTIVATION DELAY (20).
Note! The recipe parameters indicated below, can also be set in the
maintenance or setting windows of the module they belong to.
Set the parameters (10), (11), (16) and (17) according to the Machine
Capacity Setting Values included in the Technical Data chapter of the OM.

15
9
16
10
17

TechPub_2614345_0107 - 0801_3057061_01.fm
11
18
12
19
13

14
20

9 Side flap width 15 Box length

10 Nominal capacity 16 Infeed conveyor speed offset
11 Over capacity 17 Infeed belt brake speed offset
12 Divider offset 18 Divider conveyor speed offset
13 Cylinder blank supply start position 19 Queue alarm activation delay
14 Feeder belt speed offset 20 Queue alarm deactivation delay

(Cont'd)

8 - 8 (22) Doc. No. MM-3047612-0101

 8 Machine Conversion 8.2 Packing Pattern Change

(Cont'd)
Note! The following instruction is valid only for machines equipped with WA
unit (OE).
g) If previously has been set WAIF or WASF or TRAY OF for the box type,
then the following additional recipe parameters are displayed: the WA
BOX LENGTH (21) and the WA HOTMELT GUN (22).
Note! The recipe parameters indicated below, can also be set in the WA
setting window.

21

22
TechPub_2614345_0107 - 0801_3057061_01.fm

21 WA box length
22 WA hotmelt gun

(Cont'd)

Doc. No. MM-3047612-0101 8 - 9 (22)

8.2 Packing Pattern Change 8 Machine Conversion

(Cont'd)
Note! The following instruction is valid only for machines installed in lines
equipped with the switch.
h) If previously has been configurated the switch, then the following
additional recipe parameters are displayed: the SWITCH (23) and the
QUEUE PHOTOCELL (24).
Note! The recipe parameters indicated below, can also be set in the
corresponding setting window.
i) Touch the PREVIOUS WINDOW button (24) to display the first window.

23

24

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25

23 Switch
24 Queue photocell
25 Previous window button

(Cont'd)

8 - 10 (22) Doc. No. MM-3047612-0101

 8 Machine Conversion 8.2 Packing Pattern Change

(Cont'd)
Recipes Handling
With the machine in IDLE, proceed as follows:
a) Touch the OPEN button (1), to open an existing recipe, or touch the
DELETE button (3), to delete an existing recipe, then continue as
follows:
• select a recipe with the ARROW buttons (5)
• confirm the recipe selected with the CONFIRMATION button (4), or
abort the selection with the CLEAR button (6)
• the RECIPE NAME (7) to be uploaded will be displayed below the
CURRENT RECIPE NAME (8).
b) Touch the NEW RECIPE button (2) to create a new recipe from the
beginning.

8
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7 1 2 3 4

1 Open button
2 New recipe button
3 Delete button 6 5
4 Confirmation button
5 Arrow button
6 Clear button
7 Recipe name
8 Current recipe name

(Cont'd)

Doc. No. MM-3047612-0101 8 - 11 (22)

8.2 Packing Pattern Change 8 Machine Conversion

(Cont'd)
Set Recipe Parameters - First Setting Window
Note! The selection of each recipe parameter, is controlled and driven by
the machine program, so that it is not possible to select a not allowed
combination. When a recipe parameter has been set, the program will
change automatically all the following parameters, with the first allowed
combination. In the first setting window, set the recipe parameters in the
order given.
a) Touch the PACKAGE TYPE icon (1), then scroll the list with the
ARROW buttons (2) to select the correct package volume and shape, pay
attention that the different packages are listed as follows:
- TBA 200B
- TBA 250B
- TBA 200M
- TBA 250S
- TBA 200S
- TBA 1000B
- TBA 1000S
- TBA 1000Sq
- TBA 125S.

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1

2
1 Package type icon
2 Arrow button

(Cont'd)

8 - 12 (22) Doc. No. MM-3047612-0101

 8 Machine Conversion 8.2 Packing Pattern Change

(Cont'd)
Note! See 8.1 Packing Pattern Definition on page 8-5 for more details.
b) Set the infeed package unit (single pack or multi pack), as follows:
• touch the INFEED PACKAGE UNIT FACE (3), then set the correct
number of packages with the ARROW buttons (2)
• touch the INFEED PACKAGE UNIT SIDE (4), then set the correct
number of packages with the ARROW buttons (2).

3 2

2 Arrow button
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3 Infeed package unit face

4 Infeed package unit side

(Cont'd)

Doc. No. MM-3047612-0101 8 - 13 (22)

8.2 Packing Pattern Change 8 Machine Conversion

(Cont'd)
Note! See 8.1 Packing Pattern Definition on page 8-5 for more details.
c) Set the outfeed packing pattern, as follows:
• touch the OUTFEED PACKING PATTERN FACE (5), then set the total
number of single packages with the ARROW buttons (2)
• touch the OUTFEED PACKING PATTERN SIDE (6), then set the total
number of single packages with the ARROW buttons (2).

5 2

2 Arrow button

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5 Outfeed packing pattern face
6 Outfeed packing pattern side

(Cont'd)

8 - 14 (22) Doc. No. MM-3047612-0101

 8 Machine Conversion 8.2 Packing Pattern Change

(Cont'd)
Note! For standard machines, the following parameter is always set as NOT
TURNED. Only for machines equipped with TD, the following parameter can
be set as TURNED.
d) Touch the TURNED/NOT TURNED icon (7), then set the correct option
with the ARROW buttons (2).

