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I 41058 VIGNOLA (MO)

CH 6933 MUZZANO (TI)

ISTRUZIONI TECNICHE
TECHNICAL INSTRUCTIONS INSTRUCTIONS TECHNIQUES TECHNISCHES ANWEISUNGEN

Macchina automatica confezionatrice


Automatic wrapping machine Machine automatique pour lemballage Automatische Verpackungsmaschine Empaquetadora automtica

(B.220)

Codice:
Code: Code: Kode: Cdigo:

Y.221.003

No

Rev.0 Valido dalla serie:

Valid from series: Valable depuis la serie: Gltig ab Maschine: Valido desde la serie:

I GB F D

Venduta da : Sold by: Vendue par: Verkauft durch: Vendida por:

-.

INTRODUCTION AND RECOMMENDATIONS ....................................................6 MACHINE MODEL "55 Pi" STANDARD .........................................8

PAR T 1 1.

GENERAL .............................................................................................................9
1.1 1.2 1.3 1.4 1.5 SAFETY - ACCIDENT PREVENTION....................................................................... 9 SPARE PARTS ........................................................................................................ 10 SPECIAL EQUIPMENT ........................................................................................... 10 LUBRICANTS .......................................................................................................... 11 PREVENTIVE MAINTENANCE AND GENERAL SERVICE TESTS ...................... 12

2.

MACHINE PRODUCT INFEED ...........................................................................14


2.1 2.2 DESCRIPTION ........................................................................................................ 14 ERRORS AND MALFUNCTIONS ........................................................................... 23 DESCRIPTION ........................................................................................................ 23 THE TOOTHED CAM DISK AND MACHINE PHASING ......................................... 30 ERRORS AND MALFUNCTIONS ........................................................................... 32 LUBRICATION OIL SEAL..................................................................................... 32

3.

CENTRAL GROUP FOR THE MAIN MOVEMENTS...........................................23


3.1 3.2 3.3 3.4

4.
4.1 4.2

FILM REEL CARRIER SHAFT........................................................................33


DESCRIPTION ........................................................................................................ 33 ERRORS AND MALFUNCTIONS ........................................................................... 33

5.
5.1 5.2

FILM TENSION ROLLERS (DANDY ROLL)...................................................33


DESCRIPTION ........................................................................................................ 33 ERRORS AND MALFUNCTIONS ........................................................................... 34 DESCRIPTION ........................................................................................................ 34 ERRORS AND MALFUNCTIONS ........................................................................... 36 DESCRIPTION ........................................................................................................ 36 ERRORS AND MALFUNCTIONS ........................................................................... 40 DESCRIPTION ........................................................................................................ 40 ERRORS AND MALFUNCTIONS ........................................................................... 40 DESCRIPTION ........................................................................................................ 40 ERRORS AND MALFUNCTIONS ........................................................................... 41

6.

FILM PERFORATION KNIFE..............................................................................34


6.1 6.2

7.

CHANGING THE LENGTH OF THE FILM ..........................................................36


7.1 7.2

8.

CHECKING THE INCOMING FILM .....................................................................40


8.1 8.2

9.

FILM TEARING MECHANISM ............................................................................40


9.1 9.2

10.
10.1 10.2 10.3

FILM CENTRING.............................................................................................41
DESCRIPTION ........................................................................................................ 41 FILM STOP PHOTOCELLS..................................................................................... 41 ERRORS AND MALFUNCTIONS ........................................................................... 50

11.
11.1 11.2 11.3

ELEVATOR .....................................................................................................50
DESCRIPTION ........................................................................................................ 50 ELEVATORS AVAILABLE ....................................................................................... 51 ERRORS AND MALFUNCTIONS ........................................................................... 51

Page 1 of 168

12.
12.1 12.2

FOLDER ..........................................................................................................51
DESCRIPTION ........................................................................................................ 51 ERRORS AND MALFUNCTIONS ........................................................................... 52

13.
13.1

LOWER EJECTOR..........................................................................................52
DESCRIPTION ........................................................................................................ 52

14.
14.1 14.2

UPPER EJECTOR...........................................................................................52
DESCRIPTION ........................................................................................................ 52 ERRORS AND MALFUNCTIONS ........................................................................... 56

15.
15.1 15.2

FOLDING CLAMP AND EJECTOR CLAMP...................................................57


DESCRIPTION ........................................................................................................ 57 ERRORS AND MALFUNCTIONS ........................................................................... 57

16.
16.1 16.2

SEALING PLATE ............................................................................................57


DESCRIPTION ........................................................................................................ 57 ERRORS AND MALFUNCTIONS ........................................................................... 58

17.
17.1 17.2

SENSOR TESTING .........................................................................................58


DESCRIPTION ........................................................................................................ 58 ERRORS AND MALFUNCTIONS CAUSED BY THE SENSORS .......................... 61

18.
18.1 18.2 18.3 18.4

BRAKE, CLUTCH AND ELECTROMAGNET TESTING ................................61


INTERNAL RESISTANCE MEASUREMENT .......................................................... 61 BRAKE AND CLUTCH TESTING............................................................................ 62 ELECTROMAGNET TESTING ................................................................................ 62 ERRORS AND MALFUNCTIONS ........................................................................... 64

19.
19.1

ELECTROMAGNET MECHANICAL ADJUSTMENT......................................64


DESCRIPTION ........................................................................................................ 64

20.
20.1 20.2 20.3 20.4

PHOTOCELLS ................................................................................................64
REFLECTING PHOTOCELLS TESTING ................................................................ 64 INFEED AND CARRIAGE PHOTOCELLS TESTING ............................................. 64 FILM STOP PHOTOCELLS TESTING .................................................................... 68 SUMMARY OF THE PHOTOCELLS FEATURES .................................................. 69

21.
21.1 21.2 21.3 21.4

MICROSWITCHES AND CONTROL BUTTONS TESTING............................74


SAFETY MICROSWITCHES ................................................................................... 74 CONTROL PANEL BUTTONS ................................................................................ 75 FILM STOP RELEASE MICROSWITCHES ............................................................ 75 ERRORS AND MALFUNCTIONS ........................................................................... 75

22.
22.1 22.2

TESTING OF THE STEPPING MOTORS .......................................................75


DESCRIPTION ........................................................................................................ 75 ERRORS AND MALFUNCTIONS ........................................................................... 76

23.
23.1 23.2 23.3

ELECTRONIC BOARD ARRAY AND COMMANDS ......................................76


DESCRIPTION ........................................................................................................ 76 CONTROL PANEL................................................................................................... 78 ERRORS AND MALFUNCTIONS ........................................................................... 78

24.
24.1

POWER BOARD AP1 .....................................................................................78


DESCRIPTION ........................................................................................................ 78

Page 2 of 168

25.
25.1

SEALING PLATE RELAY BOARD AP2 .........................................................79


DESCRIPTION ........................................................................................................ 79

26.
26.1

OUTPUT INTERFACE BOARD AP5...............................................................79


DESCRIPTION ........................................................................................................ 79

27.
27.1

INPUT INTERFACE BOARD AP6...................................................................81


DESCRIPTION ........................................................................................................ 81

28.
28.1

COMPLETE 10.4 L.C.D. AP17......................................................................82


DESCRIPTION ........................................................................................................ 82

29.
29.1 29.2

CPU BOARD AP7 ...........................................................................................83


DESCRIPTION ........................................................................................................ 83 ERRORS AND MALFUNCTIONS ........................................................................... 89

30.
30.1 30.2

INFEED, CARRIAGE AND FILM STOP PHOTOCELLS BOARD AP11 AP12 - AP13 - AP14 AP15 AP16........................................................................90
DESCRIPTION ........................................................................................................ 90 ERRORS AND MALFUNCTIONS ........................................................................... 91

31.
31.1

DAC BOARD AP 10 ......................................................................................91


DESCRIPTION ........................................................................................................ 91

32.
32.1

STEPPING MOTORS DRIVER BOARD AP8 + AP9 ......................................92


DESCRIPTION ........................................................................................................ 92

33.
33.1 33.2

FREQUENCY CONVERTERS AP3 AND AP4................................................92


DESCRIPTION ........................................................................................................ 92 ERRORS AND MALFUNCTIONS OF THE INVERTERS ....................................... 93

34.
34.1 34.2

INPUTS FOR CONNECTING EXTERNAL DEVICES TO THE MACHINE .....93


DESCRIPTION ........................................................................................................ 93 ERRORS AND MALFUNCTIONS ........................................................................... 96

35.
35.1

MANAGEMENT OF THE CUSTOMERS INFEED..........................................96


DESCRIPTION ........................................................................................................ 96

36.
36.1

CONTROL PANEL ..........................................................................................98


DESCRIPTION ........................................................................................................ 98

37.
37.1 37.2

PROBLEMS WHEN SWITCHING ON THE MACHINE...................................98


MALFUNCTIONS WITHOUT ERROR INDICATION ON DISPLAY........................ 98 MALFUNCTIONS WITH ERROR INDICATION ON DISPLAY ............................... 98

38.
38.1

SELFTEST.......................................................................................................99
DESCRIPTION ........................................................................................................ 99

39.
39.1 39.2

MALFUNCTIONS DURING THE WRAPPING OPERATIONS........................99


DESCRIPTON ......................................................................................................... 99 ERRORS AND MALFUNCTIONS ........................................................................... 99

40.
40.1 40.2

DIAGNOSTICS ................................................................................................100
INCIDENTAL ERRORS (NOT LINKED TO THE MOVEMENTS) ........................... 100 ERRORS CAUSES SOLUTIONS...................................................................... 102

Page 3 of 168

40.3 40.4

MACHINE PARAMETERS....................................................................................... 104 MACHINE PROGRAMMING ................................................................................... 107

PART 2 1.

OPTIONAL DEVICES FOR MACCHINE 55 Pi MODEL ......................117

PRODUCT EXIT CONTROL PHOTOCELL (OPTIONAL C.220.021).................117


1.1 1.2 1.3 DESCRIPTION ........................................................................................................ 117 OPERATION ............................................................................................................ 117 MALFUNCTIONS..................................................................................................... 119 DESCRIPTION ........................................................................................................ 119 MALFUNCTIONS..................................................................................................... 120

2.

SIDE STRETCH DEVICE (OPTIONAL C.220.047 AND C.220.047.1) ...............119


2.1 2.2

3.

INTEGRATION FOR ELEVATOR TYPE A (OPTIONAL C.220.101 AND C.220.101.1) ........................................................................................................120


3.1 3.2 DESCRIPTION ........................................................................................................ 120 MALFUNCTIONS..................................................................................................... 121 DESCRIPTION ........................................................................................................ 121 PRINTED FILM CHARACTERISTICS..................................................................... 122 OPERATION ............................................................................................................ 122 ERRORS AND MALFUNCTIONS ........................................................................... 122

4.

PRINTED FILM CENTRING PHOTOCELL (OPTIONAL C.215.031) .................121


4.1 4.2 4.3 4.4

5.

INFEED EXTENSION L=1 m (OPTIONAL C.220.005, C.220.005.1 and C.220.040) INFEED EXTENSION L=2m (OPTIONAL C.220.003, C.220.003.1 and C.220.040.1).................................................................................................124 IN-LINE OUTLET CONVEYOR (OPTIONAL C.220.009 L=850mm) (OPTIONAL C.220.009.1 L=1270mm) ....................................................................................124
6.1 DESCRIPTION ........................................................................................................ 124

6.

7.

MOTORIZED OUTLET CONVEYOR (OPTIONAL C.220.010 90 RIGHT) (OPTIONAL C.220.011 90 LEFT) (OPPIONAL C.220.012 180 RIGHT) (OPTIONAL C.220.013 180 LEFT) ..................................................................124
7.1 7.2 7.3 DESCRIPTION ........................................................................................................ 124 OPERATION ............................................................................................................ 124 ERRORS AND MALFUNCTIONS ........................................................................... 125 DESCRIPTION ........................................................................................................ 125 ERRORS AND MALFUNCTIONS ........................................................................... 129 DESCRIPTION ........................................................................................................ 129 ERRORS AND MALFUNCTIONS ........................................................................... 131

8.

AUTOMATIC CARRIAGE MOVEMENT (OPTIONAL C.220.026) .....................125


8.1 8.2

9.

CUSTOMER BELT CONTROL PHOTOCELL (OPTIONAL C.220.018)............129


9.1 9.2

10.
10.1

OPTIONAL DEVICE FOR FRAGILE TRAYS (OPTIONAL C.220.029) .........131


DESCRIPTION ........................................................................................................ 131

11.
11.1

SUPPORT FOR SECOND REEL (OPTIONAL C.220.042)............................131


DESCRIPTION ........................................................................................................ 131

Page 4 of 168

11.2

ERRORS AND MALFUNCTIONS ............................................................................ 132

12.
12.1

REEL CARRIER FOR PRINTED FILM (OPTIONAL C.220.042.1).................132


DESCRIPTION ......................................................................................................... 132

13.
13.1

OPTIONAL DEVICE FOR PIZZA up to = 280 mm (OPTIONAL C.220.066) ..........................................................................................................................132


DESCRIPTION ......................................................................................................... 132

14.
14.1

OPTIONAL DEVICE FOR SMALL TRAYS (OPTIONAL C.220.102) .............133


DESCRIPTION ......................................................................................................... 133

15.
15.1

OPTIONAL DEVICE FOR NARROW AND LONG TRAYS (OPTIONAL C.220.105) ........................................................................................................133
DESCRIPTION ......................................................................................................... 133

16.
16.1

OPTIONAL DEVICE FOR INSERTING TRAYS AT 90 (OPTIONAL C.220.041) ........................................................................................................134


DESCRIPTION ......................................................................................................... 134

Page 5 of 168

-.

INTRODUCTION AND RECOMMENDATIONS

This manual, its use and the information it holds, are reserved for the technicians of technical service centres of our distributors who sell our model 55 Pi machine. Therefore, the text and drawings cannot be reproduced either wholly or in part, nor can they be given to third parties It is therefore not intended for the use of customers or their technical staff. The manual concentrates in detail on the electric and electronics of the machine, whereas the mechanical aspects have been limited intentionally to the main adjustments required, and does not cover the assembly and dismantling of the various machine part groups, part replacements, etc. These operations are handled by the technical staff specialized in the maintenance of the type of machine we produce. Should the need arise for the dismantling and reassembly of any machine part, or for the installation of optionals or weighing system integration kits, the relevant assembly drawings required can be obtained by specifying the part name and the machine series. An integral part of this manual is the booklet Use and Maintenance (code no. Y.220) and the catalogue Spare parts (code no. Y.221.002) for the model 55 Pi machine in the edition which corresponds to the machine series. We wish to remind you that PCPocket is not essential when any checks or work on the model 55 Pi machine are necessary. The technical manual is divided into two main parts and each part is divided into chapters followed by the Enclosures (part 3). The sequence of the functions and the causes for errors are depicted for each machine function with a flow chart. The order of the chapters follows the logical sequence that a product undergoes when it is being wrapped, from the infeed to the exit. Some other chapters follow that deal with special adjustments and checks, as well as a detailed explanation of the electrical and electronic parts. In the second part, the various optional devices available are described technically, as well as their operation.

Page 6 of 168

The third part, Enclosures, includes all the technical bulletins related to all modifications made to the machine 55 Pi. The technical communications represent the continuous update of this manual. * ATTENTION * DURING WORK OR CHECKS ON THE MODEL 55 Pi MACHINE, ALWAYS COMPLY WITH THE COUNTRYS REGULATIONS AS REGARDS TO SAFETY AT WORK FOR YOUR OWN PROTECTION. WHEN MACHINE MAINTENANCE IS COMPLETED, ALWAYS CHECK THAT THE MACHINE SAFETY DEVICES WORK EFFECTIVELY, EFFICIENTLY AND THAT THEY GUARANTEE OPERATOR SAFETY.

Page 7 of 168

PART 1

MACHINE MODEL "55 Pi" STANDARD

Page 8 of 168

1.
1.1

GENERAL
SAFETY - ACCIDENT PREVENTION

All 55 Pi machines that leave the factory are equipped with a numbered CEECertificate and conform to the present European standards. During maintenance and aftersales service, it is therefore advisable to check the perfect operation of all parts which have a direct or indirect bearing on the safety of the operator (covers, microswitches, connections with earthing circuits, etc.) and that any malfunctioning, evidence of tampering, or missing parts intrinsic to accident prevention, is brought to the attention of the customer.

* ATTENTION *

AFTER ANY MAINTENANCE OR ADJUSTMENT THAT HAVE TO BE MADE INVOLVING REMOVAL OF ANY PART RELATED TO SAFETY - THIS DONE ONLY WITH THE UTMOST CARE, EVEN BY SKILLED TECHNICIANS, SINCE HIGH VOLTAGE AND MOVING PARTS ARE INVOLVED IT IS ABSOLUTELY NECESSARY THAT ALL OF THE ELECTRICAL AND MECHANICAL SAFETY DEVICES ARE RESTORED TO THEIR ORIGINAL POSITIONS, AND ARE IN PERFECT WORKING ORDER.

