2 Panel

Description
This chapter describes how to navigate through the panel, what to do when
alarm occur and how to do make the machine settings
Caution
This chapter contains the instruction for making the machine settings. These
settings must only be performed by a panel trained operator.

Description
The panel display is a touch sensitive screen. Touching the buttons and the
icons allows the operator to manage and communicate with the machine

Panel Main Window

The panel main window displays the buttons and the icons used to identify
the status of the machine and to access the different section of the machine
control system.
1 Display name
2 Progam step icons
3 Progam step name
4 Machine configuration button
5 System setup button
6 Maintenance button (for service technician only)
7 Recipe button
8 Production control button
9 Alams button
10 PLMS BUTTON
11 Status icon
12 Current loaded recipe

Recipe Status Icon

The status icon (1), when activated, notify the operator that a parameter of
the recipe has been change, but the recipe has not been saved

Status Icon – Colours Convention

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

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

Touch the OK button to record a data entry and close the active window.

If an entry number is incorrect, touch the CLEAR button and enter the
correct number

Touch the EXIT button to close an active window.

Common Buttons
NOTE! Some settings have more than one factory value. For these settings
the FACTORY buton only provides an approximate value.
• FACTORY button – touch and hold for at least three seconds to
reset values to the factory setting. The button changes to white
to indicate that the value has been reset.
• NUMERIC button – This button allows the numeric values to
be entered.

The ENABLE ICONS button.

Touch the ENABLE ICONS button to enable the gray icons in the module
window.
The icons in the module window become white.

The CHANGE WINDOW button.

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

Common Icons
• Process – current value.
• Set point – value that has been set for the particular function.
• Hour counter.

Changing Values
If a dialogue window has arrow keys, it means that some values can be
changed. The changes can be, for example, in increments of 10 with the
double-arrow keys and in increments of 1 with the single-arrow keys.

Function Buttons
All the available icons are while, when an icon is selected its colour changes
to blue.

Touch the icon of a particular function display the dialogue window.

The function can be selected with the ON button(1) and deselected with the
OFF button(2), then confirm with the CONFIRMATION button(3).

NOTE! A green dot(4) close to the symbol indicates that the function has
been activated or selected.

Program Steps
This section describes the program steps displayed on the panel to indicate
the machine status before, during and after PRODUCTION

Program Step Ladder

The icons in the program step ladder(1) show the machine status and what
the machine can do next.

A flashing light means that the machine is ready to go to the next program
step.

A fixed light means that the machine is at the current program step.

Program Step Status

Machine status goes from STEP 0 to STEP 2.

STEP 0 means the machine status is OFF. When the power supply
disconnector (main switch ) is set to ON, the panel is energised and the
machine sensors receive low voltage. There are no component movements.
The machine is in a safety condition. The flashing light shows that the
machine is ready for the next machine step.

STEP 1 is PREPARATION. All the electrical devices are energised, the

pnecumatic system is pressurised, the machine is synchronised. When the
 Heating Chamber is at the correct temperature, the PRODUCTION icon will
flash. The machine is then ready to go to PRODUCTION.

STEP 2 is PRODUCTION. The fixed light shows that the machine is in

PRODUTION.

The fixed light on the HOMING icon indicates the homing procedure of
some of the servomotor alarm.

The fixed light on the END

PRODUCTON icon indicates that the machine is emptying before stopping
the production.

WARNING
Risk of injury.
During the HOMING procedure th machine moves for afew seconds.

System Seup
This section describes how to:
• Set the language used by the PANEL
• Login, logout and change password.

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

2
On the SETUP window are displayed the following buttons:
• LANGUAGE (1)
• INSTALLATION LIST (2)
• USER MANAGEMENT (3)
• DIAGNOSTIC (4)
• SHUT DOWN (5)

Language Seting

1
Touch the LANGUAGE button to display the LANGUAGE window.
 NOTE! The LANGUAGE window will take about 1 minute to open,
locking temporary the panel.
2
Touch the required LANGUAGE button and wait for a few seconds.
3
Touch the EXIT button.