7
2

2 Arrow button
7 Turned/not turned icon
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(Cont'd)

Doc. No. MM-3047612-0101 8 - 15 (22)

8.2 Packing Pattern Change 8 Machine Conversion

(Cont'd)
Note! For standard machines the following parameter is always set as
TRAY. Only for machines equipped with WA unit (OE), the following
parameter can be set as WASF, WAIF or as TRAY OF.
e) Set the box type as follows:
• according to the actual configuration displayed on the TPOP, touch one
of the icons (8), (9), (10) or (11), then set the correct box type with the
ARROW buttons (2).

8 9 10 11

2 Arrow button

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8 Tray icon
9 WAIF icon
10 WASF icon
11 Tray OF 2

(Cont'd)

8 - 16 (22) Doc. No. MM-3047612-0101

 8 Machine Conversion 8.2 Packing Pattern Change

(Cont'd)
• according to the actual configuration displayed on the TPOP, touch one
of the icons (12) or (13), then set the correct box side closure with the
ARROW buttons (2).
Note! The BOX TYPE icon (18) will change according to the new
configuration set.
f) Confirm the recipe creation with the CONFIRMATION button (14), in
this case type a new recipe name using the KEYBOARD (16), then touch
the ENTER button (17); otherwise abort the recipe creation with the
CLEAR button (15).
g) Touch the NEXT WINDOW button (19) to display the second window,
see Set Recipe Parameters - Second Setting Window on the next page.

18
12 14

13 15 2 19
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16

17

2 Arrow button 16 Keyboard

12 Open box side closure icon 17 Enter button
13 Closed box side closure icon 18 Box type icon
14 Confirmation button 19 Next window button
15 Clear button

(Cont'd)

Doc. No. MM-3047612-0101 8 - 17 (22)

8.2 Packing Pattern Change 8 Machine Conversion

(Cont'd)
Set Recipe Parameters - Second Setting Window
Note! Set the parameters (2), (7) and (9) according to the Machine Capacity
Setting Values included in the Technical Data chapter of the OM.
The divider offset (4) can also be set from the INFEED UNIT
MAINTENANCE window, see 1.1-4 Divider - Set Offset on page 1-19.
a) Touch one of the icons from (1) to (12) to display the dialogue window,
then set a new value as follows:
• touch the FACTORY button (18) to display the factory value in the
SETTING VALUE field (13)
• touch the DOUBLE-ARROW buttons (14) to increase or decrease the
value of 10 units
• touch the SINGLE-ARROW buttons (15) to increase or decrease the
value of 1 unit
• touch the KEYBOARD button (16) to display the numeric keyboard, then
type the value
• touch the CONFIRMATION button (17) to confirm the value displayed
in the SETTING VALUE field (13).

1 7 13 18 17

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2 8
3 9
4 10
5 11
6 12 14 15 14 16
1 Side flap width 10 Divider conveyor speed offset
2 Nominal capacity 11 Queue alarm activation delay
3 Over capacity 12 Queue alarm deactivation delay
4 Divider offset 13 Setting value field
5 Cylinder blank supply start position 14 Double-arrow button
6 Feeder belt speed offset 15 Single-arrow button
7 Box length 16 Keyboard button
8 Infeed conveyor speed offset 17 Confirmation button
9 Infeed belt brake speed offset 18 Factory button

(Cont'd)

8 - 18 (22) Doc. No. MM-3047612-0101

 8 Machine Conversion 8.2 Packing Pattern Change

(Cont'd)
Note! The following instructions are valid only for machines equipped with
the WA unit (OE) and in the case that previously has been set WAIF or
WASF for the box type. For standard machine continue from next page.
b) Touch one of the icons from (19) to (20) to display the dialogue window,
then set a new value as follows:
• touch the FACTORY button (18) to display the factory value in the
SETTING VALUE field (13)
• touch the DOUBLE-ARROW buttons (14) to increase or decrease the
value of 10 units
• touch the SINGLE-ARROW buttons (15) to increase or decrease the
value of 1 unit
• touch the KEYBOARD button (16) to display the numeric keyboard, then
type the value
• touch the CONFIRMATION button (17) to confirm the value displayed
in the SETTING VALUE field (13).

19 13 18 17
TechPub_2614345_0107 - 0801_3057061_01.fm

20

14 15 14 16

13 Setting value field 17 Confirmation button

14 Double-arrow button 18 Factory button
15 Single-arrow button 19 WA box length
16 Keyboard button 20 WA hotmelt gun

(Cont'd)

Doc. No. MM-3047612-0101 8 - 19 (22)

8.2 Packing Pattern Change 8 Machine Conversion

(Cont'd)
Note! The following instructions are valid only for machines installed in lines
equipped with the switch.
c) Touch the SWITCH icon (21) to display the dialogue window, then
continue as follows:
• touch the ON button (23) or the OFF button (24) to select the status that
the switch photocell must have in the desired switch position
• touch the CONFIRMATION button (25) to confirm the selection.
d) Touch the QUEUE PHOTOCELL icon (22) to display the dialogue
window, then continue as follows:
• the queue photocell actually selected is displayed in the CURRENT
SELECTION field (26) while the new queue photocell selected is
displayed in the SELECTION field (27)
• touch the SINGLE-ARROW buttons (28) to change the queue photocell
• touch the CONFIRMATION button (29) to confirm the new queue
photocell selected.
e) Touch the EXIT button (30).