For the detailed description concerning safety circuits and their service requirements, see chapter 21.

Page 9 of 168

1.2

SPARE PARTS

In the case of parts must be replaced, it is necessary, to use only original spare parts, in order to permit good operation of the machine and to avoid the cancellation of the warranty terms. The codes of the spare parts constituting the machine and the relative optionals are listed in the booklet Spare Parts to be requested under code Y.221.002. For the customer having its own internal technical service trained for 55 Pi machine maintenance, in addition to the spare parts already supplied with the machine, a special package of spare parts is foreseen, which can easily be substituted and that is grouped under code C.220.Z02. 1.3 SPECIAL EQUIPMENT

As for the maintenance of the 55 Pi machine it is necessary to be equipped not only with the usual tools (keys, screwdrivers, extractors, etc.) and instruments (tester), but also with: Welder for the flat belts of the film unwinding and product infeed (code V.147.001).

Page 10 of 168

1.4

LUBRICANTS

Only use lubricants authorized for use on food machinery. Use lubricants classified as H1 by the USDA (United States Department of Agriculture) and by the FDA (Food and Drug Administration). We advise use of the following lubricants : Synthetic Grease UH1 14-151 NLGl1 (code 4.A1.503 in 1 kg. packs) It is resistant to water, protective, anti-wear and anti-corrosion. It can be used on all parts of the machine where grease lubrication is required: (cams, bearings, bushes, linear guides, sliding shafts, etc.), but not on parts that work at high temperatures. Oil 4 UH1 ISO VG100 (code 4.A1.005 in 1 litre packs) This is anti-corrosion and has longlasting lubrication properties. It can be used on all machine parts which require oil lubrication (articulated joints etc.). Oil spray 4 UH1 ISO VG1500 (code 4.A1.006, spray packs of 0.4 l.) This is anti-corrosion, water repellent and highly adherent to the surfaces it is applied to. It should be used for guides, plastic cogs etc. It is essential that these lubricants are not mixed with others. Read the instructions for use given on the lubricant packs. The lubricants listed above should be recommended to customers who have their own internal maintenance services, that are able to maintain the model 55 Pi machines.

Page 11 of 168

1.5

PREVENTIVE MAINTENANCE AND GENERAL SERVICE TESTS

To ensure good operation of the model 55 Pi machine, service tests and inspections should be carried out periodically in order to prevent major interventions and inconvenience to the customer. It is therefore advisable to make the customers aware of the need to contract a service programme or a preventive maintenance programme for their machine. The programming menu of the 55 Pi machine allows the maintenance interval to be programmed, i.e. that the Assistance Service must be called to carry out programmed maintenance after a certain number of wrapped packages,. This maintenance interval can be correctly defined only by the technician who looks after the individual machine. Given the great variety of applications the machine 55 Pi is used for, not only in terms of the quantity of wrappings per day but also the physical work environment and the type of maintenance provided by the customers themselves, it is impossible to draw up a single preventive maintenance chart. We are therefore limited to listing the major preventive operations we recommend be applied. For lubrication, use only the lubricants indicated in paragraph 1.5. 1. 2. A check and retensioning of all the toothed belts and poly V belts (unwinding, infeed, main movement group, etc.) Lubrication with grease of the unwinding carriage sliding shafts, exit roller conveyor gears, carriage unwinding and movement gears, infeed extension motion gears - if present - and upper ejector movement screws and unwinding adjustment. Use oil to lubricate the articulated joints of the rods and of the levers and check their condition (elevator and grinders, folder, ejector, etc.). Also lubricate all of the bushings (knives, dandy roll, clamps, etc.). All the joints of the elevator mushrooms have to be oiled, too. Check and clean the flat belts for film transport and product infeed, verifying the tension and the joints. Keep the roller grooves clean. Check the condition of the sealing plate belt, especially along the rim equipped with the guide system. Check and adjust the air gaps of the brakes and clutches if necessary.

3.

4. 5. 6.

Page 12 of 168

7. 8. 9.

Check the film stop photocells (see chapter 20). Check the alignment and the reading height of all the photocells and, if necessary, check thier cleanliness. Check that the various motors function properly through the relevant tests that can be performed with the control panel or with the PCPocket (see the chapters concerning the movements managed by the motors). Detect and assess, if possible with the PCPocket, the error statistics and other data (total no. of products wrapped, etc.). Check the grounding of the various machine parts and the efficiency of all the safety circuits (see chapter 20). Also check that all the protections, movable or not, are integral.

10. 11.

At the end of each maintenance session, we recommend you to switch off the machine, switch it on again and to wrap several trays of the whole customer range.

Page 13 of 168

2.

MACHINE PRODUCT INFEED

See the flow chart at the end of the chapter. 2.1 DESCRIPTION

2.1.1 The standard machine is equipped with a 1 m infeed. 2.1.2 Infeed extensions of the 1 m and 2 m length are available as optional devices. 2.2 The maximum infeed can reach 7 m, that is 6 m of infeed extension plus 1 m of the standard machine infeed. 2.2.1 The infeed can be installed on the machine in such a way as to allow the wrapping of products with a maximum height of 200 mm. 2.2.2 Movement of the infeed is obtained with a three-phase gearmotor M2 always connected to 230 volts. 2.2.3 Feeding or stopping the trays is obtained through a clutch YC5. The air gap of the infeeds clutch must be 0.3 mm at the most in the smallest point. 2.2.4 A 0.75 CV frequency converter AP4 with a 230 V single-phase input and a 230 V three-phase output manages the movement. 2.2.5 The CPU AP7, the DAC AP10, the board AP5 and the hybrid IB2 manage the frequency converter AP4. 2.2.6 A sensor SR8 controls the infeeds movement. 2.2.7 Two direct ray photocell barriers, AP11 and AP12 (infeed) and AP13 and AP14 (carriage), control the packages entrance into the machine. 2.2.8 Under normal conditions, meaning without the photocells prohibitions, it is sufficient that only one channel of each barrier (infeed and carriage) be obscured in order to correctly read the package entering. 2.2.9 The photocells AP11, AP12, AP13 and AP14 are controlled by the CPU AP7 and by AP6. 2.2.10 The channels used and those affected by each transmitter are shown in fig. 1. 2.2.11 It is possible to activate and deactivate all of the photocells channels during programming of the package. 2.2.12 It is possible to introduce a non-read window of a part of the package during programming of the package. The flow chart representing operation of the infeed is shown here below.

Page 14 of 168

The flow chart representing operation of infeed is shown here below

INFEED - 1

REPHASING COMPLETED INFEED clutch = ON

INFEED photocell OBSCURED ? YES Wait for about 30 mm

NO

NO INFEED photocell OBSCURED ? YES PACKAGE detected

Page 15 of 168

NO

Was the package preceded by another package ? YES Is the distance with the preceding package less than the "ideal" distance ? NO

YES

INFEED clutch = OFF The package is a SECOND PACKAGE (**NOTE 1)

Is the distance with the preceding package almost the same of the "ideal" distance ? NO

YES

INFEED clutch = OFF

The package is a FIRST PACKAGE THAT STOPS (**NOTE 1) The package is a FIRST PACKAGE (**NOTE 1)

INFEED clutch = ON

Wait for the appropriate number of sensor pulses of the MAIN SENSOR (corresponding to the correct spacing with the package preceding it)

NOTE 1: - 1 PACKAGE: this package starts the CAM (that means that when it arrives up to the limit on the ELEVATOR, the CAM itself is stopped because the last wrapped package was far away from the one arriving) - 2 PACKAGE: this package does NOT start the CAM (that means that when it arrives up to the limit on the ELEVATOR, the CAM itself is already moving because the last wrapped package was close to the one arriving).

Mod. 55 Plus - TEC.MAN. - Infeed/belt PTC

2/3

Page 16 of 168

// It starts PERFORATION + CENTRING (see PERFORATION + CENTRING flow - 1)

Is the "transparent tray window" package parameter <> 0 ? NO Wait for the free INFEED photocell (at least 10 consecutive mm)

YES

Do not check the INFEED photocell for the mm set in the parameter

Page 17 of 168

INFEED - 5

REPHASING COMPLETED It waits for INFEED clutch on ON

NO CARRIAGE photocell OBSCURED ? (min. 30 mm) Is the package arriving ? YES It starts the tally NO TOO MUCH time has gone by with respect to the SCHEDULED arrival of the package on the CARRIAGE photocell (in pulses/marks P - about 60-70 mm more - is the NO YES

ERROR 89

CARRIAGE photocell OBSCURED ? (min. 30 mm) SI PACKAGE detected

NO

YES

ERROR 87

NOT ENOUGH time has gone by with respect to the SCHEDULED arrival of the package on the CARRIAGE photocell (in pulses / marks P - about 60-70 mm more - is the package late) ? YES VALID PACKAGE

NO

ERROR 88

YES

The package is a FIRST PACKAGE (it starts the ELEVATOR ) ? ** see page 2 "INFEED

NO

Mod. 55 Plus - TEC.MAN. - Infeed./carriage PTC

1/2

Page 18 of 168

//

It starts the tally that takes into account: 1. Where the package is located (based on the carriage position) 2. Cam inertia/sliding + time to take the elevator even with the belts 3. How much the package has to straighten on the locks

It starts the tally

The "transparent tray window" package parameter <> 0" ? NO

YES

Do not check the INFEED photocell for the mm set in the parameter

Is the tally completed ? YES

NO

CARRIAGE photocell OBSCURED ? NO

YES

NO Has the tally reached a value of marks P equal to 400 mm ?

YES

CARRIAGE photocell FREE for 10 YES Stop the tally

NO

It starts the CAM/ELEVATOR (see CAM flow - 1)

Has the tally reached a value greater than what is foreseen for the package with maximum size (see Variable 126)? NO

ERROR 85 YES

Mod. 55 Plus - TEC.MAN. - Infeed./carriage PTC

2/2

Page 19 of 168

Note: *1) see also photocells prohibiting

Code

DESCRIPTION

CAUSE FOR ALARM SITUATION TURNING ON THE MACHINE : IF ONE OR MORE INFEED BARRIER CHANNELS ARE OBSCURED STARTING : IF ON THE SECOND ATTEMPT ONE OR MORE INFEED BARRIER CHANNELS ARE OBSCURED TURNING ON THE MACHINE : IF ONE OR MORE CARRIAGE BARRIER CHANNELS ARE OBSCURED

24*

E24 THE INFEED PHOTOCELL IS OBSCURED OR FAULTY

84*

E84 THE CARRIAGE PHOTOCELL IS OBSCURED OR FAULTY

STARTING : IF ON THE SECOND ATTEMPT ONE OR MORE CARRIAGE BARRIER CHANNELS ARE OBSCURED (the internal infeed is made to go back on the first attempt) See INFEED / ELEVATOR operation flow - PAGE 2 See CAM / ELEVATOR flow PAGE 1

85

E85 THE PACKAGE ON THE IF, WITH THE OPERATING INFEED IS TOO LONG OR INTERNAL INFEED AND WITH NOT CORRECTLY THE MACHINE IN CYCLE, THE POSITIONED

CARRIAGE BARRIER REMAINS OBSCURED FOR A VALUE OF MORE THAN 40 P UNITS, CORRESPONDING TO A PACKAGE OF MORE THAN 400 mm

86 87

E86 THE CARRIAGE PHOTOCELL IS OBSCURED See CAM / ELEVATOR flow - PAGE DURING THE ELEVATOR X UPSTROKE E87 THE CARRIAGE See INFEED / ELEVATOR operation PHOTOCELL IS OBSCURED flow - PAGE 1 TOO LATE

Page 20 of 168

Code

DESCRIPTION

CAUSE FOR ALARM SITUATION

88 89

E88 THE CARRIAGE See INFEED / ELEVATOR operation PHOTOCELL IS OBSCURED flow - PAGE 1 TOO SOON E89 PACKAGE IS NOT READ BY THE INFEED PHOTOCELL, See INFEED / ELEVATOR operation BUT BY THE CARRIAGE flow - PAGE PHOTOCELL

20

START: IF A INFEED SENSOR SWITCHING IS NOT DETECTED 1 SECOND FOLLOWING THE COMMAND TO THE INFEED E20 THE INFEED SENSOR INVERTER DOES NOT TRANSMIT
PULSES

2) IF A INFEED SENSOR SWITCHING IS NOT DETECTED WITH THE MACHINE IN CYCLE FOR 0.5 SEC.

21 22

IF A NUMBER OF INFEED SENSOR SWITCHING (PULSES OR MARKS) E21 SYNCHRONIZATION - CORRESPONDING TO A RATE THE INFEED SPEED IS NOT HIGHER OR LOWER THAN THAT SET OF AT LEAST 5 CYCLES/MIN IS CORRECT TALLIED FOR 8 CONSECUTIVE TIMES (CHECK EVERY 3 SEC.) IF THE "ALARM FROM INFEED INVERTER" INPUT IS DETECTED ON E22 THE INFEED INVERTER WITH THE MACHINE IN CYCLE AND IS FAULTY WITH THE COMMAND TO THE INVERTER ACTIVE

Page 21 of 168

A short list of constants/parameters linked to the topic follows.

DESCRIPTION
Correspondence of mm INFEED / MAIN pulses (downstream of the speed change)

VALUE
2.6 2.9 3.2 21.7

UNIT
mm mm mm m/min m/min m/min m/min -msec msec

NOTE
Elevator E , E1 Elevator A (Package parameter "Elevator type" included = 3) Elevator type PIZZA280 mm

at 45 cycles / min (reference value)

Linear INFEED speed / downstream of the speed change (fast part)

26.5 16.8

at 55 cycles / min

at 35 cycles / min

Linear INFEED speed / upstream of the speed change (slow part) Ratio between the fast part and the slow partpporto fra parte veloce e parte lenta Infeed sensor pulse (or mark) duration

14.5 1.5 25 38

at 45 cycles / min (reference value)

approx. Value

at 55 cycles / min

at 35 cycles / min

Page 22 of 168

2.2

ERRORS AND MALFUNCTIONS

In addition to the description seen above, another list of ERRORS possible CAUSES possible SOLUTIONS is presented in chapter 40. NOTE. The EXXbis or XXXXbis errors are found at the end of the errors chapter. The errors concerned by this movement are: E20, E20bis, E21, E22, E22bis, E23, E24, E84, E85, E86, E87, E88, E89, 1017, 1018, 1026, 1026bis, 1028, 1031, 1049,1050,

3.

CENTRAL GROUP FOR THE MAIN MOVEMENTS

See the flow chart at the end of the chapter. 3.1 DESCRIPTION

3.1.1 The movement group is the part of the machine that encloses the movement cams relating to the elevator, folder and ejector, and the main reduction unit, all of which is in an oil bath. This group also comprises the main motor M1, the brake and the clutch that gives motion to the cams. 3.1.2 Motion to this group is given by the main motor M1. 3.1.3 Management of the main motor M1 is guaranteed by the frequency converter of the main motor AP3. 3.1.4 Commands to the frequency converter AP3 are sent by the CPU AP7 through the DAC AP10 and the hybrid IB2 that controls the direction relays. 3.1.5 Motion to the various machine functions is transmitted with poly V and toothed belts. 3.1.6 A clutch YC4 and a brake YB3 guarantee synchronization of the main movements with the infeed. 3.1.7 The clutch YC4 and the brake YB3 are managed by the CPU AP7, by the hybrid IB4 and by the card AP5. 3.1.8 A position sensor SR4 and another one that reads the teeth of the toothed disk SR3 assure the phase with the other movements. 3.1.9 The main sensor SR1 acts as the clock for synchronization of all of the machines movements and relative controls. 3.1.10 The sensors SR1, SR3 and SR4 are controlled by the CPU AP7, by AP6, by AP5 (only SR1 and SR3) and by the hybrid IB1. The flow chart representing operation of the movement case (CAM) is shown here below.

Page 23 of 168

The flow chart representing operation of cam is shown here beloow

CAM - 1

CAM POSITION sensor on ON (1)?

YES

ERROR 12

Has the ELASTIC ROD microswitch been activated (1)?

YES

ERROR 66

CAM brake = OFF CAM clutch = ON

NO

3-4 CAM pulses (ABOUT 20) to sensor are lacking. Is CAM POSITION to ON (1)? YES UPPER EJECTOR brake = ON Carriage PTC to ON (Is it obscurred ) ? NO YES

ERROR 85

YES

CAM POSITION sensor on ON (1)? NO Has the CAM phase disk made about a HALFREVOLUT. (180) ? SI

NO

ERROR 12

Page 24 of 168

Have about 15CAM phase (2 pulses) passed from 'MUSHROOMS EVEN with the belts' ? SI

NO

Carriage PTC on ON (is it obscured) ? NO

SI

ERROR 86

Have about 40 CAM phase (5 pulses) passed from 'MUSHROOMS EVEN YES ?