USER MANAGEMENT
1
Touch the USER MANAGEMENT button to display the USER
MANAGEMENT window.
2
In the USER MANAGEMENT window are displayed:
- The LOGOUT button (1)
- The LOGIN button (2)
- The CHANGE PASSWORD button (3)
- The actual user (4).
NOTE! The change of password could be not available for the operator.
3
Login
Touch the LOGIN button.
3a
Touch the USER button (1) and the PASSWORD button (2) to display
the keyboard then type the data entry.
Touch the ENTER button (3) to confirm the data entry or touch the ESC
button (4) to close the LOGIN window.
4
Change Password
If available, touch the CHANGE PASSWORD button.
4a
NOTE! After any change, the system will not accept any old passwords.
Touch the OLD PASSWORD button (1), the NEW PASSWORD
BUTTON (2) and the CONFIRM button (3) to display the keyboard, then
type the data entry.
Touch the ENTER button (4) to confirm the data entry or touch the ESC
button(5) to close to the LOGIN window.

Machine Configuration
This section describes how to enable/disable the available machine option
through the panel.
1
Touch the MACHINE CONFIGURATION button to display the
MACHINE CONFIGURATION window.
2
This is a read only page for operation. The window displays the actual
configuration of the machine, through the following icons:
• MACHINE NUMBER (1)
• SWITCH (2)
• LINE AUTOMATION (3)
• LINE COMMUNICATION ETHERNET CARD IP ADRESS
(4)
3
Note! A green dot (1) close to the symbol indicates that the funtion has
been activated.
Note ! The mark “X” over an icon, means that the option equipment is
not installed on the machine.
Touch one of the icons avalable, the icon become blue and the
corresponding confinguration window is displayed.

Alarm Group Buttons

The alarms show where there is a problem on the machine and how to
resolve it.
The alarm are divided into groups. When an alarm is activated, an alarm
window is displayed with the activated alarm lit up.
If no alarms appear, touch the ALARM SYSTEM window is displayed,
showing the alarm groups. Each button opens the corresponding alarm
window.

General Informationtion
The ACKOWLEDGE button is used to acknowledge the alarm.

Alarm Colour Codes

The alarms are colour coded:
• RED (1) – hazardous condition
• YELLOW (2) –abnormal condition
• BLUE (3) – information or operator action.
• GREEN (4) – PRODUTION step, no operator action required.
Every alarm must be acknowledged. When the alarm is acknowledged, the
light on the warning lamp passes from flashing to fixed.
The alarms disappear when the cause is corrected and acknowledged.
If the alarm window does not close after pressing the ACKNOWLEDGED
button, it means that some alarms still exist.

Alarm Handling
1
When an alarm occurs, the ALARM window opens and the active alarm
(1) appears.
2
If necessary, touch the active alarm (1) to open the ALARM
INSTRUCTION window.
3
The active alarm (1) become blue and the ALARM INSTRUCTION
window (2) is displayed.
Look at the ALARM INSTRUCTION window (2) for alarm details.
Follow the instructions.
Touch the flashing ACKNOWLEDGED button to acknowledge the
alarm.
Note ! In the meantime other alarms could occur and the ALARM
window will be displayed on the panel.
Note ! To make the safety relay disengaged symbol (3) disappear for the
divider and the combiner modules, push the local
RESET/ACKNOWLEDGED button (4).
4
Touch the EXIT button to return to the Main window.

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

RECIPE Window
1
Note! The machine can produce only if a recipe has been selected.
Touch the RECIPE button to display the RECIPE window.

The current recipe name (1) is show on the top side of the RECIPE
window.
 Each recipe includes the machine settings necessary for that specific type
of production.

The RECIPE window appears.

From this window it is possible to select the package, the patten and the
kind of film required. The configuration selected is show in the fields under
the symbols
2
Recipes Handling
Note! Make sure that the machine is in STEP ZERO.

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).

Touch the NEW RECIPE button (2) to create a new recipe from the
beginning.

PRODUCTION CONTROL
This section describes how to use the panel to check and change
machine settings, view process parameters, run machine functions and
view package counters.

Production Control Modules

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

FILM MAGAZINE button

1
Touch the FILM MAGAZINE button,
2
The FILM MAGAZINE window appears.

This window shows the setting options for the film magazine. The
options are as follows:
 • Cycles after emptybobbin (1)
• Bobbin 1 selected (2)
• Bobbin 2 selected (3)
• Film splice time (4)
• Web tension motor homing (5).

When any of the options are selected a new window appears and
within this window the changes can be applied.
3
Touch the exit button to return to the SYSTEM SETTING window.