26

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21

22 27 29

23 24 25 28

21 Switch icon 26 Current selection field

22 Queue photocell icon 27 Selection field
23 ON button 28 Single-arrow button
30
24 OFF button 29 Confirmation button
25 Confirmation button 30 Exit button

(Cont'd)

8 - 20 (22) Doc. No. MM-3047612-0101

 8 Machine Conversion 8.2 Packing Pattern Change

(Cont'd)
Note! The RECIPE STATUS icon (20) 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.
f) Touch the SAVE button (21), to save the recipe with the same name, or
touch the SAVE AS button (22), to save the recipe with a new name, in
this case, type a new name using the KEYBOARD (23), then touch the
ENTER button (24).
g) Touch the EXIT button (25).

30 31 32 35

33
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34

31 Recipe status icon

32 Save button
33 Save as button
34 Keyboard
35 Enter button
36 Exit button

Doc. No. MM-3047612-0101 8 - 21 (22)

8.2 Packing Pattern Change 8 Machine Conversion

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8 - 22 (22) Doc. No. MM-3047612-0101

 9 General
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Doc. No. MM-3047612-0101 9 - 1 (12)

 9 General

Description
This chapter contains general information regarding: lubricants and cleaning
compounds, templates and tools, recommended for the maintenance of the
machine.

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9 - 2 (12) Doc. No. MM-3047612-0101

 9 General Table of Contents

9.1 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 5
9.1-1 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 5
9.1-2 Cleaning Compounds . . . . . . . . . . . . . . . . . . . . . . 9 - 7

9.2 Templates and Tools . . . . . . . . . . . . . . . . . . . . . 9 - 10

9.3 Safety Functions . . . . . . . . . . . . . . . . . . . . . . . . 9 - 12

9.3-1 Safety Functions - Check . . . . . . . . . . . . . . . . . . 9 - 12
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Doc. No. MM-3047612-0101 9 - 3 (12)

 9 General

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9 - 4 (12) Doc. No. MM-3047612-0101

 9 General 9.1 Consumables

9.1 Consumables
9.1-1 Lubricants

WARNING
Risk of personal injury!
Certain lubricants can cause injury if they come into contact with the eyes,
skin, mucous membranes, or clothing. Always follow the manufacturer’s
instructions for handling chemical products.
The table below lists only a selection of lubricants with their respective
designations.
Lubricant specifications may be ordered from:
Tetra Pak GTS AB - Parts Supply Chain, Ruben Rausings gata, SE-221 86
LUND, Sweden
.

Lubricant Code Part No. Supplier Product Designation

(used when ordering (2004-06)

from Tetra Pak)

A
Motor oil 90 296-28 Shell Shell Rimula Oil X 10W-30
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B
High-pressure oil 90 296-73 Shell Shell Omala Oil 220

90 296-72 Shell Shell Omala Oil 150

For use in production

plant with start
temperature below 5° C.
C
Hydraulic oil 90 296-53 Shell Shell Tellus Oil T 32
D
Mist lubrication oil 90 296-80 Shell Shell Donax Oil TA
E
Compounded 90 296-2 Shell Shell Valvata Oil J460
cylinder oil
F
Lithium grease, 90 296-68 Shell Shell Alvania Grease EP2
EP type
H
High-pressure oil 90 296-75 Shell Shell Omala oil 320
90 296-76

90 296-73 Shell Shell Omala oil 220

For use in production

plant with start
temperature below 5° C.

K
Circulation oil 90 296-15 Shell Shell Tellus Oil 100

Doc. No. MM-3047612-0101 9 - 5 (12)

9.1 Consumables 9 General

Lubricant Code Part No. Supplier Product Designation

(used when ordering (2004-06)

from Tetra Pak)

L
Silicon grease 90 296-9 Dow Corning 7
M
Lithium grease, 90 296-70 Shell Shell Alvania Grease EP1
EP type
N
PTFE 90 296-91 Sikema Teflon Grease
grease
O
Lithium complex 90 296-61 BP Energrease LS 3
grease Esso Unirex N3
Statoil UniWay HT-63
P
Synthetic compressor 90 296-54 Shell Shell Corena Oil P68
oil
Q
Low friction assembly 90 296-12 Dow Molykote G-N Plus
paste Kluber Unimoly Plus
R
Synthetic grease 90 459-246 Kluber Klubersynth UH1 14-1600

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S
Synthetic 90 296-10 Mecman 435-1
hydrocarbon grease
T
Synthetic lubricating 90 459-0340 Shell Cassida HDS2
grease
U
Hydraulic fluid 90 459-1310 Shell Cassida Fluid HF32
V
Oil 90 296-104 Molykote Molykote Foodslip EP Gear Oil 220
W
Hydraulic fluid 90 458-1427 Shell Shell Tellus Oil T46
X
Oil 330002-2201 Shell Shell Cassida Fluid GL 220
330002-2202
Y
Lubrication oil 90 458-2735 Mobil Mobil SHC 634
Z
Grease H1 330004-0201 Shell Cassida EPS 2, plastic cartridge
330004-0202 Shell Cassida EPS 2, pail

9 - 6 (12) Doc. No. MM-3047612-0101

 9 General 9.1 Consumables

9.1-2 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)
TechPub_2614345_0107 - 0901_3057062_01.fm