NO

ELASTIC ROD control activated

Carriage PTC on ON ( is it obscured) ? NO

YES

ERROR 86

Have about 60 CAM phase (8 pulses) passed from 'CAM EVEN with the belts' ? (==> ELEVATOR is about 75% of the stroke) SI

NO

CENTRING completed ? SI

NO

ERROR 41

Page 25 of 168

Have about 135 CAM phase (18 pulses) passed from 'MUSHROOMS EVEN with the belts' ? (FOLDER almost ahead) YES

NO

Tally for UPPER EJECTOR brake is activated = OFF (see the relevant package parameter)

Have about 230 CAM phase (30 pulses) passed from 'MUSHROOMS EVEN with the belts' ? (PACKAGE ejected) YES

NO

Deactivate ELASTIC ROD control

Update package counters

Are about 15 CAM phase (2 pulses) lacking to the STOPPING POINT ? YES

NO

Is there already another package arriving at exact distance of one cycle ?

4 YES

CAM brake = ON CAM clutch = OFF

END

Page 26 of 168

Code 11 12

DESCRIPTION

CAUSE ALARM SITUATION CHECK MADE IN ANY SITUATION, IN CYCLE OR TEST. 400 msec following CAM CLUTCH on ON and up to CAM CLUTCH on OFF: ALARM IF SWITCHING OF THE CAM PULSE SENSOR IS NOT DETECTED FOR ABOUT 350 msec See CAM / ELEVATOR flow PAGE 1 ALARM IF A CAM INERTIA GREATER THAN 4 CAM PULSES IS DETECTED MORE THAN 3 CONSECUTIVE TIMES DURING THE CYCLE (INERTIA = NUMBER OF CAM PULSES DETECTED BETWEEN THE STOP COMMAND AND THE ACTUAL ARREST OF THE MOVEMENT). NOTE: THE ALARM IS GIVEN ONLY ONE TIME AFTER THE MACHINE IS TURNED ON. THAN IT IS DISABLED UNTIL THE NEXT TIME THE MACHINE IS TURNED ON. START: IF SWITCHING OF THE MAIN SENSOR IS NOT DETECTED ONE SECOND AFTER THE CAM INVERTER COMMAND IF SWITCHING OF THE MAIN SENSOR IS NOT DETECTED FOR 0.5 SEC WITH THE MACHINE IN CYCLE
CHECK MADE CONTINUOUSLY WITH THE MACHINE IN CYCLE: ALARM IF THE INVERTER ALARM INPUT IS on ON (1)

E11 THE CAM MARKS SENSOR DOES NOT TRANSMIT PULSES

E12 THE CAM REST SENSOR DOES NOT TRANSMIT PULSES

14

E14 THE CAM BRAKE SLIPS TOO MUCH

15 16 17

E15 THE MAIN SENSOR DOES NOT TRANSMIT

E16 THE CAM INVERTER IS FAULTY

IF WITH THE MACHINE IN CYCLE AND E17 SYNCHRONIZATION - THE A NUMBER OF MAIN SENSOR MAIN SPEED IS NOT SWITCHINGS IS COUNTED (PULSES CORRECT OR MARKS) CORRESPONDING TO A RATE HIGHER THAN OR LESS THAN

Page 27 of 168

Code 41

DESCRIPTION

CAUSE ALARM SITUATION


WHAT IS SET FOR AT LEAST 5 CYCLES/MIN 8 CONSECUTIVE TIMES (CHECK EVERY 3 sec)

E41 THE FILM CENTRING IS TERMINATED TOO LATE

See CAM / ELEVATOR flow - PAGE 1 SEE FILM CENTRING ALARMS FOR ADDITIONAL EXPLANATIONS ABOUT THIS ALARM

See CAM / ELEVATOR flow PAGE 1 CHECK MADE DURING THE E66 THE ELASTIC ROD MICRO CYCLE, REPHASING OR TEST AND IS ACTIVATED DURING THE SWITCH HAS BEEN ACTIVATED CAM MOVEMENT STAGE (See CAM / ELEVATOR flow - PAGE 2-3) : ALARM IF THE ELASTIC ROD MICRO SWITCH INPUT IS on ON (1) See CAM / ELEVATOR flow PAGE 2

66

86

E86 CARRIAGE PHOTOCELL OBSCURED DURING ELEVATOR RISE

CHECK MADE DURING THE REPHASING AND TEST AND IS ACTIVATED DURING THE ELEVATOR RISE STAGE: ALARM IF THE CARRIAGE PHOTOCELL IS OBSCURED (that is when it is on ON-1)

Page 28 of 168

A short list of constants/parameters linked to the topic follows.

DESCRIPTION
CAM phase disk

VALUE
24 48

UNIT
TEETH PULSES / MARKS

NOTE
24 full - 24 empty

1 IMPULSO = 7.5

CAM position disk

TOOTH

1 full of 180 (ELEVATOR highter than the BELTS LEVEL) - 1 empty of 180 (ELEVATOR lower than THE BELTS LEVEL)

Correspondenca CAM pulses / MAIN pulses

3.83

--

1 pulse CA = 3.83 pulses P (1 CAM revol. = 48 CAM pulses = 184 MAIN pulses )

CAM sensor pulse (or mark) duration

22.5 36 5.93 9.3

msec msec msec msec

at 55 cycles / min

at 35 cycles / min

MAIN sensor pulse (or mark) duration

at 55 cycles / min

at 35 cycles / min

Page 29 of 168

3.2

THE TOOTHED CAM DISK AND MACHINE PHASING

The toothed disks mounted on the camshaft and the sensors SR3 and SR4 are the machine control parts that keep in phase all the movements of the 55 Pi machine (infeed, unwinding, clamps, product exit, etc.). Correct positioning of these disks is therefore paramount to obtain correct machine running as well as the best results in the product wrapping. The toothed disk position determines also the film tension on the product, for which, in certain difficult cases, the disk position may be adjusted (max. 2-3 degrees in relation to its standard position), always bearing in mind the elevator position. To put the machine in phase, the toothed disk on the camshaft needs to be correctly positioned in relation to sensor SR4 (position sensor). The correct position of the mechanical phase is obtained by manually turning the handwheel located on the back of the cam group case counter-clockwise and positioning the external sector of the toothed disk in the centre of the position sensor SR4, in the point where the elevator is close to the top surface of the infeed belts. This is the correct position of the mechanical phase, so the toothed disk has to be locked in this position. Now turn on the machine and be sure that after the power factor corrector cycle the elevator is about 4-5 mm below the top surface of the infeed belts. Operation of the brake YB3 and the clutch YC4 is of primary importance since they are the parts that give motion to the cams and consequently also to the toothed disk, so incorrect connections or disconnections or excessive slipping can cause anomalies that are not always easy to identify. See figure 1 of the disk in phase.

Page 30 of 168

SR3

SR4

Fig. 1

Page 31 of 168

3.3

ERRORS AND MALFUNCTIONS

In addition to the description seen above, another list of ERRORS possible CAUSES possible SOLUTIONS is presented in chapter 40. NOTE. The EXXbis errors are found at the end of the errors chapter. The errors concerned by this movement are: E11, E11bis, E12, E14, E15, E15bis, E16, E17, 1027, 1028, 1031, 3.4 LUBRICATION OIL SEAL

The oil contained in the movement case must be replaced periodically at intervals of about 3000-6000 hours, depending on the average operational speed of the machine. The mineral-based oil to be used is the type for reduction units with a 150 VG 220 viscosity. (Example: ESSO SPARTAN EP220, MOBILGEAR 622, SHELL OMALA 220, and BP ENERGOL GR-XP 220). A synthetic-based oil, such as SHELL TIVELA OIL WB or AGIP BLASIA S 220, allows the interval between replacements to be doubled. In the event replacement of the rings MIN that guarantee the lubricant remains sealed between the case body and shafts should prove necessary, use the specially provided guide tools, code F.004.066 and F.004.067, so as to prevent damage to the delicate seal lip of these rings.

Page 32 of 168

4.
4.1

FILM REEL CARRIER SHAFT


DESCRIPTION

The film reel used for wrapping the products is positioned on the film reel carrier shaft. The internal diameter of the reels for the standard machine is 111 mm. However, a special group is available, code E.150.Z.10, that lets you use reels having a 75-mm internal diameter. Model 55 Pi machines are equipped with two reel carrier shafts, a standard one and a second optional reel carrier shaft (C.220.042). In order to obtain correct film transport and wrapping of the product, be sure you have these conditions: 4.1.1 The reel must be firmly locked axially on the carrier shaft. If this is not the case, unlock the locking lever, screw it by a few turns clockwise and then re-lock the lever. 4.1.2 The reel carrier shaft has to rotate freely when the shaft brake is released. 4.1.3 The reel brakes YB5 or YB6 are the permanent magnet type. The minimum brake air gap has to be 0.2 mm when the brake is released. Take care that there is no mechanical clearance along the shaft axis. 4.1.4 The shaft brakes YB5 or YB6 are powered through the sensor SQ6 and are controlled through the boards CPU AP7, AP5 and through the hybrid IB5. 4.2 ERRORS AND MALFUNCTIONS

The errors shown on the display, other errors or malfunctions are described in chapter no. 40. 1035, 1046,

5.
5.1

FILM TENSION ROLLERS (DANDY ROLL)


DESCRIPTION

5.1.1 The dandy roll allows a quantity of film to be already unwound and stretched. 5.1.2 Its tension should be such as to allow a progressive unrolling of the film without causing malfunctions. 5.1.3 The tension of the dandy roll can be adjusted by increasing or decreasing the force exerted by spring F.220.G.017.

Page 33 of 168

5.1.4 On the dandy roll is also fixed the cam F.220.F.047 which, coming out of the slot in sensor SQ6, opens the brakes YB5 and YB6 allowing the reel rotation. 5.1.5 Adjustment of this cam must be done so as to have a small reserve of film, even when the machine carries out the maximum unwinding. Moreover, it must recover the film during the film length change operation. These adjustments must be made by positioning the cam so that the dandy roll does not go to the end of stroke and strike the locks placed at the bottom and top during machine operation or during the unwinding length change operation. 5.1.6 The sensor SQ6 is controlled by the boards AP6 and CPU AP7. 5.2 ERRORS AND MALFUNCTIONS

The errors shown on the display, other errors or malfunctions are described in chapter no. 40. 1001, 1002,

6.

FILM PERFORATION KNIFE

See the flow chart at the end of the chapter 10 (CENTRING). 6.1 6.1.1 6.1.2 6.1.3 6.1.4 DESCRIPTION

The knife has to perforate the film. The knife movement is activated by the stepping motor M9. The knife movement is controlled by a sensor SQ8. The height clearance varies between 5 and 7 mm, depending on the film thickness and on the working temperature. It is important that the film does not break during the transport, but does so without the application of excessive force during the tearing action (see figure 2). 6.1.5 The knife height can be adjusted by operating either the knife movement rod or the screws which fix the blade on its bearing. 6.1.6 In the case the perforations are imperfect or insufficient, also check the knifes parallelism (in high position) with respect to its support and the sharpness of the blades points. 6.1.7 The motor M9 is controlled through the boards CPU AP7, AP5, AP9, AP6 and through the hybrid IB2 controlling the switch. 6.1.8 The sensor SQ8 is controlled through the boards CPU AP7, AP6 and through the hybrid IB3. 6.1.9 As the film perforating actions are rapid, the knife movement have to be free, so as to avoid any impediment to the film transport. 6.1.10 Take care to lubricate all the moving parts of the knife.

Page 34 of 168

SQ8

Fig. 2

Page 35 of 168

71

7 3

The flow chart representing operation of the infeed and the movement case is shown here below. 6.2 ERRORS AND MALFUNCTIONS

The errors shown on the display, other errors or malfunctions are described in chapter no. 10 and no. 40. E70, E71, 1005, 1033,

7.

CHANGING THE LENGTH OF THE FILM

See the flow chart at the end of the chapter. 7.1 DESCRIPTION

7.1.1 The length of the film that is necessary for wrapping a given product is set by moving the roll F.150.G.023. 7.1.2 The roll always moves when the machine is turned on (machine phasing) and when the wrapping programmes change if the lengths of the film are different between them. 7.1.3 Correct positioning of the roll F.150.G.023 is managed by the stepping motor M8 and by the sensors SQ7 (sensor that depicts the starting point for calculating the length of the film) and SR6 (sensor that determines the length of the film). 7.1.4 Each time it is necessary to change the length of the film, the roll carries itself into the zero position to then go into the position foreseen for the length of film required. 7.1.5 The motor M8 is controlled through the boards CPU AP7, AP5, AP9 ed AP6. 7.1.6 The sensors SQ7 and SR6 are controlled through the boards CPU AP7, AP6, and through the hybrids IB1 (SR6) and IB5 (SQ7). 7.1.7 Since the film remains stretched during the rolls descent, the roll goes back by a certain quantity at the end of the descent stroke in order to prevent the film from breaking during the first perforation following the film length change. This quantity can be programmed through test no. 120 in the variables menu. 7.1.8 The machine does not perform any other operations during the film length change.

Page 36 of 168

The flow chart representing operation of the FILM LENGTH adjustment is shown here below.

FILM LENGTH - 1

YES

Is a REPHASING in progress ? NO Has the programme been changed or has the current programme been modified ? YES Is the current FILM LENGTH ROLLER POSITION different than that programmed ? YES FILM LENGTH POSITION sensor on ON (1) ? YES FILM LENGTH movement downwards (a few cm) NO

NO

NO

FILM LENGTH POSITION sensor on OFF (0) ? YES

NO

ERROR 42

FILM LENGTH movement upwards

Page 37 of 168

NO FILM LENGTH POSITION sensor on ON (1) ? YES NO Has the maximum possible displacement been reached ? YES

FILM LENGTH STOP in highest position ( 35 cm of film)

ERROR 42

FILM LENGTH movement in the programmed position

END

Page 38 of 168

Code

DESCRIPTION

CAUSE ALARM SITUATION

42 48

E42 FAILED ZEROING OF THE See FILM LENGTH ROLLER flow FILM LENGTH ROLLER PAGE 1 - 2

E48 THE PULSE SENSOR OF THE FILM LENGTH MOTOR IS DEFECTIVE

CHECK MADE IN ANY SITUATION, IN CYCLE OR TEST, 100 msec FOLLOWING ROLLER MOVEMENT on ON up to ROLLER MOVEMENT on OFF: ALARM IF SWITCHING OF THE ROLLER PULSE SENSOR IS NOT DETECTED FOR ABOUT 300 MSEC

A short list of constants / parameters linked to the topic follows.

DESCRIPTION
Stepping motor speed

VALUE
800

UNIT
rpm cm of actual/ motore rev.

NOTE

Mechanical transmission

0.435

Page 39 of 168

7.2

ERRORS AND MALFUNCTIONS

In addition to the description seen above, another list of ERRORS possible CAUSES possible SOLUTIONS is presented in chapter 40. NOTE. The EXXbis errors are found at the end of the errors chapter. The errors concerned by this movement are : E42, E42bis, E48

8.
8.1

CHECKING THE INCOMING FILM


DESCRIPTION

8.1.1 The presence of incoming film is checked by the small cam F.220.F.072 mounted on the roll F.150.F.073, and by the sensor SR5. 8.1.2 The roll F.150.F.073 must always be very clean and must turn freely. 8.1.3 This condition is necessary so that the presence of the film is detected and the roll completes at least a 180 rotation during the unwinding operation. 8.1.4 The sensor SR5 is controlled through the boards CPU AP7, AP6 and through the hybrid IB1. 8.2 ERRORS AND MALFUNCTIONS

The errors shown on the display, other errors or malfunctions are described in chapter no. 40. NOTE. E44, 1012, 1016,

9.
9.1

FILM TEARING MECHANISM


DESCRIPTION

9.1.1 The tearing of the film after its perforation is performed by a brake and clutch system. 9.1.2 In this operation the clutch YC1 and the brake YB1 are activated through the boards CPU AP7, AP5 and through the hybrid IB0. 9.1.3 There is the possibility to manage the film separation point in each wrapping programme.