FLIGHT BAR button

1
Touch the FLIGHT BAR button
2
The FLIGHT BAR window appears
This window shows the setting options for the flight bar. The options
are as follows:
• FLIGHT BAR infeed motor homing (1)
• FLIGHT BAR main motor homing (2)
When any of the options are selected, a new window appears and within
this window changes can be applied.
3
Touch the EXIT button to return to the SYSTEM SETTING window.

WRAPING Button
1
Touch the WRAPPING button.
2
The WRAPPING window appears
This window shows the setting options for the Wrapping. The
options are as follows:
• LAPPING BAR MOTOR HOMING (1)
• FILM POSITION (2)
• FILM LENGTH (3)
• FILM INCHING (4)
• FILM MOTOR HOMING (5)
• KNIFE MOTOR HOMING (6)
 When some of the options are selected, a new window appears and
within this window the changes can be applied.
3
Touch the EXIT button to return to the SYSTEM SETTING
window.

SHRINK TUNNEL button

1
Touch the SHRINK TUNNEL button.
2
The SHRINK TUNNEL window apears.
This window shows the setting option for the SHRINK TUNNEL:
• HEADTER TEMPERATURE SETPOINT (1).
When the option is selected, a new window apears and within this
window the changes can be applied.
3
Touch the EXIT button to return to the SYSTEM SETTING
WINDOW.

OUT – FEED Button

1
Touch the OUT – FEED Button.
2
The OUT – FEED Button window appears.
This window shows the setting option for the combiner. The option
are as follows:
• STOP TIME FOR BELT BRAKE SWITCH (1)
• TIME FOR PACKAGES RELEASE (2),
When any of the option are selected, a new window appears and
within this window the changes can be applied
3
Touch the EXIT button to return to the SYSTEM SETING window.

PACKAGE COUTER Button

1
Touch the PACKAGE COUTER Button
2
The PACKAGE COUTER window appears.
This window show the number of packages in and out of the
machine.
 The RESET button allows the counter to be reset to zero.
3
Touch the EXIT button to returns to the SYSTEM SETING window.

SERVICE PARTS Button

1
Touch the SREVICE PARTS button to display the SERVICE
PARTS window.
2
On the SERVICE PARTS window are normally displayed the
following icon:
• FLIGHT BAR INFEED WATER LUBRICATION (1)
• MACHINE LIGHT (2)
• LAMP AND HOOTER TEST (3)
• MACHIN INCHING (4)
• INCHING SPEED (5)
• MACHINE MOVE TO POSITION (6)
• END PRODUCTION (7).
Touch the icons to dislay the dialogue window, then make the
changes or perform the action required.
3
Touch the EXIT button to return to the PRODUCTION CONTROL
window.

3 PREPARATION
Description
This chapter describes how to prepare the machine for the first
production run of the day.
WARNING
Risk of personal injury.
To ensure maximum safety, always read this section and the Chapter ii
Sefety Precaution carefully before doing any work on the equipment or
making any adjustment.

PREPARING AFTER CARE AND CLEANING

Note! Do the cleaning procedure, see 9 Care and Cleaning before
starting this procedure.

POWER SUPPLY DISCONNECTOR

1
Make sure that the power supply disconnector (1) is the ON position.

AIR SUPPLY
1
The figure shows the shut – off valve in the CLOSED position.
Check that the shut – off valve is open. To open, push down and turn
the shut – off handle (1).
2
Check the main air supply pressure
Look at the pressure gauge (1) and check that the main air supply
pressure is set correctly.
See 11 Technical Data for setting values. To change the pressure
setting, call a service technician.

Doors and covers

1
Check that all the door are closed and all the covers are installed.

Alarms
1
Look at the panel. If any alarm are displayed, take the corrective
action, see the chapter 2 Panel, section Alarm Handling.

Lamp and Hooter Test

1
Touch the SETTING SYSTEM button to open the SERVICE
window.
2
Touch the SERVICE button.
3
a) Touch the LAMP AND HOOTER TEST button (1)
b) Touch the ENABLE button (2).
c) Check that all the push – button indicator lamps on the panel
come ON. Check that the light in the warning lamp come ON.
d) Check that the audible alarm sounds steadily for 3 seconds.
 e) Touch the DISABLE button (3) to exit the test.
Note! If some lamp or the audible alarm does not work correctly,
replace them.
4
Touch the EXIT button to return to the MAINTENANCE window.