Doc. No. MM-3047612-0101 9 - 7 (12)

9.1 Consumables 9 General

(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 Deterge Raw Material Formulated Products
Type Code nt
Type Name Max Use Use Ecolab Use Use Johns Use Use
Con Conc Tem Con Tem onDive Con Tem
c w/w p c. p. rsey c. p.
w/w °C w/w °C vol/ °C
vol
CIP A 1 Alkali NaOH 30% 1.50% 80 P3-mip 2.0% 80 VC 13 3.0% 80
CIP VC 7 4.5%
B 1 Acid HNO3 50% 1.00% 60 P3- 1.0% 60 VA 5 2.0% 60
horolith

TechPub_2614345_0107 - 0901_3057062_01.fm
L31
1 Alkali P3-Topax 3.0% 25 VF 9 3.0% 25
foam (*) 12
2 Alkali P3-mip 2.0% 55 VK 12 1.0% 55
External solution FPC
Cleaning C (**)
(automati
c) 3 Disinfecti P3-Topax 2.0% 25 VS 1 1.0% 25
on foam 99
(***)
4 Acid P3-Topax 25 VF 11 2.0% 25
foam 56
(***)
Manual
Cleaning D 1 Alkali P3-mip 2.0% 25 VK 12 1.0% 25
(wiping) FPC
1 Low P3-Topax 2.0% 25 VS 1 1.0% 25
alkali 99
Manual 2 Low P3-Steril 2.0% 25 VT 1 1.0% 25
Disinfecti F alkali
on
(immersi 3 Acid Peracetic Oxonia
on) solution acid 15% 200pp 25 Active 0.50 25 VT 6 0.10 25
solution m % %
1 Alcoholic Isopropa 70% 25 Spitader Pure 25 VT 10 pure 25
solution nol m
Manual 2 Alcoholic Ethanol 70% 25 Alcodes Pure 25 pure 25
Disinfecti G solution
on
(spraying 3 Acid Peracetic Oxonia
) solution acid 15% 200pp 25 Active 0.50 25 VT 6 0.10 25
solution m % %

9 - 8 (12) Doc. No. MM-3047612-0101

 9 General 9.1 Consumables

Hand H 1 Manodes pure 25 H34 pure 25

Disinfecti
on
Deliming K 1 Citric Lime-A- pure 25
agent acid Way
compoun Special
d (***)

(*) 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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Doc. No. MM-3047612-0101 9 - 9 (12)

9.2 Templates and Tools 9 General

9.2 Templates and Tools

Illustration Description
Dynamometer
TP No. 74767-0102
1 Infeed Unit
3 Grouping Unit
4 Feed Unit

Force Gauge
TP No. 90459-1467
3 Grouping Unit

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Tachometer
TP No. 90243-0105
1 Infeed Unit
5 Base Unit

Pneumatic grease-gun
TP No. 1512559
1 Infeed Unit

9 - 10 (12) Doc. No. MM-3047612-0101

 9 General 9.2 Templates and Tools

Illustration Description
Crank (1)
1 2 TP No. 318820-0105

Shaft (2)
TP No. 2728268
2 Magazine Unit
4 Feed Unit
7 Wrap Around Unit

Bailer
TP No. 90243-0209
5 Base Unit
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Doc. No. MM-3047612-0101 9 - 11 (12)

9.3 Safety Functions 9 General

9.3 Safety Functions

9.3-1 Safety Functions - Check
Machine Status AIR ON

Make sure that the machine can not be inched if:

– any of the doors or covers are open
– any of the EMERGENCY STOP push-buttons is pushed.
To identify the correct location of safety components, see the Safeguards and
Emergency Stop Push-Buttons sections in the ii Safety Precautions chapter.
Make sure that when any of the EMERGENCY STOP push-buttons is
pushed the machine stops immediately and resets to IDLE (STEP ZERO).
Check that the warning sign labels are present and readable. Replace any
missing and /or illegible signs, see Locations of Safety Signs section in the
ii Safety Precautions chapter.

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9 - 12 (12) Doc. No. MM-3047612-0101