Page 40 of 168

9.2

ERRORS AND MALFUNCTIONS

The errors shown on the display, other errors or malfunctions are described in chapter no. 40. NOTE. The XXXXbis errors are found at the end of the errors chapter. The errors concerned by this movement are : 1014, 1042, 1042bis, 1043

10. FILM CENTRING


See the flow chart at the end of the chapter. 10.1 DESCRIPTION

10.1.1 Part made up of the film conveying belts that supply both its shifting and its positioning with respect to the product to be wrapped. Motion is given by the main motor through the clutch YC3, and it is stopped by the brake YB2. The sensor SR2 checks that the belts move. 10.1.2 The film conveying belts must always be: properly stretched, clean and with the right texture. 10.1.3 The centring movement is achieved through the motor M1, the clutch YC3 and the brake YB2 managed by the CPU AP7, AP5 and hybrid IB0. 10.1.4 The sensor SR2 is controlled by the boards CPU AP7, AP6 and by the hybrid IB1. 10.1.5 There are several toothed belts on the centring movement for transmitting the motion. 10.1.6 Proper tension of these belts is of primary importance. 10.2 FILM STOP PHOTOCELLS

10.2.1 The photocells AP15 and AP16 check whether or not pieces of film normally meant to wrap the products are used, and based on the programming of each wrapping programme (quantity of film pieces necessary for stopping the machine), stop the machine. 10.2.2 The photocells AP15 and AP16 have a variable threshold and their switching point is always put at a value that is 40 units higher than the value read when the machine is turned on. The boards AP6 and AP7 manage these photocells. 10.2.3 These photocells stop the machine when one or more channels of each individual photocell is obscured (errors 46 and 47), or when one or more channels of the two photocells is obscured (error 45). 10.2.4 Since the film conveying belts could obscure these photocells and consequently stop the machine with the errors 46 or 47 if they are too

Page 41 of 168

long or poorly welded, it is important that the belts always be kept in good condition. 10.2.5 If the grooves of the unwinding rolls where the belts run are not clean, they can cause the belt to veer and this could obscure some of the photocells channels, consequently stopping the machine with the errors 46 or 47. The flow chart representing operation of the perforation and centring (including CLAMPS) is shown here below.

Page 42 of 168

The flow chart representing operation of the perforation and centering (clamps included) is shown here below

PERFORATION + CENTRING - 1

KNIFE movement control

YES

KNIFE sensor on OFF (0 - cam out of the sensor) ? NO

300 msec have passed from motor starting ? YES

NO

ERROR 71 Is the knife movement completed? YES NO

KNIFE sensor on ON (1 - cam inside the sensor) ? YES

NO

Page 43 of 168

YES

Is there a centred film in the machine?

The film was taken away from the package (3 marks CA after opening of the EXIT clamp or the last clamp that opened) ? YES

NO

TEARING brake = OFF TEARING clutch = ON

See NOTE 1 CENTRING brake = OFF CENTRING clutch = ON

It activates the FILM passage control con the distributing roller

It activates the FILM in excess presence control (FILM STOP)

NOTE 1: the UNWINDING ROLLERS RELEASE CLUTCH is always on ON (engaged) except when the FILM LENGTH ROLL moves or when the DISTRIBUTOR GUARD (LEFT TOP) opens

Page 44 of 168

The requested film length is unrolled ? YES

NO

TEARING brake = ON TEARING clutch = OFF

NO Was the film taken to the centred position ? SI NO There is no pulse / mark at the and of the movement ? YES //

CENTRING brake = ON CENTRING clutch = OFF

It deactivates the FILM passage control on the distributing roll It deactivated the FILM in excess presence control (FILM STOP)

It starts CAMPS (see - 4)

Was the failed passage of FILM detected ? NO One or more FILM STOP PHOTOCELL is obscured ? NO

YES

ERROR 44

YES

ERROR 45, 46 or 47

END

Mod. 55 Plus - TEC.MAN. - Film / Clamps

3/4

Page 45 of 168

CLAMPS - 4

//

FOLDING clamp enabled (package parameter other than 0) ?

NO

EXIT clamp enabled (package parameter other than 0) ? END

NO

END YES EXIT clamp magnet on ON

SIDE STRETCH DEVICE enabled (package parameter other than 0) YES SIDE STRETCH DEVICE magnet on ON

NO

END

YES FOLDING clamp magnet on ON

Programmed CAM PULSES / MARKS reached for clamp opening ?

NO

Programmed CAM PULSES / MARKS reached for clamp opening ?

NO

Programmed CAM PULSES / MARKS reached for clamp opening ?

NO

YES

YES

YES

FOLDING clamp magnet on OFF

EXIT clamp magnet on OFF

SIDE STRETCH DEVICE magnet on

FINE

Page 46 of 168

A description of the errors reported by the display and linked to the topic follows

Code

DESCRIPTION

CAUSE ALARM SITUATION

40

CHECK MADE IN ANY SITUATION, IN CYCLE OR TEST, 300 msec E40 THERE ARE NOT PULSES FOLLOWING CLUTCH TRUING on FROM THE UNWINDING ON and up to CLUTCH TRUING on SENSOR OFF : ALARM IF SWITCHING OF THE CAM PULSE SENSOR IS NOT DETECTED FOR ABOUT 250 msec See CAM / ELEVATOR flow - PAGE 2 - NOTE: A HIGH NUMBER OF THESE ALARMS MAY BE DUE TO THE FACT THAT THE OUTLET CLAMP AND SPEED VALUES ARE SIMULTANEOUSLY TOO HIGH FOR A PARTICULAR PROGRAMME (Example: 55 CYCLES/MIN and 20; situation however practically impossible) See PERFORATION + CENTRING flow - PAGE 3 - NOTE: PASSAGE OF THE FILM IS DETECTED WITH A MINIMUM OF 2 PULSES OF THE FILM PRESENCE SENSOR (CORRESPONDING TO ABOUT HALF A REVOLUTION OF THE FILM PRESENCE ROLL)
See PERFORATION + CENTRING flow PAGE 3 - NOTE: THIS ALARM SIGNAL IS GIVEN WHEN AT LEAST ONE OF THE TWO CARRIAGE PHOTOCELLS AND AT LEAST ONE OF THE TWO SIDE PHOTOCELLS ARE OBSCURED See PERFORATION + CENTRING flow PAGE 3 - NOTE: THIS ALARM SIGNAL IS GIVEN WHEN ONLY THE SIDE PHOTOCELLS ARE OBSCURED See PERFORATION + CENTRING flow PAGE 3 - NOTE: THIS ALARM SIGNAL IS GIVE WHEN ONLY THE CARRIAGE PHOTOCELLS ARE OBSCURED

41

E41 THE FILM CENTRING IS TERMINATED TOO LATE

44

E44 THERE IS NO FILM IN THE DISTRIBUTOR OR THE FILM SENSOR IS FAULTY

45 46 47

E45 NOT USED FILM IS PRESENT OR THE FILM STOP PHOTOCELLS ARE OBSCURED E46 NOT USED FILM IS PRESENT OR THE FIXED FILM STOP PHOTOCELLS ARE OBSCURED E47 NOT USED FILM IS PRESENT OR CARRIAGE FILM STOP PHOTOCELLS ARE OBSCURED

Page 47 of 168

llows

Code

DESCRIPTION

CAUSE ALARM SITUATION


THIS ALARM SIGNAL OCCURS WHEN : 1 . AT THE END OF THE MOVEMENT, IN ORDER TO GET OUTSIDE THE SENSOR DURING REPHASING, THE KNIFE SENSOR IS on ON, or 2. AT THE END OF THE MOVEMENT, IN ORDER TO GET INTO THE 0 POSITION DURING REPHASING, THE KNIFE SENSOR IS on OFF See PERFORATION + CENTRING flow PAGE 1 ALARM IF, DURING THE CENTRING CYCLE, THE PRINTED FILM PHOTOCELL IS NEVER DETECTED AS FREE ALARM IF THE PRINTED FILM PHOTOCELL IS NEVER DETECTED AS OBSCURED FOR THE 8 CONSECUTIVE TRUING CYCLES (REFERENCE MARK IDENTIFIED)

70 71 91 92

E70 THE KNIFE SENSOR DOES NOT SWITCH DURING MACHINE PHASING

E71 THE KNIFE SENSOR DOES NOT SWITCH DURING PERFORATION E91 THE PRINTED FILM PHOTOCELL IS FAULTY

E92 THE PRINTED FILM HAS NOT BEEN READ CORRECTLY

Page 48 of 168

A short list of constants / parameters linked to the topic follows.

DESCRIPTION
UNWINDING sensor puls (or mark) duration

VALUE
5.85 9.2 99 63

UNIT
msec msec m/min m/min mm rpm motor revol. for making the cut msec

NOTE
at 55 cycles / min.

at 35 cycles / min.

Linear film speed

at 55 cycles / min.

at 35 cycles / min.

Unwinded film for each pulse of UNWINDING sensor KNIFE stepping motor speed KNIFE mechanical transmission Cutting time

9.7 650 1 200

approx. value

Page 49 of 168

10.3

ERRORS AND MALFUNCTIONS

In addition to the description seen above, another list of ERRORS possible CAUSES possible SOLUTIONS is presented in chapter no. 40. NOTE. E40, E41, E45, E46, E47, 1007, 1008, 1009, 1010, 1011

11. ELEVATOR
11.1 DESCRIPTION

11.1.1 The elevator is the part of the machine that lifts the product against the film in which it is then wrapped. 11.1.2 It is driven by the cam F.150.C.019 and its height can be adjusted with the two rods F.220.B.010. 11.1.3 Particular care should be given to fixing the elevator to its support. The elevator locking knobs should always be well-tightened. 11.1.4 To modify the elevators stroke from 160 to 200 mm, fasten the rods F.220.B.010 in the two threaded holes located on the ends of the levers F.220.C.001. Refer to drawing E.220.B.03, sheet 1 of 2. 11.1.5 The top part of the elevator must be approximately 4-5 mm under the top surface of the infeed belts when in the low position. 11.1.6 The top part of the elevator must be approximately 2-3 mm above the upper part of the folder when in the high position. 11.1.7 If elevator E or E1 is used, switch no. 4 of DS1 on board AP7 has to be on position OFF. 11.1.8 If only elevator A is used, switch no. 4 of DS1 on board AP7 has to be on position ON. 11.1.9 If, on the other hand, both elevators E and A are used, switch no. 4 of DS1 must be on OFF and the type of elevator must be selected through correct programming in the wrapping programme (see Wrapping Programmes HELP).

Page 50 of 168

11.2

ELEVATORS AVAILABLE Type Code Product Dimensions (mm) Reel Width (mm) width. x length 120-320 x120-230 330-500 180-407x180-260 380-550 120-280x100-160 280

Type E (standard) E.220.S.01 Type A (America) E.222.M.03 (C.220.101.1) Elevator for small E.220.Z.12 trays (C.220.102) Elevator for E.220.Z.10 narrow/long trays (C.220.105)

160-350x 100-140 280

11.3

ERRORS AND MALFUNCTIONS

The errors shown on the display, other errors or malfunctions are described in chapter no. 40. 1015, 1044, 1045

12. FOLDER
12.1 DESCRIPTION

12.1.1 The folder is the part of the machine that, with the grinders, folds the film on the sides around the product. 12.1.2 The folder movements are controlled by the cam F.220.C.020 and by an automatic disengagement rod controlled by a microswitch SB8 that stops the machine whenever a product is crushed between the folder and the exit roller conveyor. 12.1.3 The microswitch SB8 is controlled through the boards CPU AP7, AP6 and through the hybrid IB3. 12.1.4 When closed (front position), the folder should be parallel and 3 mm from the first roller of the exit roller table. 12.1.5 The resting position of the folder must always depend on the maximum product dimensions and on the type of elevator installed on the machine. 12.1.6 In the event several types of elevators are used, the position of the folder must allow the largest elevator to be used. 12.1.7 The different positions of the folder are obtained by moving its fastening point on the lever F.220.C.009, F.220.P.068 and F.220.P.069. 12.1.8 Work with the rods F.220.P.008 in order to optimize the adjustments. 12.1.9 Refer to drawing E.220.B.03, sheet 1 (enclosed), to adjust the folders strokes.

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12.2

ERRORS AND MALFUNCTIONS

The errors shown on the display, other errors or malfunctions are described in chapter no. 40. E66

13. LOWER EJECTOR


13.1 DESCRIPTION

13.1.1 The lower ejector is that part of the machine which pushes the product towards the machine exit (sealing plate), completing its wrapping. 13.1.2 It is operated by the cam F.220.C.020 and by adjustable rods. 13.1.3 Its position must be changed by using the holes on the control lever and on the ejector slide in the rods connection point. 13.1.4 For it to properly operate, its departure must be as close to the product to be ejected as possible. 13.1.5 In relation to the dimensions of the maximum tray/product to be wrapped, different strokes are foreseen for the lower ejector. 13.1.6 Its stroke can be changed by moving the fastening point of the connection rod F.150.P.079 on the control lever F.220.C.006 and of the rods F.220.P.010 on the ejector slide. Work with the rods F.220.P.010 and F.150.P.079 in order to optimize the adjustments. 13.1.7 Refer to drawing E.220.B.03, sheet 1 (enclosed), to adjust the lower ejectors strokes.

14. UPPER EJECTOR


See the flow chart at the end of the chapter. 14.1 DESCRIPTION

14.1.1 The function of the upper ejector is that of stabilizing the product during folding. 14.1.2 The products stability is guaranteed not only by the springs, but also by the brake YB4 mounted on the upper ejector fulcrum shaft. The function of the brake is to friction the ejectors movement and therefore to always keep it in contact with the product during the wrapping operation. 14.1.3 The brakes opening time is modifiable in the various wrapping programmes, depending on the type of product to be wrapped (see the Wrapping Programmes HELP). 14.1.4 The height of the upper ejector can be programmed based on the height of the product to be wrapped.

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14.1.5 The upper ejectors positioning is obtained through the stepping motor M6. 14.1.6 The stepping motor M6 is controlled by the boards AP5, AP6, AP7 and AP8. 14.1.7 Control of the zero position is assured by the sensor SQ1 and by the hybrid IB1.

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The flow chart representing operation of the upper ejector is shown here below.

UPPER EJECTOR 1

YES

Is a rephasing in progress ? NO Has the programme been changed or has the current programme been modified? YES NO

UPPER EJECTOR POSITION sensor on ON (1) ? YES UPPER EJECTOR movement upwards(a few

NO

UPPER EJECTOR POSITION sensor on OFF (0) ? YES

NO

ERROR 30

UPPER EJECTOR movement downwards

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NO UPPER EJECTOR POSITION sensor on ON (1) ? YES NO Has the maximum possible displacement been reached ? YES

It stops the UPPER EJECTOR in the lowest position (27 mm)

ERROR 30

UPPER EJECTOR movement in programmed position

END

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A description of the error reported by the display and linked to the topic follows.

Code 30

DESCRIPTION

CAUSE ALARM SITUATION

E30 FAILED ZEROING OF See UPPER EJECTOR flow THE UPPER EJECTOR PAGE 1 - 2

A short list of constants / parameters linked to the topic follows.

DESCRIPTION
Stepping motor speed

VALUE
600 4.65

UNIT
rpm mm height / motor rev. mm height / motor rev.

NOTE

Machines from N 31 on

Mechanical transmission 5.4

Machines up to N 30

14.2

ERRORS AND MALFUNCTIONS

In addition to the description seen above, another list of ERRORS possible CAUSES possible SOLUTIONS is presented in chapter no. 40. NOTE. The EXXbis errors are found at the end of the errors chapter. The errors concerned by this movement are : E30, E30bis, 1036,

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15. FOLDING CLAMP AND EJECTOR CLAMP


See the flow chart in the chapter no. 10. 15.1 DESCRIPTION

15.1.1 The clamps hold the film while the product rises, and stretch the film against the product while it is being wrapped. 15.1.2 The clamps are electromagnet-operated, YA1 controls the folder clamp and YA2 the exit clamp. 15.1.3 When the clamp closes, the film must be held uniformly and firmly along the whole length of the clamp. When the clamp opens the film must run freely out of the belts. 15.1.4 When the clamps are open, the lower part of the clamp must graze the internal part of the relative belt. 15.1.5 Follow the steps described in chapter 19 to adjust the closing force of the clamps. 15.1.6 Ninety-nine different wrapping programmes, where different clamp opening times have already been contemplated, are in the machines programme. In the event one that is suitable for perfectly wrapping a given product is not among these programmes, you can also modify the clamp opening time in programmes 1-29 (see the Wrapping Programmes HELP). 15.2 ERRORS AND MALFUNCTIONS

The errors shown on the display, other errors or malfunctions are described in chapter no. 40. 1039, 1040

16. SEALING PLATE


16.1 DESCRIPTION

16.1.1 The sealing plate heat-seals the film under the product after it has been wrapped. 16.1.2 The complete sealing plate is made up of three resistor groups connected to each other. 16.1.3 The sealing plate can be connected to both 230 VAC and 400 VAC (see wiring diagram E.220.I.100a and E.220.I.100b). 16.1.4 The ohmic value of the sealing plate resistor is about 60 ohm. The value of resistance between one of the two terminals of the resistor and the aluminium structure of the plate must be infinite.