Film Reels
1
If necessary, put new film reels in the Film Magazine, see the chapter
6 Supplies of Material.

Emergency Stops
1
Check that no Emergency Stop button is pressed.

Preparation – Machine Step

1
Push the STEP UP button once.
Result: The HOMING icon (1) becomes fixed and the machine starts
the homing procedure for the servomotors.
At the end of the HOMING procedure, the PREHEATING icon (2)
becomes fixed and the Shrink Tunel starts to warm. The machine is at
STEP 1 – PREPARATION.
Note! It will take about 20 minutes to reach the correct working
temperature is 20 C (68 F), if PREHEATING takes more than 40
minutes, call a sevice technician.

4 START
Description
This chapter describes how to start the machine for PRODUTION after the
Preparation produre is done. To start the machine after an Emergecy Stop or
a Normal Stop, see 7 Stop.
Warning
Risk of personal injury.
To ensure maximum safety, always read this section and the chapter ii
Safety Precaution carefully before doing any work on the equipment or
making any adjustment,
Waning
Risk of impaired hearing.
Wear hearing protection whenever this equipment is in operation.

Starting Prodution
Checks
Make sure that all the covers and the doors on the machine are closed.
Reset any alarms on the panel.
If any alarm is present, take the appropriate action or call a technician.

Step up to PRODUCTION
The machine is ready to start the PRODUCTION when the PREHEATING
icon (1) is fixed and the PRODUCTION icon (2) is flashing.

Note! During the homing procedure of the PREPARATION program step

the Cutting Unit launches some pieces of film onto the Wrapping. Remove
any film sheet from the Wrapping.
Keep the PROGRAM UP button (3) pressed for 3 seconds.

Result: the siren of the Warning Lamp gives an audible alarm for 3 seconds.
The PRODUCTION icon (2) becomes fixed and the machine start to run.

Restarting After Fault

This section describes how to start the prodution again in the case of a fault
on the Infeed and/or Dischange Unit.

Stop the Machine

DANGER
Risk of death, serious injury or damage to the equipment.
When there is risk of danger to people or damage to the machine,
immediately push an EMERGENCY STOP push – button. To restart the
machine, see the chapter 7 STOP, section Emergency Stop.

In the case of a fault on the Infeed or Dischange Unit, such as fallen or

jammed packages, push the STEP DOWN button (1) on once of the
connection boxes (2).
Result: the machine empties the Shrink Tunel unit. All the machine units
stop in a synchronised stop condition.

Solve the Problem and Acknowledge the Alarm

Solve the fault on the Infeed and/or Discharge unit.
Acknowledge the alarm by pressing the RESET/ACKNOWLEDGE push –
button (1).

Checks before Restarting

Perform the following operations on the Infeed before restarting the
production:
• Check that there are no turned packages on the conveyors. Remove
them if requied
• Remove all the damaged packages
• Check that there no obstacles, for example straws, in front of the
photocells and fibre optic units. Remove them if required.

Restart the Machine

Note! If there are any other alarms on other Units, the machine will not start.
Push the STEP UP button (1) to start the production again.

5 CHECKS

Descpription
This chapter describes all the checks that the operator must perform during
the production run.
When there is a fault or a fault cannot be eliminated, call a service
technician.

5.1 Checks

General
Make sure that the equipment runs properly.
Listen for any abnormal sounds.
If there are any abnormal sound, stop the equipment immediately.
Alarm
1
Indication
If an alarm occurs, the warning lamp start to flash and the alarm
corresponding indicator (1) appears on the panel screen.

Take the action required.

See Chapter 2 Panel for further information.

When the cause of the alarm is eliminated, the fixed light disappears.

Packages with Straws

1
Check that the straw (1) on the package is neither longer than the diagonal
of the package, nor misplaced. Otherwise it could cause a stop in production.
Check the proper bottom shape of the package. A misshapen package
could cause a stop in prodution.

Film
1
Film centring
Check that the film is correctly centred on the unit. The film opening must
be the same size at both unit ends.

If not, check that the knife (1) cuts the film into two equal parts.

If necessary, adjust the position of the divider (2) to separate, more or

less, the sliced film parts.
2
Film Shrinking
Check that the ends of the package unit are shrink.
Check that the overlapped film area under the pattem is correctly welded.
If any of the conditions above are not respected, perform the following
operation.