 Index of Procedures

A Chain Unit - Change . . . . . . . . . . . . . . . . . . . . 7 - 43

Chain Unit - Check . . . . . . . . . . . . . . . 3 - 35, 7 - 42
Accumulation Conveyor - Change Conveyor
Chain Unit - Overhaul . . . . . . . . . . . . . . . . . . . 3 - 37
Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 100
Chain Unit - Set Tension . . . . . . . . . . . 3 - 33, 7 - 41
Accumulation Conveyor - Check . . . . . . . . . 1 - 102
Cleaning Compounds . . . . . . . . . . . . . . . . . . . . 9 - 7
Accumulation Conveyor - Overhaul . . . . . . . 1 - 104
Cleaning Equipment - Check . . . . . . . . . . . . . . 5 - 5
Accumulation Unit - Check Conveyor Chains 1 - 68
Conveyor Lubrication - Check . . . . . . . . . . . . 1 - 130
Accumulation Unit - Check Guides . . . . . . . . 1 - 69
Conveyor Lubrication - Clean Nozzles . . . . . 1 - 131
Accumulation Unit - Set Conveyor
Chains Tension . . . . . . . . . . . . . . . . . . . . . . . 1 - 67 Conveyor Lubrication - Set . . . . . . . . . . . . . . 1 - 129
Accumulation Unit - Set Slide Rails . . . . . . . . 1 - 66 Cooling Unit - Change Filter . . . . . . . . . . . . . 6 - 265
Adjustment Bracket - Set Timing Cooling Unit - Check . . . . . . . . . . . . . . . . . . . 6 - 267
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 74 Cooling Unit - Clean Filter . . . . . . . . . . . . . . . 6 - 263
Air Equipment - Clean Regulator Filter . . . . . 2 - 78 Cooling Unit - Overhaul . . . . . . . . . . . . . . . . . 6 - 269
Air Equipment - Set Pressure Switch . . . . . . . 2 - 75 Cooling Unit - Troubleshooting . . . . . . . . . . . 6 - 275
Air Equipment - Set Regulators . . . . . . . . . . . 2 - 66 CPU Module - Change . . . . . . . . . . . . . . . . . . 6 - 30
Air Equipment - Set Shut-Off Valve . . . . . . . . 2 - 65 CPU Module - Change Battery . . . . . . . . . . . . 6 - 58
Arm - Change Rubber Strip . . . . . . . . . . . . . . 3 - 71 CPU Module - Convert Program . . . . . . . . . . . 6 - 42
Arm - Set Proximity Switch . . . . . . . . . . . . . . 2 - 63 CPU Module - Download Program . . . . . . . . . 6 - 45
TechPub_2614345_0107 - MM_3047612_0101IOM.fm

Armorblocks - LED Description . . . . . . . . . . 6 - 304 CPU Module - LED Description . . . . . . . . . . . . 6 - 56

Armorblocks - Set the Node Address . . . . . . 6 - 301 CPU Module - Load Firmware . . . . . . . . . . . . . 6 - 36

B D
Bar (for WA Unit) - Set Position . . . . . . . . . . . 5 - 97 DeviceNet Point I/O Adapter - Change . . . . . 6 - 119
Bevel Gear - Change Chains . . . . . . . . . . . . . 4 - 73 DeviceNet Point I/O Adapter -
Bevel Gear - Check . . . . . . . . . . . . . . . . . . . . 4 - 72 Download Program . . . . . . . . . . . . . . . . . . . . 6 - 124
DeviceNet Point I/O Adapter -
LED Description . . . . . . . . . . . . . . . . . . . . . . 6 - 140
C DeviceNet Point I/O Adapter -
Set Node Address . . . . . . . . . . . . . . . . . . . . . 6 - 123
Carton Magazine - Check . . . . . . . . . . . . . . . 2 - 53 DeviceNet Point I/O Module - Change . . . . . 6 - 144
Carton Magazine - Set Proximity Switch . . . . 2 - 49 DeviceNet Point I/O Module -
Carton Magazine - Set Timing Belts Tension 2 - 52 LED Description . . . . . . . . . . . . . . . . . . . . . . 6 - 147
Carton Transfer - Check . . . . . . . . . . . . . . . . 2 - 55 DeviceNet PowerFlex Adapter - Change . . . 6 - 152
Carton Transfer - Overhaul . . . . . . . . . . . . . . 2 - 58 DeviceNet PowerFlex Adapter -
LED Description . . . . . . . . . . . . . . . . . . . . . . . 6 - 158
Carton Transfer - Set Timing Belt Tension . . 2 - 54
DeviceNet PowerFlex Adapter - Set . . . . . . . 6 - 155
Chain Tensioner - Change Rollers . . . . . . . . . 1 - 80
DeviceNet Scanner Module - Change . . . . . . . 6 - 89
Chain Tensioner - Change Sliding Profile . . . 3 - 45
DeviceNet Scanner Module -
Chain Tensioner - Check . . . . . . . . . . . 3 - 44, 4 - 78
Download Program . . . . . . . . . . . . . . . . . . . . . 6 - 97
Chain Tensioner - Check Rollers . . . . . . . . . . 1 - 79
DeviceNet Scanner Module - Error Codes . . 6 - 116
Chain Tensioner - Overhaul . . . . . . . . . . . . . . 4 - 79
DeviceNet Scanner Module -
Chain Tensioner - Set Spring Force . . . . . . . 3 - 43 LED Description . . . . . . . . . . . . . . . . . . . . . . 6 - 114

Doc. No. MM-3047612-0101 iii - 1

Index of Procedures

DeviceNet Scanner Module - Load Firmware 6 - 96 Feed Unit - Functional Description . . . . . . . . . . 4 - 5