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16.1.5 The relay K3 mounted on AP2 sends the necessary voltage/current to the sealing plate. A red LED mounted on AP2 indicates whether or not the command arrives. When it is lit, the command from the CPU AP7 is arriving and if it is unlit, it is not arriving. 16.1.6 The temperature is controlled by the probe ST1 and the CPU AP7. 16.1.7 Protection is guaranteed by the fuses FU4, 5 and 6. 16.1.8 The sealing plate is controlled through the boards AP1, AP2, AP5, AP7 and through the hybrid IB0. 16.1.9 A gearmotor M3 used for turning the Teflon sealing tape is also present in the sealing plate group. The motor is protected by the fuses FU1, FU2 and FU3 and by a thermal pad inside the motor connected to the electromagnetic switch K1 coil in series. 16.2 ERRORS AND MALFUNCTIONS

The errors shown on the display, other errors or malfunctions are described in chapter no. 40. NOTE. The XXXXbis errors are found at the end of the errors chapter. The errors concerned by this movement are : 1037, 1038, 1038bis,

17. SENSOR TESTING


17.1 17.1.1 17.1.2 17.1.3 DESCRIPTION The sensors mounted on the machine model 55 Pi are of two types: fork optical with sender and receiver, and inductive. The latter is mounted starting from series 30. Special care must be used when mechanically adjusting the cams that activate the sensors so as to avoid dangerous interferences with the sensors. The electrical connection of the hall-effect sensors is made through a three-pin connector which is arranged in fixed-coupling. In case of replacing the connector, particular attention must be paid to the power supply polarities. If a sensor is connected with the polarities reversed, it will be irreparably damaged. In the case of optical sensors, keep the internal part of the fork where the optical components are arranged clean. Any deposits of dust, grime or moisture can compromise its operation. The inductive sensors operate correctly even if they are not thoroughly clean. See fig. 3 / 3A for the electrical control and mechanical adjustment of the sensors.

17.1.4 17.1.5 17.1.6

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AP5
- + V>20Vdc V
46 45

SENSORE OTTICO OPTISCHE SENSOR OPTICAL SENSOR CAPTEUR OPTIQUE SENSOR OPTICO

AP5
- + V<2Vdc V
46 45

Fig. 3

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SENSORE INDUTTIVO INDUKTIVER SENSOR INDUCTIVE SENSOR CAPTEUR A INDUCTION SENSOR INDUCTIVO

~0.4 mm

~20 Vdc

+
45 46 XX 45 46 XX

~0 Vdc

+
45 46 XX 45 46 XX

Fig. 3A

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17.2

ERRORS AND MALFUNCTIONS CAUSED BY THE SENSORS

Defective functioning of the sensors may cause the following errors:

Error 11, 12, 15 20 30 40. 44. 42. 48 54. 55. 70. 71.

Charter to consult Main movement group (see chapter 3) Infeed unit (see chapter 2) Upper ejector group (see chapter14) Film CENTRING group (see chapter 10) Changing the length of film (see chapter 7) Automatic carriage (see chapter 8 Opt.) Knife (see chapter 6)

The description and the corrective actions to carry out for each of the above mentioned errors are indicated in chapter no. 40.

18. BRAKE, CLUTCH AND ELECTROMAGNET TESTING


18.1 INTERNAL RESISTANCE MEASUREMENT

To measure the internal resistance, disengage the connectors from the brake, clutch or electromagnet to be checked and ensure that the resistance values are within those given below. The resistance of each individual component should be between : 33 and 37 ohm 25 and 30 ohm 28 and 32 ohm 28 and 32 ohm 19 and 24 ohm 23 and 28 ohm 45 and 50 ohm 20 and 24 ohm for the tearing operation brake YB1 for the film reel brakes YB5 and YB6 for the tearing operation clutch YC1 for the unwinding release clutch YC2 for the CENTRING and cam clutches YC3, YC4 and YC5 for the CENTRING and cam brakes YB2 and YB3 for the upper ejector brake YB4 for the electromagnets YA1-YA2 and YA3

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If the ohm value differs greatly from these above, replace the faulty part. Check also that there is perfect insulation (infinite resistance) for all brakes, clutches and electromagnets between the reel terminals and the metal envelope. Brake and clutch operation can be checked with the PCPocket. When the test indicates 0 (zero) on the respective coils, it is necessary to measure about 0 (zero) VDC. On the other hand, it is necessary to measure about 24 VDC when the test shows 1. 18.2 BRAKE AND CLUTCH TESTING

The air gap between the armature of the brakes and clutches and their fixed part must be 0.2-0.3 mm when the machine is turned off (see fig. 4). The air gap of the brakes YB5 and YB6 should be 0.2 mm. In order to check the film reel brakes YB5 and YB6 with the brakes connected, switch the machine on and lower the dandy roll. At this point the brake should be closed (film reel locked) and about 0 VDC should be measured on its winding. As the dandy roll is raised, the corresponding film reel brake should open (film reel free) and about 22 VDC should be measured on its winding. In this position it is possible to measure the gap. The film reel brakes can be tested with the PCPocket. 18.3 ELECTROMAGNET TESTING

The machine parts operated by the electromagnets can be tested for their correct operation through the PCPocket. To carry out the test on any electromagnet, follow these directions: 1. 2. Select the test appropriate for the electromagnet to be tested on the PCPocket and press Enter. For all the electromagnets, when the PCPocket display shows 1, about 25 VDC 10% should be present on the electromagnet, while about 0 VDC should be measured, when 0 (zero) appears. The electromagnets are controlled by the boards AP5 and AP7. The hybrids which control the brakes, clutches and electromagnets are IB0, IB2 and IB4.

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0.2/0.3 mm

0.2/0.3 mm

Fig. 4

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18.4

ERRORS AND MALFUNCTIONS

In the event the brakes, clutches or electromagnets do not correspond to the specifications given above, they should be replaced.

19. ELECTROMAGNET MECHANICAL ADJUSTMENT


19.1 DESCRIPTION

To have maximum force available from the electromagnets, a correct mechanical adjustment is of primary importance. An electromagnet exercises its greatest force only when its armature is fully within the magnetic field generated by its coil. Since under this condition there would be a loud noise of the striking of the armature on the magnet casing at the stroke end, the following adjustments of the clamp magnets should be carried out : 1. 2. 3. 3. Unscrew the holding nut (A) located between the electromagnet shaft and the adjustment rod (B) (where fitted); see fig. 5. On the PCPocket select the relevant test for the electromagnet to be adjusted and press Enter. Rotate either the electromagnet shaft or the adjustment rod until the armature reaches the end of its run. Rotate the shaft slowly in the opposite direction until the mechanical noise of the electromagnet stops, providing a few tenths mm clearance between the fixed and the moving parts, though without sacrificing any of the electromagnet force, while at the same time not having any disagreeable mechanical noise. When this position has been attained, lock the holding nut so the positionis maintained.

5.

20. PHOTOCELLS
20.1 REFLECTING PHOTOCELLS TESTING

Adjustable reflecting photocells are installed on the optional devices C.220.018, C.220.021 and C.220.031 of the 55 Pi machines, in order to read correctly even the product wrapped in transparent trays, or the film in case the optional C.220.031 is used.

Page 64 of 168

Fig. 5

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All the optional devices are equipped with photocells adjusted for the maximum reading power. In the case transparent trays have to be read, the photocells will have to be adjusted using the appropriate potentiometer mounted on each photocell. Keep in mind that the power of the emitted ray increases by turning the potentiometer clockwise, while it decreases turning it counter-clockwise. All photocells may be tested with the PCPocket (see ENTRIES menu). The height of these photocells can also be mechanically adjusted in order to make them suitable for the particular types of products/trays. Once adjustment is completed, slowly pass the most transparent empty tray in front of the photocell while being sure that the red LED never turns off for the entire width of the tray. In the event there are some points where the LED turns off, slightly turn the potentiometer counter-clockwise until it reads the tray in its entirety. These photocells work properly only with the original reflector. Use only original spare parts if you have to replace it. The electrical check can be performed as shown in figure 6. The reflecting photocells can cause following errors : 90, 91, 92, See chapter no. 40. 20.2 INFEED AND CARRIAGE PHOTOCELLS TESTING

The infeed and carriage photocells are the same. They are direct reading photocells and several receivers receive the ray emitted by each transmitter. See chap. 20.4.1 and 20.4.2. If each sender-receiver group functions properly, the maximum theoretical level of reception of each channel is 255. However, in the event a channel receives a signal that is lower than the foreseen maximum theoretical level but much higher than the switching point shown on the display (minimum 80), it can be considered correct. The tests for checking these photocells are available in the SINGLE PHOTOCELL TEST menu. All of the information necessary for executing the test of these photocells is nevertheless available in the displays help. These photocells can cause following errors : E24, E84, E85, E86, E87, E88, E89, See chapter 2 and 40.

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AP6
- + V>20Vdc V
46 45

AP6
- + V<2Vdc V
46 45

Fig. 6

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20.3

FILM STOP PHOTOCELLS TESTING

The two film stop photocells are the same and work in reflection. Unlike the infeed photocells, these have a variable threshold, i.e. the switching threshold is detected each time the machine is turned on and can therefore be subject to variations. It is for this reason that a channel is activated always when the reflected ray exceeds the threshold value detected at the time it is turned on by 40 units. The tests for checking these photocells are available in the SINGLE PHOTOCELL TEST menu. All of the information necessary for executing the test of these photocells is nevertheless available in the displays help. These photocells can cause following errors : E45, E46, E47, See chapter 10 and 40.

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20.4

SUMMARY OF THE PHOTOCELLS FEATURES

20.4.1 BELT BARRIER (Seen from INFEED)

20.4.2

CARRIAGE BELT (Seen from INFEED)

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20.4.3 FILM STOP PHOTOCELLS

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20.4.4 PHOTOCELL REFERENCES PTCNA_01................. "Tx01-Rx09" PTCNA_02................. "Tx09-Rx01" PTCNA_03................. "Tx17-Rx01" PTCNA_04................. "Tx09-Rx17" PTCNA_05................. "Tx02-Rx10" PTCNA_06................. "Tx17-Rx17" PTCNA_07................. "Tx02-Rx02" PTCNA_08................. "Tx18-Rx10" PTCNA_09................. "Tx18-Rx02" PTCNA_10................. "Tx03-Rx03" PTCNA_11................. "Tx18-Rx18" PTCNA_12................. "Tx11-Rx03" PTCNA_13................. "Tx10-Rx02" PTCNA_14................. "Tx10-Rx18" PTCCA_01................. "Tx12-Rx04" PTCCA_02................. "Tx04-Rx12" PTCCA_03................. "Tx20-Rx04" PTCCA_04................. "Tx12-Rx20" PTCCA_05................. "Tx20-Rx20" PTCCA_06................. "Tx05-Rx13" PTCCA_07................. "Tx05-Rx21" PTCCA_08................. "Tx21-Rx13" PTCCA_09................. "Tx06-Rx06" PTCCA_10................. "Tx21-Rx21" PTCCA_11................. "Tx06-Rx14" PTCCA_12................. "Tx13-Rx21" PTCCA_13................. "Tx14-Rx14" PTCCA_14................. "Tx13-Rx05" PTCFF_01................. "Tx07-Rx07" PTCFF_02................. "Tx08-Rx08" PTCFF_03................. "Tx15-Rx15" PTCFF_04................. "Tx16-Rx16" BELT PHOTOCELL THRESHOLD: 35

CARRIAGE PHOTOCELL THRESHOLD: 35

FILM STOP PHOTOCELL THRESHOLD: Variable: Threshold = level when turned on + 40 (if the level when turned on is greater than 100 threshold = 150)

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20.4.5 CORRESPONDENCE WITH LED ON CPU CARD X X X X X X X X FFILM 1 FFILM 2 FFILM 3 FFILM 4 FREE FREE FREE FREE X X X X X X X X CARRIAGE 2 CARRIAGE 1 CARRIAGE 6 CARRIAGE 5 CARRIAGE 10 CARRIAGE 9 CARRIAGE 14 CARRIAGE 13 X X X X X X X X BELT 1 BELT 2 BELT 5 BELT 6 BELT 9 BELT 10 BELT 14 BELT 12

NOTE: The rays were chosen so that at least one LED turns on for any defective sender or receiver.

20.4.6 CORRESPONDENCE WITH TESTING OF ALL PHOTOCELLS (302) OR PROHIBITED PHOTOCELL TEST (301)

BELT Photocell from LEFT to RIGHT: 6-5-4-3-2-1-14-13-12-11-10-9-8-7 FFILM Photocell from LEFT to RIGHT: FF4-FF3-FF2-FF1 CARRIAGE Photocell from LEFT to RIGHT : 6-5-4-3-2-1-14-13-12-11-10-9-8-7

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20.4.7 RAYS USED IN THE PACKAGES PARAMETER USE OF LOW PHOTOCELLS

VALUE 0: Value 1 - 5: Value 2 - 6:

all of the rays rays 1 and 2 (BELT and CARRIAGE) 1 ENABLES 5 DISABLES rays 1 and 2 (BELT and CARRIAGE) rays 3 and 4 (BELT and CARRIAGE) 2 ENABLES 6 DISABLES rays 1 and 2 (BELT and CARRIAGE) rays 3 and 4 (BELT and CARRIAGE) rays 5 and 6 (BELT and CARRIAGE) 3 ENABLES 7 DISABLES rays 1 and 2 (BELT and CARRIAGE) rays 3 and 4 (BELT and CARRIAGE) rays 5 and 6 (BELT and CARRIAGE) rays 7 and 8 (BELT and CARRIAGE) 4 ENABLES 8 DISABLES

Value 3 - 7:

Value 4 - 8:

20.4.8 PHOTOCELL PROHIBITION PROCEDURE AUTOMATICALLY PERFORMED BY THE MACHINE EVERY TIME IT IS TURNED ON. THE PROCEDURE IS CARRIED OUT SIMILARLY ON BELT BARRIER AND ON CARRIAGE BARRIER: 1. IF ONE OR MORE RAYS IS DETECTED AS BEING OBSCURED, ALARM 24 (84) IS GIVEN. 2. IF AT LEAST ONE OF RAYS 1 AND 2 AND AT LEAST ONE OF RAYS 3 AND 4 ARE FREE WITH THE NEXT START, THE OBSCURED RAYS ARE PROHIBITED, MEANING THEY ARE NOT TAKEN INTO CONSIDERATION IN CALCULATING THE FREE OR OBSCURED BARRIER. IF RAYS 1 AND 2 OR RAYS 3 AND 4 ARE BOTH OBSCURED, ALARM 24 (84) IS MAINTAINED, EVEN WITH SUBSEQUENT STARTS. 3. THE WARNING W80 (W81) IS DISPLAYED WITH THE NEXT START. 4. THE SITUATION DESCRIBED HEREIN IS VALID UNTIL THE MACHINE IS TURNED OFF.

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WARNING !!!
Photocell PROHIBITION is a procedure that the machine automatically carries out, and any possible USE OF LOW PHOTOCELLS parameter that may have been programmed in one or more wrapping programmes is not taken into account.

21. MICROSWITCHES AND CONTROL BUTTONS TESTING


21.1 SAFETY MICROSWITCHES

The standard 55 Pi machine is equipped with 7 safety microswitches with 2 normally closed contacts, and two STOP buttons. All the safety microswitches from SB3 to SB7 and from SB9 to SB10 included and the STOP buttons SB1 (wires 80 and 81) and SB2 (wires 81 and 82) are connected in series through one of the two contacts. Since all of the microswitches and STOP buttons are individually connected with a connector to the board AP6, the series was made on the board itself. The second contact is connected to a hybrid input and serves to identify which microswitch is activated. Furthermore, the entire power fail circuit is protected by the fuse FU19. The contacts of these microswitches and of the STOP buttons are also connected in series with the coils of the relay K1 and K2, positioned on board AP1, and K4 on board AP5. Should one of the safety microswitch contacts open while the machine is working, this stops the machine while displaying error no. 05, which is common to all of the contacts in series of the microswitches, or the error relating to the activated microswitch. If the STOP buttons SB1 and SB2 are pressed, the machine stops with error 05 (contact in series to the microswitches) or 01 if it is the other contact that is activated. NOTE: Error 01 has priority over error 05. Refer to the list of errors to identify the errors of each individual microswitch or button.

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21.2

CONTROL PANEL BUTTONS

All of the control panel buttons can be controlled with a simple operation described below, which is to be performed on the control panel itself. 1. 2. 3. 4. 21.3 Turn on the machine As soon as the display surface lights up, press the ENTER key Press the panels keys one by one while being sure that the corresponding key is highlighted on the display. If all of the buttons are correctly highlighted, the test result is positive. FILM STOP RELEASE MICROSWITCHES

When the machine stops due to error 45, 46 or 47, it means that the film not used has obscured the film stop photocells and settled onto the film stop photocells. To exit from this condition it is necessary to: Open the upper right cover. Remove the film which has caused the machine to stop. Re-close the cover which was opend earlier. Press the START button.

The contact controlling this is that of the microswitch SB4 with the numbers 83 and 84. 21.4 ERRORS AND MALFUNCTIONS

The errors shown on the display, other errors or malfunctions are described in chapter no. 40. NOTE. The EXXbis errors are found at the end of the errors chapter. The errors concerned by this movement are: E00, E01, E03, E05, E05bis, E60, E61, E62, E63, E64, E65, E66, E67

22. TESTING OF THE STEPPING MOTORS


22.1 DESCRIPTION

All the model 55 Pi movements except for those of the main movement, of the infeed and of the sealing plate are powered by stepping motors. This type of motor is also mounted on the optional Automatic carriage. The stepping motors for the upper ejector and the automatic carriage movements are controlled by driver AP8, while the knife and the film length movements are controlled by AP9.