Warning
Risk of burns.
The Shrink Tunel is hot. Pay attention when working on it. Use protective
gloves.
 a) Remove convers (1).
b) More the sheets (2) to open or close the holes from which the hot
air reachs the pattems. Respect the following rules:
- Keep the holes on wich the pattems do not pass closed
- Open completely the holes corresponding to the side of the
patterns
- Set the opening of the maining holes until the film is correctly
shrink.
c) Fit the covers (1).

9 CARE AND CLEANING

Description
This chapter contains instructions for all the cleaning tasks to be
performed on the machine or equipment at regular, described intervals
after PRODUCTION.

Daily Care
This section describes what to do after each PRODUCTION run or at
least every 24 operating hours.

Machine Body – Clean Protection

1
Open the doors on the LH side of the machine.
2
Extract the panels (1).
Clean the panels (1) with a wet sponge.
Dry the panels (1) with a clean cloth and fit them back.
3
Remove the cover (1)
Extract the panel (2).
Clean the panel (2) with a wet sponge.
Dry the panel (2) with a clean cloth and fit it back.
Fit the cover (1) and close all the doors.
 Machine Body – Pick up Film Resedues
1
Open the doors on the HL and RH sides of the machine.
2
Remove the cover (1).
Pick up all the film resedues below the Machine Body frame.
Fit the cover (1).
Close all the doors.

Machine Body – Clean Plate

1
Use a soft, wet piece of cloth to clean the table top and the connection
table plate.
Use the cleaning compound code D to clean the lime scale deposits.
After cleaning, rinse thoroughly with drinking water.
Dry using the machine’s compressed air.
Finish the cleaning process using a clean cloth.
Note! For cleaning compound code information, see chapter 11
Technicial Data.

Weekly Care
This section describes what to do once a week or at least every 120
operating hours.
Note! Make sure that the Daily Care has been carried out before.

Infeed – Clean Photocells and Fibre Optic Units

Clean the following photocells and fibre optic with a clean cloth:
- Divider fibre optic (1)
- Congestion photocell (2)
- Max level photocell (3)
- Max right photocell (4)
- Min right photocell (5)
- Right belt brake fibre optic (6)
- Length right photocell (7)
- Max left photocell (8)
- Min left photocell (9)
- Left belt brake fibre optic (10)
- Length left photocell (11).

Machine Body – Clean Protection

1
Open the doors on the LH side of the machine.
2
Extract the panels (1) with a wet sponge.
Dry the panels (1) with a clean cloth and fit them back.
3
Remove the cover (1)
Extract the panel (2).
Clean the panel (2) with a wet sponge.
Dry the panel (2) with a clean cloth and fit it back.
Fit the cover (1) and close all the door.

Cutting Unit – Clean Film Residues

1
Open the doors on the RH sides of the machine.
2
Extract the Cutting Unit (1).
Clean the rollers (2) and (3) with a wet sponge.
Dry rollers (2) and (3) with a clean cloth.
3
Remove the film residues from the knife with the air gun (1).
Fit the Cutting Unit (2) back.
4
Close the doors.

Shrink Tunnel – Clean Film Residues

1
Remove the covers (1) with the four screws(2)
2
Remove the film residues from the knife with the air gun (1).
3
Clean the Shrink Tunnel below the Out-feed belt, see the arrow.
Sweep the floor under the Shrink Tunnel.
Fit the cover (1) with the four screws (2).
4
If on the Shrink Tunnel belt there are residues of melted film,clean with a
metal brush.

Covers – Clean Windows

 Clean the windows on the machine with a sponge. Use cleaning
compound code information, see chapter 11 Technical Data.

Cleaning after Smashed Packages

Carry out Cleaning after Shmashed Packages when packages have been
smashed during PRODUTION and package content has solied the machine,

Remove Shmashed Packages

1
Remove all the smashed packages from machine.
There are position on the machine where the packages can smash more
easily, see the arrows in the illustration aside.

Clean Photocells
1
If smashed packages have splashed over the photocells, wipe off all the
solied photocells.
Note! Make sure to use a soft, lint-free piece of cloth.

Cleaing
1
Danger
Risk of immediate danger to life.
Do not flush water towards the elictrical cabinet anf all the elictrical
equipments. Failure to observe will result in dange to life and damage
to the equipment.

Clean the dirty area with a wet sponge.

Dry the area with a clean cloth.