DeviceNet Scanner Module - Set Node Address Feed Unit - Referencing . . . . . . . . . . . . . . . . . 4 - 36
and Baud Rate . . . . . . . . . . . . . . . . . . . . . . . . 6 - 93
Feed Unit - Rephase Feed Motor . . . . . . . . . . 4 - 45
DeviceNet Slave Module - Reset Genius Feed Unit - Set Chains Offset . . . . . . . . . . . . . 4 - 49
Communication . . . . . . . . . . . . . . . . . . . . . . 6 - 290
Feed Unit - Set Chains Tension . . . . . . . . . . . 4 - 46
Digital Input Module - Change . . . . . . . . . . . . 6 - 82
Feed Unit - Set Front Flap Folder . . . . . . . . . . 4 - 29
Digital Input Module - Load Firmware . . . . . . 6 - 86
Feed Unit - Set Guide Unit . . . . . . . . . . . . . . . 4 - 35
Distributed I/O - Description . . . . . . . . . . . . . . 6 - 87
Feed Unit - Set Gun Holder . . . . . . . . . . . . . . . 4 - 33
Divider - Check Parallelism . . . . . . . . . . . . . . 1 - 15
Feed Unit - Set Rear Flap Folder . . . . . . . . . . 4 - 28
Divider - Set Belt Brakes Tension . . . . . . . . . 1 - 13
Feed Unit - Set Width . . . . . . . . . . . . . . . . . . . 4 - 14
Divider - Set Number of Units for Lane . . . . . 1 - 21
Feed Unit - Setting Sequence, Type I . . . . . . . . 4 - 7
Divider - Set Offset . . . . . . . . . . . . . . . . . . . . . 1 - 19
Feed Unit - Setting Sequence, Type II . . . . . . . 4 - 8
Divider - Set Width . . . . . . . . . . . . . . . . . . . . . 1 - 16
Feed Unit - Setting Sequence, Type III . . . . . . . 4 - 8
Divider Conveyor - Change
Conveyor Chains . . . . . . . . . . . . . . . . . . . . . 1 - 106 Feed Unit - Synchronize Rear Flap Folder . . . 4 - 42
Divider Conveyor - Check . . . . . . . . . . . . . . 1 - 108 Flight Bar - Referencing . . . . . . . . . . . . . . . . . 3 - 18
Divider Conveyor - Overhaul . . . . . . . . . . . . 1 - 110 Flight Bar - Set Dead Plate . . . . . . . . . . . . . . . . 3 - 9
Drive Shaft - Change Ball Bearings . . . . . . . . 3 - 48 Flight Bar - Set Side Guides . . . . . . . . . . . . . . 3 - 12
Drive Shaft - Check . . . . . . . . . 1 - 76, 1 - 97, 3 - 46 Folding Unit - Basic Settings . . . . . . . . . . . . . . 7 - 51

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Drive Shaft - Overhaul . . . . . . . . . . . . .1 - 77, 1 - 98 Folding Unit - Disable Waif Alarm Clutch . . . . 7 - 54
Drive Shaft (for Inner Chains) - Frame - Check . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 62
Change Chain . . . . . . . . . . . . . . . . . . . . . . . . 4 - 66 Frequency Converters - Change . . . . . . . . . . 6 - 222
Drive Shaft (for Inner Chains) - Check . . . . . . 4 - 65 Frequency Converters - Error Codes . . . . . . 6 - 230
Drive Shaft (for Outer Chains) - Frequency Converters - Parameters . . . . . . . 6 - 228
Change Chain . . . . . . . . . . . . . . . . . . . . . . . . 4 - 77
Front Flap Folder - Check Guides . . . . . . . . . . 4 - 61
Drive Shaft (for Outer Chains) - Check . . . . . 4 - 76
Fuses - Rated Current . . . . . . . . . . . . . . . . . . 6 - 232
Drive Unit - Change Chains . . . . . . . . . . . . . . 4 - 70
Drive Unit - Check . . . . . . . . . . . . . . . . . . . . . 4 - 67

G
E Grouping Conveyor - Change
Conveyor Chain . . . . . . . . . . . . . . . . . . . . . . . . 1 - 70
EtherNet/IP Module - Change . . . . . . . . . . . . 6 - 59 Grouping Conveyor - Check . . . . . . . . . . . . . . 1 - 72
EtherNet/IP Module - LED Description . . . . . . 6 - 80 Grouping Conveyor - Overhaul . . . . . . . . . . . . 1 - 74
EtherNet/IP Module - Load Firmware . . . . . . . 6 - 79 Grouping Unit - Functional Description . . . . . . . 3 - 5
EtherNet/IP Module - Set IP Address . . . . . . . 6 - 65 Grouping Unit - Setting Sequence, Type I . . . . . 3 - 7
Grouping Unit - Setting Sequence, Type II . . . . 3 - 8
Grouping Unit - Setting Sequence, Type III . . . . 3 - 8
F Guide Rail - Set . . . . . . . . . . . . . . . . . . . . . . . . 1 - 82
Feed Unit - Basic Setting . . . . . . . . . . . . . . . . . 4 - 9 Gun Holder - Set . . . . . . . . . . . . . . . . . . . . . . . 7 - 56
Feed Unit - By-pass Down
Stream Equipment . . . . . . . . . . . . . . . . . . . . . 4 - 54
Feed Unit - Change Chains . . . . . . . . . . . . . . 4 - 52
Feed Unit - Check Chains . . . . . . . . . . . . . . . 4 - 51

iii - 2 Doc. No. MM-3047612-0101

 Index of Procedures

H Infeed Unit - Setting Sequence, Type II . . . . . 1 - 11

Infeed Unit - Setting Sequence, Type III . . . . . 1 - 12
HMI - Enable/Disable Languages . . . . . . . . 6 - 254
HMI - Set Machine Capacity . . . . . . . . . . . . 6 - 256
HMI Installation List - Check Version of Software L
and Firmware Installed . . . . . . . . . . . . . . . . . 6 - 247
HMI User Management - Change Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 5
User Password . . . . . . . . . . . . . . . . . . . . . . . 6 - 240
HMI User Management - Description . . . . . . 6 - 235
HMI User Management - Enable/Disable M
Operator Settings . . . . . . . . . . . . . . . . . . . . . 6 - 246
Magazine - Configure Magazine Side . . . . . . . 2 - 42
HMI User Management - Log On as a User 6 - 237
Magazine - Referencing . . . . . . . . . . . . . . . . . 2 - 44
Hotmelt Equipment Nordson -
Functional Description . . . . . . . . . . . . . . . . . . . 5 - 6 Magazine - Set Adjustment Bracket . . . . . . . . 2 - 12