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These motors are then alternatively used through the board AP6, which makes only one motor at a time operate for each driver. All the stepping motors are powered by the transformer TV1, the rectifier bridge V2 and the board AP5 through about 65 VDC 10%. There is also a power supply on the board AP6 to supply power to the bridge H of the drivers MOSFET. All the movements controlled by the stepping motors are controlled by sensors, so that a malfunction of one of these sensors should stop immediately the machine displaying an error. See chapter 37. All the tests for checking these motors are to be found in the menu TESTS/MOVEMENTS. 22.2 ERRORS AND MALFUNCTIONS

The errors shown on the display, other errors or malfunctions are described in chapter no. 40. 1029, 1030

23. ELECTRONIC BOARD ARRAY AND COMMANDS


23.1 DESCRIPTION

The electronic board array is that part of the machine which co-ordinates all the machine functions. Besides the electronic boards, it contains all the power supply and protection circuits, as well as all the connections to and from the machine. For the electric circuit protectors of the machine motors, transformer and sealing plate and for the safety circuit refer to the electrical machine diagrams. For the boards connection to the electrical panel see fig. 7. All electrical, electronic and connection circuits are on printed circuit boards. Therefore, the following boards are placed in the electronic board array and in the control panel :

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X11

CN1 X36

X40 X43

X41

AP1

AP10
X8 X9 X10 CN4 X4

AP7
CN5 X5 CN6 X6

CN7

X7

AP5

AP2

X34 X51

X39 X49 X48 X38 X47

AP6
X11

TV1
CN12 CN12

+~

AP8 AP9

CN11 CN11

V1

V2

Fig. 7

Page 77 of 168

AP1 AP2 AP5 AP6 AP7 AP8 AP9 AP10 AP11 AP12 AP13 AP14 AP15 AP16 AP17 23.2

Power Board Sealing Plate Static Relay Board Output Interface Board Input Interface Board CPU Board Upper Ejector/Automatic Carriage Stepping Motor Driver Knife / Film Length Stepping Motor Driver Board DAC controlling frequency converters Right Infeed Photocells Board Left Infeed Photocells Board Right Carriage Photocells Board Left Carriage Photocells Board Film Stop Photocells Board for carriage side Fixed Film Stop Photocells Board Control Panel Board CONTROL PANEL

The control panel constitutes the interface means between the machine and the operator. To learn about its functions, refer to paragraphs 4.3 and 4.4 of the Users Manual. 23.3 ERRORS AND MALFUNCTIONS

Refer to the chapter problems when switching on the machine.

24. POWER BOARD AP1


24.1 DESCRIPTION

Remote control switches, relays, filters, fuses and connections relative to the power mains voltage and users that operate with the power supplied by it are mounted on this board. The functions of each single component are clearly depicted on the machines wiring diagrams. The functions of the LEDs on this board are: 1red LED on AP2: when lit, it indicates the presence of the activation signal of the static relay of the sealing plate.

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2-

yellow LED on the remote control switch K2: when lit, it indicates proper closing of the safety microswitch circuit and of the STOP buttons.

NOTE: The inverters and the motors connected to them are always powered at 230 VAC, regardless of what power grid voltage the machine is fed. Since there are power grid filters on the machine, they must be strictly and properly connected in order to prevent the emission of undesirable disturbances on the power grid. When making the electrical connections, refer to the respective chapter in the Users Manual.

25. SEALING PLATE RELAY BOARD AP2


25.1 DESCRIPTION

This board serves to power the sealing plate and therefore guarantee its correct temperature. The red LED indicates: abif lit, the CPU sends the signal for activating the static relays if turned off, the CPU does not send the signals for activating the static relays or the connections are incorrect.

26. OUTPUT INTERFACE BOARD AP5


26.1 DESCRIPTION

This board is used to: abcdefgInterface the CPU with the brakes, clutches and electromagnets installed on the machine. Transmit the START and DIRECTION signals to the two inverters. Send the management signals to the customer belt (if present) through the relay K5 and the terminal board XT4 (see wiring diagram E.220.I.100m). Indicate each single function of the board through LEDs, see fig. 8. Create the 27 VDC voltage for feeding brakes, clutches, electromagnets and the safety circuit. Create the 65 VDC voltage for feeding the stepping motors. Allow connection of the control cables of the inverters and probe for controlling the temperature of the sealing plate.

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27. INPUT INTERFACE BOARD AP6


27.1 DESCRIPTION

This board is used to : aInterface the CPU with the photocells, sensors, safety micros and inverter alarm signals. bInterface the machine with other external equipment that must be synchronized with the machine or act as process control. The only condition required in order to be able to connect an external device to the machine is that it has a contact without potential. These contacts must be connected on the terminal board XT3 as follows: Between Terminal 4 and 1 for optional 1 Between Terminal 4 and 2 for optional 2 Between Terminal 4 and 3 for optional 3 Terminal no. 4 is the ground (GND) See wiring diagram E.220.I.100m. NOTE: Each separate input must be activated after having read the Help, with tests 123, 124 and 125 located in the variables menu. cdGenerate the 12 VDC voltage for the bridges H of the MOSFET Switch the outputs of the stepping motors since on the machine we can have up to 4 stepping motors and we have only 2 drivers.

There are also 4 yellow LEDs on the board that indicate which stepping motors can operate. The following functions of the stepping motors are represented by the LEDs: abcdHL1 exit upper ejector stepping motor activated HL2 exit automatic carriage stepping motor activated HL3 exit film length stepping motor activated HL4 exit knife stepping motor activated

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28. COMPLETE 10.4 L.C.D. AP17


28.1 DESCRIPTION

This unit comprises the monitor board with the L.C.D. mounted on it. The monitor board is powered by the same 48 VAC that feeds the CPU. Communication between the monitor and CPU boards takes place through the serial connection RS 485. Also the piezoelectric keyboard (CN6), the PCPocket (CN1 + Sub D 25 external pin connector), the L.C.D. display (CN2), the inverter for the display lamp (CN7) and the potentiometer for adjusting the brightness (CN8) are connected to the monitor board. The memory for operation of the monitor in the desired language is mounted on the base IC1. The versions of these programmes are F.220.I.630 / 631 / 632 . Contact the Waldys or Automac service centres to find out which memories are available. Also the RAM in which the data are stored following the programme save operation (test 113 of the FUNCTIONS menu) is present on this board. There are also two potentiometers having the following functions on this board: abpotentiometer T1 adjusts the L.C.D. displays brightness potentiometer T2 adjusts the L.C.D. displays contrast

In the event you have doubts about the keyboard functioning properly, check it by using the procedure described below: a. b. c. d. e. check that the keyboard is correctly connected to the connector CN6 of AP14. Switch on the machine. As soon as the display starts to take on an off-white colour (before seeing any image), press the ENTER key Press all of the keys sequentially while checking whether or not the corresponding symbol located on the left of the display becomes activated. If all of the symbols become activated in a normal manner, the keyboard functions.

The errors shown on the display, other errors or malfunctions are described in chapter no. 40. NOTE. The XXXXbis errors are found at the end of the errors chapter. The errors concerned by this movement are : 1006, 1006bis, 1047

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29. CPU BOARD AP7


29.1 DESCRIPTION

The CPU Master is the board which manages all the functions of the machine. On it are mounted all the power supply elements for the electronic circuits, INPUT and OUTPUT hybrids, the transmission and receipt circuits of photocells of the infeed, carriage and film stop device, the switches for selection of the optional devices, the memory for the management of all machine operations and the circuits controlling the command signals of stepping motors of the machine. 29.1.1 Feeders The AP7 board is fed with a single 48 VAC supply to pins 7 and 8 of the connector CN1. The supply presence is indicated by the LED LD1 and the continuous voltages to connector CN7 are those shown in the table below. Pin of CN7 30 c 29 c 29 a 25a-25c 26a-26c Voltage (DC) + 12 V - 12 V +5V LED Function LD4 transmission system RS232 transmission system RS232 transmission system RS485 for PCPocket Sensor, photocell and relay power supply the the the the the

+ 20 V

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29.1.2 Signalling LEDs On the board are located also the following LEDs with the functions indicated below : LED LD1 LD2 LD3 LD4 LD5 LD6 L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 L11 L12 L13 L14 L15 L16 L17 L18 L19 L20 L21 L22 L23 L24 Function +70 VDC Not used Serial channel RS485 for PCPocket + 12 VDC indicates that the value of 5 VDC is less than 4.75 VDC reset FILM STOP photocell 1 FILM STOP photocell 2 FILM STOP photocell 3 FILM STOP photocell 4 / / / / CARRIAGE photocell 2 CARRIAGE photocell 1 CARRIAGE photocell 6 CARRIAGE photocell 5 CARRIAGE photocell 10 CARRIAGE photocell 9 CARRIAGE photocell 14 CARRIAGE photocell 13 BELT photocell 1 BELT photocell 2 BELT photocell 5 BELT photocell 6 BELT photocell 9 BELT photocell 10 BELT photocell 14 BELT photocell 12

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29.1.3 Connectors The functions of the connectors mounted on this board are : Connector CN1 CN2 CN4 / CN5 CN6 CN7 Function 48 VAC voltage supply entry Serial lines connection RS485 per monitor and RS232 Connection TX and RX for photocells All the INPUT and OUTPUT signals of the hybrids Voltage supply, signals managing the stepping motors and INPUT and OUTPUT signals of the hybrids.

29.1.4 Reset Button By pushing button PS1, the CPU board is reset. After resetting, the programme starts from the beginning. The same is achieved by switching the machine off and restarting it with the mains switch. 29.1.5 Programme Memory On the 55 Pi machine, only one memory is installed on the board CPU AP7, which contains the machine operation programme, the version of which is (F.220.I.610,611,612.....). In this memory there are also 99 different wrapping programmes that can be selected through the keys and on the control panel keyboard. On the board AP7 is also mounted a RAM, fed by an incorporated battery, that keeps all the parameters stored in the memory that have been varied through the machine keyboard or the PCPocket.

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29.1.6 Functions of the switches DS1


Switch no. OFF 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 X X X X X X X X X X X X X X X X ON Function Machine from series 1 included 0 series machine Free Free Machine without customer belt photocell Machine with customer belt photocell Machine with elevator Europa Machine with elevator A Machine without automatic carriage Machine with automatic carriage Machine without carriage extra stroke Machine without carriage extra stroke Machine without elevator for Pizza 280 mm Machine with elevator for Pizza 280 mm Free Free

To check the operation of the switches, see test no. 704 in VARIOUS TESTS menu. 29.1.7 Hybrids On the board AP7 are located all the hybrids of Input and Output (fig. 15), the operational functions of which are listed in the following pages.

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OUTPUT SIGNALS

IDO IB0 b0 b1 b2 b3 b4 b5 b6 b7 CN7/5a CN7/5c CN7/6a CN7/6c CN7/7a CN7/7c CN7/8a CN7/8c

FUNCTION UNWINDING ROLLER RELEASE CLUTCH TEARING BRAKE TEARING CLUTCH CENTRING BRAKE CENTRING CLUTCH BRAKE REEL 1 BRAKE REEL 2 RELAY SEALING PLATE (STATIC)

HYBRID IB2

FUNCTION

b0 CN6/8c KNIFE / FILM LENGTH MOTOR SWITCHOVER b1 CN6/9c UPPER ELEVATOR / CARRIAGE MOTOR SWITCHOVER b2 CN6/10c REEL 1 / REEL 2 MOTOR SWITCHOVER b3 CN6/11c REMOTE CONTROL SWITCH OF OPT. OUTLET CONVEYOR MOTOR b4 CN7/9a INFEED INVERTER FORWARD RUNNING b5 CN7/9c INFEED INVERTER BACKWARD RUNNING b6 CN7/10a MAIN INVERTER FORWARD RUNNING b7 CN7/10c UPPER EJECTOR BRAKE HYBRID IB4 b0 b1 b2 b3 b4 b5 b6 b7 CN6/17c CN6/18c CN6/18a CN6/19a CN6/17a CN6/20a CN6/19c CN6/20c FUNCTION FOLDER CLAMP MAGNET EXIT CLAMP MAGNET INFEED CLUTCH SEALING PLATE MOTOR ELECTROMAGNETIC SWITCH CAM BRAKE CAM CLUTCH SIDE STRETCH DEVICE MAGNET CUSTOMER BELT RELAY

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INPUT SIGNALS

HYBRID IB1 b0 b1 b2 b3 b4 b5 b6 b7 CN7/1a CN7/1c CN7/2a-CN6/3c CN7/2c-CN6/5c CN7/3a-CN6/2c CN7/3c-CN6/7c CN7/4a-CN6/4c CN7/4C-CN6/6c

FUNCTION MAIN SENSOR CAM MARK SENSOR CAM POSITION SENSOR UNWINDING SENSOR FILM PRESENCE SENSOR UPPER EJECTOR POSITION SENSOR FILM LENGTH MARK SENSOR FREE FUNCTION CN6/12c CN6/14c CN6/14a CN6/15a CN6/13c CN6/16a CN6/15c CN6/16c PRODUCT EXIT PHOTOCELL PRINTED FILM PHOTOCELL KNIFE SENSOR MACHINE STOP BUTTON ELASTIC ROD MICRO INFEED STOP SELECTOR INFEED MARK SENSOR MAIN INVERTER ALARM

HYBRID IB3 b0 b1 b2 b3 b4 b5 b6 b7 HYBRID IB5 b0 b1 b2 b3 b4 b5 b6 b7 CN6/21c CN6/22c CN6/22a CN6/23a CN6/21a CN6/24a CN6/23c CN6/24c

FUNCTION CARRIAGE SENSOR 1 CARRIAGE SENSOR 2 CARRIAGE SENSOR 3 CARRIAGE SENSOR 4 FILM TIGHTENING SENSOR FILM LENGTH POSITION SENSOR CUSTOMER BELT PHOTOCELL INFEED INVERTER ALARM FUNCTION INTERRUPTED SAFETY CIRCUIT SIGNAL RIGHT COVER SAFETY MICRO (1) ELEVATOR DOOR SAFETY MICRO (2) FILM DOOR SAFETY MICRO (3) LEFT COVER SAFETY MICRO (4) CONTROL PANEL SAFETY MICRO (5) LOWER INFEED COVER SAFETY MICRO (6) FREE (possibly micro)

HYBRID IB6 b0 b1 b2 b3 b4 b5 b6 b7 CN6/25c CN6/26c CN6/26a CN6/27a CN6/25a CN6/28a CN6/27c CN6/28c

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HYBRID IB7 b0 b1 b2 b3 b4 b5 b6 b7 CN6/29c CN6/30c CN6/30a CN6/32c CN6/29a CN6/31c CN6/32a CN6/31a

FUNCTION INFEED STOP BUTTON OPTIONAL 1 INPUT OPTIONAL 2 INPUT OPTIONAL 3 INPUT FREE FREE FREE FREE

29.2

ERRORS AND MALFUNCTIONS

The errors shown on the display, other errors or malfunctions are described in chapter no. 40. E07, E18 Other possible malfuctions. 29.2.1 No LED is lit on board AP7. Corrective actions 29.2.1.1 29.2.2 Check that on connector CN1 48 VAC are present. LED LD6 is always lit. Corrective actions 29.2.2.1 Make sure that all components are firmly connected to the sockets. If the malfunction persists, replace board AP7. Check also that button PS1 is not mechanically locked and that there are no short circuits on the 24 VDC machine tension. Selection of the optional devices with switch DS1 is not operating correctly. Corrective actions Check the switches (test no. 704 VARIOUS TESTS menu); if negative, replace the board AP7. The PCPocket does not communicate with the CPU. Corrective actions 29.2.4.1 Check that :

29.2.3.

29.2.3.1 29.2.4

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a. b. c.

The PCPocket is correctly connected and the connection to the CPU (AP7) is correct. The PCPocket programme is the appropriate one for the series and programme of the machine to be checked. Replace the CPU board (AP7).

30. INFEED, CARRIAGE AND FILM STOP PHOTOCELLS BOARD AP11 AP12 - AP13 - AP14 AP15 AP16
30.1 DESCRIPTION

The function of the photocells AP11, AP12, AP13 and AP14 is to detect the presence of a tray/product on the infeed and on the carriage for the purpose of managing all of the movements and checks of the tray/product. The photocells AP15 and AP16, on the other hand, check the presence of any pieces of film not used to wrap a product and that could therefore be wound onto the unwinding rollers. These photocells are made up of senders and receivers managed by the CPU board (AP7) and by the machines programme. The conditions of the individual photocells are the following: AP11, AP12, AP13 and AP14 TYPE OF READING: direct THRESHOLD = 35 LEVEL: Maximum level read in real time by a channel = 255 SWITCHOVER OF A CHANNEL: When the value of the LEVEL becomes less than 35 STATUS: If 0 (zero), the photocell is not switched If 1, the photocell is switched SWITCHOVERS: Number of times that the STATUS acquires the value 1 during a test AP15 and AP16 TYPE OF READING: Reflected THRESHOLD: Value read by the photocells when the machine is turned on + 40 LEVEL: Value read in real time by a channel

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SWITCHOVER OF A CHANNEL: When the value of the LEVEL becomes equal to the threshold value + 1 or greater STATUS: If 0 (zero), the photocell is not switched If 1, the photocell is switched SWITCHOVERS: Number of times that the STATUS acquires the value 1 duringa test The functions of the infeed and carriage photocells are described in the flow chart found in chapter 2, whereas details about the alarms linked to the film stop photocells are described in chapter 10. The photocell channels used, their positioning and display on the CPU board are indicated in fig. XX and XX as well as in the tables herein enclosed. 30.2 ERRORS AND MALFUNCTIONS

SEE CHAPTER 2 AND 10.

31. DAC BOARD AP 10


31.1 DESCRIPTION

The DAC board AP10 serves to manage the speed of the main and infeed motors by sending the command signals to the respective frequency converters. By converting the digital signals into analogue, a signal in current that acquires values of between 4 and 20 mA in relation to the programmed speed values in each single wrapping programme is sent to the frequency converters. Should the errors 15 and 20 appear on the machine and the main or infeed motor not function, it can all be attributed to the DAC board AP10 or its connections.

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32. STEPPING MOTORS DRIVER BOARD AP8 + AP9


32.1 DESCRIPTION

The following movements are managed by the stepping motors controlled by the driver AP8 and AP9: Knife, film length (AP9) and upper ejector and automatic carriage Opt. C.220.026 (AP8). These boards receive the signals from the CPU (AP7) and the voltage supply from the boards AP5 and AP6 (bridge supply H of MOSFET). Since the board has LEDs on the input signals, you can see right away if the command signals are reaching it properly. The LEDs on this board have the following functions : d1 Enable d2 Direction d3 Step

33. FREQUENCY CONVERTERS AP3 AND AP4


33.1 DESCRIPTION

The motors of the main movements and of the infeed are managed by the frequency converters. These are controlled by the boards CPU AP7 and DAC AP10. The speed is managed by a signal in current sent from the DAC AP10 onto the terminals C1 and 11 of AP3 and AP4, the value of which is between 4 and 20 mA. The direction signals are sent: abcto the main movement by the relay K6 mounted on the board AP5. The signal is sent onto the terminals P24 and FWD of AP3 when the LED HL1 is on to the clockwise movement of the infeed by the relay K8 mounted on the board AP5. The signal is sent onto the terminals P24 and FWD when the LED HL7 is on to the counter-clockwise movement of the infeed by the relay K7 mounted on the board AP5. The signal is sent onto the terminals P24 and REV when the LED HL4 is on

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The frequency converters send the alarm signals from the terminals 30b and 30c first to the board AP6 and then to the AP7. These signals come in: onto hybrid IB5 - the alarm signal of the converter AP4 onto hybrid IB3 - the alarm signal of the converter AP3 These alarm signals are sent from the frequency converters when they are either in error or their internal temperature exceeds the maximum level allowed for correct operation, about 135C. 33.2 ERRORS AND MALFUNCTIONS OF THE INVERTERS

The only error that appears on the inverters display and on which you can intervene is the error OH2, which indicates that the thermal pellet of the motor or its connection has been interrupted. It is therefore necessary to reinstate the connection of the thermal pellet or replace the motor. The only solution for any other error that appears on the inverters display is to replace the inverter. The errors shown on the machine display, other errors or malfunctions are described in chapter no. 40. E16, E17, E21, E22

34. INPUTS FOR CONNECTING EXTERNAL DEVICES TO THE MACHINE


34.1 DESCRIPTION

The 55 Pi machine has three inputs to which you can connect external devices (weighing systems, metal detectors, etc.) that must either stop the infeed or the entire machine in the event an error occurs. It is also possible to connect contacts (STOP buttons or another type of push button or switch) to perform the same operations described above. These connections make using the equipment present on the line easier, and in any case allow the machine to properly stop when it must work in perfect synchronism in the production line. See chapter 27 and consult the HELP on the display to activate these possibilities.

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The flow chart representing operation of the optional imput is shown here below

OPTIONAL INPUT(1, 2 or 3)

NO

The relative variable is other than 0 [see Variables description] ? YES The relative variable is equal to 1 [see Variables description] ? NO

YES

NO

Is the machine in cycle ? YES

YES

The relative variable is equal to 2 [see Variables description] ?

NO

NO

Is the OPTIONAL input on ON (1) ?

Is the OPTIONAL input on OFF (0) ?

NO

ERROR 73, 74 or 75 (OPT. INPUT 1, 2 or 3)

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NO

Is the machine in cycle? YES

NO

Is the OPTIONAL input on ON (1) ? YES WARNING 95, 96 or 97

Start tally for stopping optional discharge

Is there a tray on the INFEED photocell ? NO Has the tally for stopping the optional discharge expired [ see Variables description] ? NO

YES

INFEED clutch: on OFF (0)

YES

OPTIONAL discharge output on OFF (0)

NO

OPTIONAL input on OFF (0) ? YES

OPTIONAL discharge output on ON (1)

INFEED clutch : on ON (1)

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A description of the errors reported by the display and linked to the topic follows.

Code 73 74 75
34.2

DESCRIPTION

CAUSE FOR ALARM SITUATION

E73/74/75 OPTIONAL DEVICE 1/2/3 IN ALARM

See OPTIONAL INPUTS flow PAGE 1

ERRORS AND MALFUNCTIONS

The errors shown on the display, other errors or malfunctions are described in harter no. 40. E73, E74, E75

35. MANAGEMENT OF THE CUSTOMERS INFEED


35.1 DESCRIPTION

The 55 Pi has a device that allows you to manage an external motorized infeed of the customer, if any. Refer to chapter 26. The management consists of interrupting the command signals going to the power devices (relays, remote control switches, etc.) that in turn drive the customers infeed motor. IT IS SEVERELY FORBIDDEN TO INTERRUPT POWER CIRCUITS. This function must be activated with test 122 of the variables. For correct use, carefully read the HELP in correspondence with test 122. In order to better manage operation of the customers belt in addition to what is described above, it is possible to mount a photocell at the end of the customers belt (from the side where the infeed of the machine starts) for the purpose of preventing the belt from making useless stops.

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The flow chart representing operation of the customer belt is shown here below

CUSTOMER BELT

The relative Variable is other than 0 [see Variables description] ? YES

NO

END

Customer Infeed Belt Relay on ON

NO

Is the machine in cycle? YES

NO

Is the INFEED clutch on OFF (0) for a longer time than that foreseen by the Variable ? YES YES Is there the customer belt PTC and is it OFF (0 - FREE) ? NO

Customer Infeed Belt Relay on OFF

Is the INFEED clutch on ON (1) ? NO

YES

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36. CONTROL PANEL


36.1 DESCRIPTION

For the common functions relative to the control panel, refer to paragraphs 4.3 and 4.4 of the USERS MANUAL. For the specific functions concerning the technician who must perform maintenance on the machine, refer to the tables given here below. It is however understood that for more detailed information about using each individual function or test, you are to refer to the HELP found on the machine.

37. PROBLEMS WHEN SWITCHING ON THE MACHINE


37.1 MALFUNCTIONS WITHOUT ERROR INDICATION ON DISPLAY

The errors shown on the display, other errors or malfunctions are described in chapter no. 40. 1020, 1021, 1022, 1023, 1024, 1025, 1019, 1054, 1055 37.2 MALFUNCTIONS WITH ERROR INDICATION ON DISPLAY

37.2.1 The display turns on and the caption THE SERIAL CONNECTION IS MISSING appears CORRECTIVE ACTION Check that : The connecting cable from the CPU AP7 to the display AP17 is correctly connected. The connection cable between the CPU AP7 and the display AP17 does not have a wire with defective insulation due to rubbing against sharpedged passages. The CPU board AP7 or the board AP17 are not faulty. If so, replace them. When turning on the machine, the following errors may be displayed. The corrective actions relevant to each error are described in chapter no. 40. For more information refer to the chapters of the various machine components.

00, 01, 03, 05, 24, 60, 61, 62, 63, 64, 65, 66, 67, 84, 90,

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38. SELFTEST
38.1 DESCRIPTION The codes for the errors which may occur on the machine are described in the various chapters, divided by argument. The relative causes for these errors, as well as the solutions, are described in chapter 40. These errors appear on the displays on the command and control panel. More details about the single errors are reported in the various chapters of this manual concerning the relevant single machine parts.

39. MALFUNCTIONS DURING THE WRAPPING OPERATIONS


39.1 DESCRIPTON

Below some of the possible problems that may occur during the product wrapping operations are listed. 39.2 ERRORS AND MALFUNCTIONS

The errors shown on the display, other errors or malfunctions are described in chapter no. 40. 1000, 1003, 1004, 1013, 1048, 1051, 1052, 1053

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40. DIAGNOSTICS
40.1 INCIDENTAL ERRORS (NOT LINKED TO THE MOVEMENTS)

Code

DESCRIPTION

CAUSE FOR ALARM SITUATION THESE ALARMS ARE SIGNALED EITHER WHEN A COVER IS OPENED OR WHEN A STOP BUTTON IS PRESSED DURING OPERATION, or WHEN THE START BUTTON IS PRESSED WHILE A COVER IS OPEN OR A STOP BUTTON IS PRESSED.

01 03 60 61 62 63 64 65 67 05 19

STOP BUTTON ALARM

STOP BUTTON ALARM

COVER ALARM

COVER ALARM

COVER ALARM

COVER ALARM

COVER ALARM

COVER ALARM

COVER ALARM WHAT WAS STATED ABOVE IS VALID FOR THIS ALARM. WARNING: THIS ALARM E05 A STOP BUTTON IS SIGNAL MAY ALSO MEAN: 1) ABSENCE OF PRESSED OR A 27 VDC VOLTAGE THAT FEEDS THE CARTER IS OPEN OR A MAGNETS 2) ANY ONE OF THE GUARD CONTACT IS FAULTY MICRO SWITCH CONTACTS OR THE STOP BUTTONS IS FAULTY E19 SPEED TO HIGH WITH RESPECT TO THE SPEED ALLOWED THE ALARM SIGNAL OCCURS WHEN THE PROGRAMME OR OPERATOR SETS A SPEED THAT IS TOO HIGH WITH RESPECT TO THE INSTALLED ELEVATOR ( 50

Page 100 of 168

Code

DESCRIPTION

CAUSE FOR ALARM SITUATION


CYCLES/MIN FOR TYPE A AND 44 CYCLES FOR TYPE PIZZA 280 mm)

51 52

E51 CARRIAGE AND ELEVATOR EXTRA STROKE IS NON SET CORRECTLY

THE ALARM SIGNAL OCCURS WHEN IT IS DETECTED THAT SW6 AND SW4 or SW7 (or PROGRAMME WITH 'ELEVATOR TYPE = 3) ARE ACTIVATED AT THE SAME TIME) THE ALARM OCCURS WHEN A CARRIAGE POSITION TOO NARROW WITH RESPECT TO THE INSTALLED ELEVATOR IS DETECTED (TYPE A: LESS THAN 7 FOR MACHINES UP TO SERIES 15 (n. 150 included) AND LESS THAN 10 FOR MACHINES FROM SERIES 16 ON (no. 151 included) - TYPE PIZZA 280 mm: LESS THAN 14)

E52 THE CARRIAGE OPENING IS TOO SMALL FOR THE ELEVATOR TYPE A

53

THE ALARM OCCURS WHEN, IN PRESENCE OF THE AUTOMATIC CARRIAGE, A PROGRAMME IS LOADED THAT HAS A E53 THIS PROGRAMME CARRIAGE POSITION TOO NARROW WITH RESPECT TO THE INSTALLED ELEVATOR CANNOT BE USED AS THE CARRIAGE IS TOO (TYPE A: LESS THAN 7 FOR MACHINES UP TO SERIES 15 (no. 150 included) AND LESS NARROW THAN 10 FOR MACHINES FROM SERIES 16 (no. 151 included) - TYPE PIZZA 280 mm: LESS THAN 14)

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OTHER ALARMS

Code

DESCRIPTION

CAUSE FOR ALARM SITUATION

07

THE ALARM OCCURS WHEN THE CPU RESETS WITHOUT TURNING OFF THE MACHINE NOTE: THIS ALARM CAN ALSO BE CAUSED BY ELECTROSTATIC DISCHARGES DUE TO E07 THE MACHINE CPU HAS ELECTRICALLY CHARGED FILM RESET AND/OR TO PARTICULARLY DRY ENVIRONMENTS, OR BY A PRESENCE OF CHARGES ON THE ELECTRICAL LINE THAT ARE SOURCES OF DISTURBANCES (e.g. INVERTER) ALARM WHEN THE DATA RELATING TO THE PROGRAMMED PACKAGES AND E18 THE PROGRAMMED VARIABLES CONTAINED IN THE DATA IN THE BATTERYPOWERED RAM HAVE BEEN RAM ARE DETECTED AS LOST CORRUPT - IN THIS CASE THE DEFAULT VALUES ARE RELOADED

18

40.2

ERRORS CAUSES SOLUTIONS

An extensive list of possible causes and relative solutions to all known errors that may be revealed on the machine is given below. The way they are structured and described reflects the same form used for the PCPocket.

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ADDED ERRORS
ERROR 20 bis 22 bis DESCRIPTION Hybrid IB2 faulty, hybrid replaced Electrical connections faulty, connections restored Electrical board connections faulty, connections restored Inverter AP 4 faulty, inverter replaced

1026 bis Hybrid IB2 faulty, hybrid replaced The thermal pad of the motor M2 is faulty or its connection has been interrupted. Check the connection continuity. 11 bis Hybrid IB2 faulty, hybrid replaced The thermal pad of the motor M1 is faulty or its connection has been interrupted. Check the connection continuity. Hybrid IB2 faulty, hybrid replaced The thermal pellet of the motor M1 is faulty or its connection has been interrupted. Check the connection continuity. The motor M1 is faulty, motor replaced Inverter AP 3 faulty, inverter replaced 42 bis The bushing sliding on the screw is defective, bushing replaced.

15 bis

1042 bis Tearing brake YB1 faulty, brake replaced Tearing brake YB1 deregulated, brake adjusted 30 bis The bushing sliding on the screw is defective, bushing replaced.

1038 bis Hybrid IB0 faulty, hybrid replaced 05 bis Fuses FU 13 and FU 14 are broken, fuses replaced Rectifier bridge V1 faulty, bridge replaced

1006 bis The potentiometer for the brilliance adjustment is deregulated, potentiometer adjusted The potentiometer for the brilliance adjustment is faulty potentiometer replaced Fuses FU 15 and FU 16 are broken, fuses replaced 1100bis Electrical connections faulty, connections restored Fuses FU 10, FU 21 and FU 22 are broken, fuses replaced Remote control switch K 9 faulty, remote control switch replaced Motor M 10 faulty, motor replaced Hybrid IB2 faulty, hybrid replaced Output interface board AP5 faulty, board replaced Input interface board AP6 faulty, board replaced CPU board AP7 faulty, board replaced

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40.3

MACHINE PARAMETERS

This screen is available during both the movement and emergency stages. It is displayed in the following way: Press the ENTER key from the main Monitor screen After the screen displays the Information screen, press the ENTER key again

The screen presents information relating to the machines operation that can be useful for having additional indications about the machines operation. The parameters list follows. * Sealing plate temperature [degrees]: Temperature value read by the probe located under the sealing plate. [APPENDAGES WARNING] * Temperature set value: Value set in the wrapping programme. The table given below is valid.
1= 78C=172F 5= 90C=194F 9=102C=216F 13=114C=237F 17=126C=259F 21=138C=280F 25=150C=302F 29=162C=324F 33=174C=345F 37=186C=367F 2= 81C=178F 6= 93C=199F 10=105C=221F 14=117C=243F 18=129C=264F 22=141C=286F 26=153C=307F 30=165C=329F 34=177C=351F 38=189C=372F 3= 84C=183F 7= 96C=205F 11=108C=226F 15=120C=248F 19=132C=270F 23=144C=291F 27=156C=313F 31=168C=334F 35=180C=356F 39=192C=378F 4= 87C=189F 8= 99C=210F 12=111C=232F 16=123C=253F 20=135C=275F 24=147C=297F 28=159C=318F 32=171C=340F 36=183C=361F 40=195C=383F

NOTE 1: It is to be kept in mind that under normal conditions the temperature displayed stays at about + / - 3C with respect to the set temperature. The following WARNINGS are tied to the temperature control: 90, 91, 92, 93, 94 (see chapter 40.1)

* Set speed [cycles/min]: Speed set in the wrapping programme. * MAIN speed (+2/-2)[cycles/min]: Speed of the main motor in cycles/min. (NOTE: the value is 0.0 when the machine is in emergency)

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* INFEED speed (+2/-2)[cycles/min]: Speed of the infeed motor in cycles/min. (NOTE: the value is 0.0 when the machine is in emergency) * CARRIAGE real position: Real position of the carriage (obtained from the 4 carriage sensors) * CARRIAGE programmed position: Carriage position set in the wrapping programme (NOTE: the 0 value corresponds to a programme that cannot be viewed by the operator! - refer to the technical manual). * INFEED behaviour (+14/-14) [MAIN pulses]: Value that indicates by how much the infeed clutch engagement/disengagement characteristics differ (and also those of the synchronism with the main motor) in comparison with the theoretical values. The 0 value indicates an ideal behaviour. The more the value moves away from 0 the greater the deviation between the ideal behaviour and the actual behaviour on the machine is. With values higher than the limits indicated, you must carefully check: - infeed clutch - infeed sensor - infeed inverter - selective infeed transmissions The following WARNINGS are tied to this parameter: 22 (see chapter 40.1) * BELT CARRIAGE photocell distance: Value measured on the basis of the carriages opening. * CLUTCH TRUING (slipping max 20) [MAIN pulses]: This value indicates the number of pulses of the main sensor that are measured by the truing start command upon the first switching of the unwinding sensor. * BRAKE TRUING (inertia max 10) [UNWINDING pulses]: This value indicates the number of pulses of the unwinding sensor that are measured by the truing stop command when the truing actually stops. * CLUTCH CAM (slipping max 20) [MAIN pulses]: This value indicates the number of pulses of the main sensor that are measured by the cam start command upon the first switching of the cam pulses sensor. * BRAKE CAM (inertia max 4) [CAM pulses]: This value indicates the number of pulses of the cam pulses sensor that are measured by the cam stop command when the cam actually stops.