Hotmelt Equipment, Nordson - Bleed System 5 - 19 Magazine - Set Carton Magazine . . . . . . . . . . 2 - 23

Hotmelt Equipment, Nordson - By-pass Unit . 5 - 18 Magazine - Set Feeder . . . . . . . . . . . . . . . . . . 2 - 30

Hotmelt Equipment, Nordson - Magazine - Set Indexing Unit . . . . . . . . . . . . . 2 - 36

Change Adhesive . . . . . . . . . . . . . . . . . . . . . . 5 - 21 Magazine - Set Lever Pusher . . . . . . . . . . . . . 2 - 47
Hotmelt Equipment, Nordson - Change Filter 5 - 23 Magazine - Set Top Frame . . . . . . . . . . . . . . . 2 - 28
Hotmelt Equipment, Nordson - Change Gun . 5 - 25 Magazine Unit - Functional Description . . . . . . 2 - 5
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Hotmelt Equipment, Nordson - Check Magazine Unit - Setting Sequence, Type I . . . . 2 - 9

Hotmelt Dot Positions . . . . . . . . . . . . . . . . . . . 5 - 8
Magazine Unit - Setting Sequence, Type II . . . 2 - 10
Hotmelt Equipment, Nordson -
Magazine Unit - Setting Sequence, Type III . . 2 - 11
Clean Nozzles . . . . . . . . . . . . . . . . . . . . . . . . 5 - 26
Motor Bracket - Set Chain Tension . . . . . . . . . 7 - 49
Hotmelt Equipment, Nordson - F2 Alarm . . . . 5 - 20
Motor Unit - Check . . . . . . . . . . . . . . . . . . . . . 7 - 64
Hotmelt Equipment, Nordson - Set . . . . . . . . . 5 - 9

I O
Outfeed Brake - Change Timing Belts . . . . . . 1 - 47
Indexing Conveyor - Change Chain . . . . . . . . 1 - 95
Outfeed Brake - Check . . . . . . . . . . . . . . . . . . 1 - 42
Indexing Conveyor - Change
Conveyor Chain . . . . . . . . . . . . . . . . . . . . . . . 1 - 88 Outfeed Brake - Check Trolleys . . . . . . . . . . . 1 - 63
Indexing Conveyor - Check . . . . . . . . . . . . . . 1 - 90 Outfeed Brake - Lubricate Trolleys . . . . . . . . . 1 - 65
Indexing Conveyor - Check Chain . . . . . . . . . 1 - 94 Outfeed Brake - Overhaul . . . . . . . . . . . . . . . . 1 - 52
Indexing Conveyor - Overhaul . . . . . . . . . . . . 1 - 92 Outfeed Brake - Set Timing Belts Tension . . . 1 - 38
Indexing Conveyor - Set Chain Tension . . . . 1 - 96 Outfeed Conveyor - Configure Outfeed Side . 5 - 80
Infeed Brake - Change Timing Belts . . . . . . . 1 - 27 Outfeed Conveyor - Configure Switch . . . . . . . 5 - 88
Infeed Brake - Check . . . . . . . . . . . . . . . . . . . 1 - 25 Outfeed Conveyor - Select Queue Photocell . 5 - 86
Infeed Brake - Check Trolleys . . . . . . . . . . . . 1 - 32 Outfeed Conveyor - Select Switch Photocell
Expected Status . . . . . . . . . . . . . . . . . . . . . . . 5 - 90
Infeed Brake - Overhaul . . . . . . . . . . . . . . . . . 1 - 28
Outfeed Conveyor - Set Speed . . . . . . . . . . . . 5 - 82
Infeed Brake - Set Photocells Position . . . . . . 1 - 23
Outfeed Conveyor - Set Timer for Queue
Infeed Conveyor - Set Speed . . . . . . . . . . . . 1 - 132
Alarm Photocells . . . . . . . . . . . . . . . . . . . . . . . 5 - 84
Infeed Unit - Functional Description . . . . . . . . . 1 - 7
Outfeed Damper - Check . . . . . . . . . . . . . . . . 5 - 96
Infeed Unit - Setting Sequence, Type I . . . . . 1 - 10
Outfeed Damper - Set . . . . . . . . . . . . . . . . . . . 5 - 91

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Index of Procedures

Outfeed Damper - Set Cylinder . . . . . . . . . . . 5 - 94

S
Overload Protection - Set . . . . . . . . . . . . . . . 6 - 233
Safety Functions - Check . . . . . . . . . . . . . . . . 9 - 12
Overvoltage Protector - Change . . . . . . . . . 6 - 291
Safety System - Description . . . . . . . . . . . . . 6 - 194
Safety System - Troubleshooting . . . . . . . . . 6 - 195
P Sercos Module - Change . . . . . . . . . . . . . . . . 6 - 168
Sercos Module - LED Description . . . . . . . . . 6 - 173
Photocell Unit - Set Position . . . . . . . . . . . . . 1 - 115
Sercos Module - Load Firmware . . . . . . . . . . 6 - 172
Photocells - Check and Clean . . . . . . . . . . . 6 - 299
Servo Drive - Change . . . . . . . . . . . . . . . . . . 6 - 176
Photocells - Set Sensitivity . . . . . . . . . . . . . . 6 - 292
Servo Drive - Error Codes . . . . . . . . . . . . . . . 6 - 187
Pivot Arm - Check . . . . . . . . . . . . . . . . . . . . . 1 - 33
Servo Drive - LED Description . . . . . . . . . . . 6 - 185
Pivot Arm - Overhaul . . . . . . . . . . . . . . . . . . . 1 - 34
Servo Drive - Load Firmware . . . . . . . . . . . . 6 - 184
PLC Power Supply - Change . . . . . . . . . . . . 6 - 277
Servo Drive - Set . . . . . . . . . . . . . . . . . . . . . . 6 - 182
PLC Power Supply - Change Battery . . . . . . 6 - 289
Servo Motor - Change Chains . . . . . . . . . . . . . 3 - 53
PLC Power Supply - Download Program . . . 6 - 279
Servo Motor - Check . . . . . . . . . . . . . . . . . . . . 3 - 51
PLMS NRG - Install Software . . . . . . . . . . . . 6 - 259
Servo Motor - Set Chains Tension . . . . . . . . . 3 - 52
PLMS NRG Configurator - Set Machine ID . 6 - 260
Servo System - Description . . . . . . . . . . . . . . 6 - 164
Pluto Module - Configure in an
Existing Application . . . . . . . . . . . . . . . . . . . 6 - 207 Side Adjuster - Check Timing Belt . . . . 4 - 75, 7 - 50

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Pluto Module - Error Codes . . . . . . . . . . . . . 6 - 218 Signal Exchange - Select Line Automation . . 6 - 276

Pluto Module - LED Description . . . . . . . . . . 6 - 205 Spindle Guide - Check . . . . . . . . . . . . . . . . . . 7 - 55

Pluto Module - Load Program . . . . . . . . . . . 6 - 197 Sprocket - Change Ball Bearings . . . . . . . . . . 3 - 32

Pluto Module - Set ID-FIX Address Sprocket - Check . . . . . . . . . . . . . . . . . . . . . . . 3 - 31

after Replacing an ID-FIX . . . . . . . . . . . . . . . 6 - 209 Stop Unit - Change Ball Bearings . . . . . . . . . . 3 - 69
Positioning Unit - Change Sliding Strips . . . . 3 - 30 Stop Unit - Change Timing Belt . . . . . . . . . . . . 3 - 66
Positioning Unit - Check . . . . . . . . . . . . . . . . . 3 - 29 Stop Unit - Check . . . . . . . . . . . . . . . . . . . . . . 3 - 65
Preparation for PLC Communication - Stop Unit - Referencing . . . . . . . . . . . . . . . . . . 3 - 60
Configure PC Network Communications . . . . . 6 - 7
Stop Unit - Set . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 54
Preparations for PLC Communication -
Stop Unit - Set Timing Belt Tension . . . . . . . . 3 - 64
Configure RSLinx . . . . . . . . . . . . . . . . . . . . . . 6 - 17
Preparations for PLC Communication -
Register EDS File . . . . . . . . . . . . . . . . . . . . . . 6 - 21
Pressure Unit - Check . . . . . . . . . . . . . . . . . . 7 - 45 T
Pressure Unit - Set Position . . . . . . . . . . . . . . 7 - 47 Touch Screen - Calibration . . . . . . . . . . . . . . . 5 - 76
Pull Down Device - Set Proximity Switch . . . . 2 - 62 Touch Screen - Change . . . . . . . . . . . . . . . . . 5 - 27
Touch Screen - Check Firmware Version . . . . 5 - 31
Touch Screen - Check/Set IP Address and
R Subnet Mask Address . . . . . . . . . . . . . . . . . . . 5 - 35
Touch Screen - Download Program . . . . . . . . 5 - 56
Rear Flap Folder - Basic Settings . . . . . . . . . 4 - 55
Touch Screen - Load Firmware . . . . . . . . . . . . 5 - 42
Rear Flap Folder - Disable Alarm . . . . . . . . . . 4 - 60
Recipe - Set . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 6 Touch Screen - Remove Existing Program . . . 5 - 53
Touch Screen - Set . . . . . . . . . . . . . . . . . . . . . 5 - 66
Residual Current Device (RCD) - Check . . . 6 - 234

iii - 4 Doc. No. MM-3047612-0101

 Index of Procedures

V
Vacuum System - Check . . . . . . . . . . . . . . . . 2 - 64

W
Wrap Around Unit - Basic Setting . . . . . . . . . 7 - 10
Wrap Around Unit - Centre Unit . . . . . . . . . . . 7 - 16
Wrap Around Unit - Functional Description . . . 7 - 5
Wrap Around Unit - Lift/Lower Unit . . . . . . . . 7 - 18
Wrap Around Unit - Referencing . . . . . . . . . . 7 - 34
Wrap Around Unit - Set Height Position . . . . . 7 - 17
Wrap Around Unit - Set Pressure Guides
and Fingers . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 19
Wrap Around Unit - Set Software Installation . 7 - 8
Wrap Around Unit - Setting Sequence, Type II 7 - 7
Wrap Around Unit - Setting Sequence, Type III 7 - 7
Wrap Around Unit- Setting Sequence, Type I . 7 - 6
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Index of Procedures

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