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* CAM STOP (172..176): This value indicates the stop coordinate of the cam. The value must be within the limits indicated. If it is not, check the cam brake and clutch and, if necessary, the mechanical phasing of the cam.

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40.4

MACHINE PROGRAMMING

Below you will find a list of the operations that can be performed on the machine through the Monitor. Moreover, you can find the description of the parameters of the wrapping programme and the variables (the same information is also found in the Monitors HELP). Refer to the Monitors HELP for anything you do not find here (e.g. description of the functions). 40.4.1 TECHNICAL MENU "Test", "Functions", "Variables", "Programmed packages" A B C D

A. MAIN TEST MENU "200= Key, sensor, micro test ", "300= Single photocell test ", "500= Exit test ", "600= Movement test ", "700= Various tests " A.1 INPUT TEST SUBMENU "201- Product exit photocell " "202- Printed film photocell " "203- Knife sensor " "204- Machine STOP button" "205- Elastic rod micro " "206- Infeed stop selector " "207- Infeed pulse sensor " 208- ALARM from main freq. conv. 209- Main sensor "210- Cam pulse sensor " "211- Cam position sensor " "212- Unwinding sensor " 213- Film presence sensor "214- Upper ejector position sensor " "215- Film length pulse sensor " A.1 A.2 A.3 A.4 A.5

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"217- Carriage sensor 1 " "218- Carriage sensor 2" "219- Carriage sensor 3" "220- Carriage sensor 4" "221- Film tightening device sensor " "222- Film length position sensor " "223- Customer belt photocell " 224- ALARM from infeed freq. conv. "225- Left upper cover micro " "226- Right upper cover micro " "227- Elevator door micro " 228- Film insertion door microswitch "229- STOP button on the infeed " "230- Lower door micro " "231- Lower infeed cover micro" 232- Infeed dome microswitch 233- Safety circuit signal 234- Optional 1 input "235- Optional 2 input " "236- Optional 3 input " A.2 INDIVIDUAL PHOTOCELL TEST SUBMENU 301- Prohibited photocells "302- All the photocells of the machine " 303- Belt infeed photocell 01 (d) "304- Belt infeed photocell 02 (d) "305- Belt infeed photocell 03 (d) "306- Belt infeed photocell 04 (d) "307- Belt infeed photocell 05 (d) "308- Belt infeed photocell 06 (d) "309- Belt infeed photocell 07 (d) "310- Belt infeed photocell 08 (d) "311- Belt infeed photocell 09 (d) "312- Belt infeed photocell 10 (d) "313- Belt infeed photocell 11 (d) "314- Belt infeed photocell 12 (d) "315- Belt infeed photocell 13 (d) "316- Belt infeed photocell 14 (d) " " " " " " " " " " " " " " " " " " "

"321- Carriage infeed photocell 01 (d) "322- Carriage infeed photocell 02 (d) "323- Carriage infeed photocell 03 (d) "324- Carriage infeed photocell 04 (d) "325- Carriage infeed photocell 05 (d) "326- Carriage infeed photocell 06 (d)

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"327- Carriage infeed photocell 07 (d) "329- Carriage infeed photocell 09 (d) "330- Carriage infeed photocell 10 (d) "331- Carriage infeed photocell 11 (d) "332- Carriage infeed photocell 12 (d) "333- Carriage infeed photocell 13 (d) "334- Carriage infeed photocell 14 (d) "338- Film stop photocell 01 "339- Film stop photocell 02 "340- Film stop photocell 03 "341- Film stop photocell 04 (r) (r) (r) (r) " " " "

" " " " " " "

A.3 OUTPUT TEST SUBMENU 501- Unwinding tightness clutch "502- Tearing brake " "503- Tearing clutch " "504- CENTRING brake " "505- CENTRING clutch " "506- Brake reel 1 " "507- Brake reel 2 " "508- Sealing plate resistor relay " "509- Folder clamp magnet " "510- Ejector clamp magnet " "511- Side stretch device magnet " "512- Sealing plate motor command " "513- Cam brake " "514- Cam clutch " "515- Infeed clutch " "516- Customer infeed relay " 517- Infeed inverter command 518- Infeed inverter back 519- Main inverter command 520- Knife/film selection switch "521- Upper ejector brake " "522- Upper ejector/carriage selection switch " 523- Opt. motorized discharge motor command

A.4 MOVEMENT TEST SUBMENU 699- Repetitive test set-up "601- Infeed movement 25 cycles" "602- Infeed movement 35 cycles "

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"603- Infeed movement 40 cycles " "604- Infeed movement 45 cycles " "605- Infeed movement 50 cycles " "606- Infeed movement 55 cycles " "607- Cam movement 25 cycles " "608- Cam movement 35 cycles " "609- Cam movement 40 cycles " "610- Cam movement 45 cycles " "611- Cam movement 50 cycles " "612- Cam movement 55 cycles " "613- Unwinding movement 25 cycles " "614- Unwinding movement 35 cycles " "615- Unwinding movement 40 cycles " "616- Unwinding movement 45 cycles " "617- Unwinding movement 50 cycles " "618- Unwinding movement 55 cycles " "619- Upper ejector movement " "620- Knife movement" "621- Film roll movement " "622- Main motor movement 25 cycles " "623- Main motor movement 35 cycles " "624- Main motor movement 40 cycles " "625- Main motor movement 45 cycles " "626- Main motor movement 50 cycles " "627- Main motor movement 55 cycles " "628- Carriage movement " 629- Infeed back A.5 MISC. TEST SUBMENU 701- BATT.-RAM zero setting 702- Daily packages zero setting 703- Error statistics zero setting 704- Bank switch SW1 display 705- Battery-powered ram test 706- Maintenance packages zero setting 707- Prod. exit photocell time measurement 708- Safety microswitch disabling B. FUNCTIONS MENU "101= Display statistic data", "102= Change no. of the machine ", "103= Change no. of wrapped packages ", "104= CPU reset of the macchine", "105= Activate operation in step cycle ",

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"106= Activate operation in continuous cycle ", "107= Change no. of daily packages ", "108= Change service packages ", "109= Activate operation in continuous cycle with stop ", "110= Packages change during the continuous cycle ", 111= Reset film in machine, 112= Enable cycle w/o carriage photocell control, 113= Saving programmes, 114= Reinstating programmes, 115= Display sliding/inertia C. VARIABLES MENU 120= Film roller extra tension, "121= Timing for machine STOP ", "122= Timing for CUSTOMER belt ", 123= OPTIONAL 1 INPUT enabling, 124= OPTIONAL 2 INPUT enabling, 125= OPTIONAL 3 INPUT enabling, "126= ELEVATOR/FOLDER stroke type" 127= Hide fixed programmes, 128= Discharge stop time correction D. PACKAGE MENU " " " " " " " " " " " " " " " " " " Wrapping speed (cycles/min.) [25,35-55] : ", Film length (cm.) [35-70,135-170] : ", Folder clamp opening (pulses CA/2)[0-20] : ", Ejector clamp opening (pulses CA/2)[0-20] : ", Side stretch device opening (pulses CA/2)[0-20] : ", Package rectifier (pulses P) [0-20-40] : ", Upper ejector height (mm) [27-200] : ", Upper ejector brake release (0.01 sec.) [0-30] : ", Carriage opening [0,1-16] : ", Elevator type [1-3] : ", Number of film stop emergencies per stop [1-5]: ", Time for obscured product exit photocell (tenths of sec.) [0-50]: ", Tearing adjustment (pulses SV)[0-5-10] : ", CENTRING adjustment (pulses SV)[0-5-10] : ", Printed film tolerance (pulses SV)[0,1-6] : ", Use of low photocells (for e. salad) [0-8] : ", Blind transparent tray window (mm) [0,10-200]: ", Sealing plate temperature [0-40] : "

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40.4.2 PACKAGE PARAMETER DESCRIPTION WRAPPING SPEED interval: 25,35-55 ; unit: cycles/min. NOTE: 26 to 34 = 35, for elevator A max 50 FILM LENGTH interval: 35-70 STD,135-170 PRINTED ; unit: cm. NOTE: 71 until 134 forced to the old value FOLDER CLAMP OPENING interval: 0-24 ; unit: cam pulses /2 NOTE: 0 = disabled EXIT CLAMP OPENING interval: 0-20 ; unit: cam pulses /2 NOTE: 0 = disabled SIDE CAMPS OPENING interval: 0-24 ; unit: cam pulses /2 NOTE: 0 = disabled PACKAGE STRAIGHTENING interval: 0-40 ; unit: MAIN pulses (1 pulse=2.6 mm STD,2.9 mm ELEVATOR A,3.2 mm ELEVATOR pizza 280mm) NOTE: default value = 20 WARNING: ELEVATOR TYPE A - TYPE pizza 280 mm => MAX = 32 UPPER EJECTOR HEIGHT interval: 27-200 ; unit: mm (approx. - distance between the rolls and the folder) UPPER EJECTOR BRAKE RELEASE interval: 0-30 ; unit: 1=10 msec. from the ejector advance NOTE: 0 = disabled CARRIAGE POSITION interval: 1-16 ; 1=completely closed, 16= completely opened NOTE: minimum value for ELEVATOR A: until series 15: 7, from series 16: 10 minimum value for ELEVATOR PIZZA 280 mm : 14 WARNING: value 0 = programme can not be selected by the operator ! (to activate, turn off and turn back on the machine) ELEVATOR TYPE interval: 1-3 VALID ONLY IF SW 4 = OFF !! if = 3 the programme operates with ELEVATOR type A even with SW4 = OFF

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if = 1,2 the programme operates with ELEVATOR type E-E1 NO. OF FILM STOP EMERGENCIES PER STOP interval: 1-5 TIMING FOR OBSCURED PRODUCT EXIT PHOTOCELL interval: 0-50 ; unit: tenths of a sec. NOTE: 0 = disabled. Use test no.707 to find the correct value TEARING ADJUSTMENT interval: 0-5-10 ; unit: UNWINDING pulses (1=about 9.5 mm film) NOTE: central value = 5 CENTRING ADJUSTMENT interval: 0-5-10 ; unit: UNWINDING pulses (1=about 9.5 mm film) NOTE: central value = 5 PRINTED FILM TOLERANCE interval: 0-6 ; unit: UNWINDING pulses (1=about 9.5 mm film) NOTE: 0= disabled, DEFAULT= 5 for e.: if l. film =155 and tolerance =3, the valid signals are between 52 and 58 cm. USE OF THE LOW PHOTOCELLS interval: 0-8 NOTE: 0= disabled 1= ENABLED up to 20 mm, 2= ENABLED up to 35 mm 3= ENABLED up to 45 mm, 4= ENABLED up to 65 mm All other rays are DISABLED 5= DISABLED up to 20 mm, 6= DISABLED up to 35 mm 7= DISABLED up to 45 mm, 8= DISABLED up to 65 mm All other rays are ENABLED BLIND WINDOW FOR TRANSPARENT TRAYS interval: 0,10-200 ; unit: mm NOTE: 0= disabled, 1-9 are forced to 10 CAUTION: the window starts at 30 mm from the start of the package!

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SEALING PLATE TEMPERATURE interval: 0-40 ; unit: see below NOTE: 0=off 1=78 C so the temperature increases 3C per unit (e.g. 21 = 138C)
1= 78C=172F 5= 90C=194F 9=102C=216F 13=114C=237F 17=126C=259F 21=138C=280F 25=150C=302F 29=162C=324F 33=174C=345F 37=186C=367F 2= 81C=178F 6= 93C=199F 10=105C=221F 14=117C=243F 18=129C=264F 22=141C=286F 26=153C=307F 30=165C=329F 34=177C=351F 38=189C=372F 3= 84C=183F 7= 96C=205F 11=108C=226F 15=120C=248F 19=132C=270F 23=144C=291F 27=156C=313F 31=168C=334F 35=180C=356F 39=192C=378F 4= 87C=189F 8= 99C=210F 12=111C=232F 16=123C=253F 20=135C=275F 24=147C=297F 28=159C=318F 32=171C=340F 36=183C=361F 40=195C=383F

40.4.3

DESCRIPTION OF VARIABLES

120 FILM LENGTH ROLLER EXTRA TENSION DESCRIPTON Modifies the extra stroke section of the film length roller in order to not keep the film stretched too much STANDARD VALUE : 10 UNIT OF MEASUREMENT Millimetres EXAMPLE If you want to have an extra stroke of 10 mm (i.e. the roller descends 10 mm more than the position set for the film length) 121 TIME FOR UNFED MACHINE STOP DESCRIPTION Time that must go by (without ever having wrapped a tray) before the machine stops by itself (ENERGY SAVING) STANDARD VALUE : 0 UNIT OF MEASUREMENT Minutes EXAMPLE

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If you enter 0, the machine even if it is not fed never stops If you enter 4, it stops 4 minutes after the machine is in operation without receiving any trays 122 TIME FOR THE CUSTOMER BELT DESCRIPTION Time that must elapse from when the infeed clutch disengages before opening the running contact of the customers external belt STANDARD VALUE: 0 UNIT OF MEASUREMENT Tenths of a second EXAMPLE If you enter 0, the running contact of the customers belt is not managed If you enter 1, the running contact of the customers belt opens as soon as the infeed clutch disengages If you enter 20, the running contact of the customers belt opens 2 sec after the infeed clutch has disengaged NOTE 1: in the case the CUSTOMER photocell is present, the customers belt stops only if the relative photocell is engaged NOTE 2: once open, the running contact of the customers belt closes as soon as the infeed clutch reengages 123, 124, 125 OPTIONALS 1, 2, 3 INPUT MANAGEMENT DESCRIPTION Enables control on the relative input VALUE 0 = control disabled (DEFAULT) VALUE 1 = when the input is ON, the infeed is stopped (operation similar to product exit photocell) VALUE 2 = when the input goes to ON, an EMERGENCY is generated VALUE 3 = when the input goes to OFF, an EMERGENCY is generated 126 - ELEVATOR TYPE AND FOLDER STROKES DESCRIPTION Allows you to set the type of elevator and strokes installed on the machine VALUE 1 = elevator and stroke EUROPA (DEFAULT) VALUE 2 = elevator and stroke EUROPA 1

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VALUE 3 = elevator and stroke A NOTE: when SWITCH 4 cuts in (ELEVATOR type A), the value is forced to 3 by the machine 127 HIDE FIXED PROGRAMMES DESCRIPTION Allows programmes 30 to 99 to not be displayed in the operators selection of the programmes (to activate turn off and turn back on the machine) STANDARD VALUE : 0 EXAMPLE Programmes 30-99 are displayed if you enter 0. Programmes 30-99 are NOT displayed if you enter 1. 128 DISCHARGE STOP DELAY CORRECTION DESCRIPTION Time that is added to (or subtracted from) the fixed delay from the moment PROD. EXIT PHOTOCELL or OPT. 1,2,3 INPUT is on ON to the actual stop of the optional motorized discharge STANDARD VALUE : 20 UNIT OF MEASUREMENT Tenths of a second EXAMPLE Fixed delay: if the speed is less than 40 cycles/min: 9 sec otherwise: 7 sec The correction value ranges from 0 to 100 with the central value being 20 The delay remains the fixed time if you enter 20 The delay is the fixed time minus 1.5 sec if you enter 5 The delay is the fixed time plus 2.4 sec if you enter 44

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PART 2 OPTIONAL DEVICES FOR MACCHINE 55 Pi MODEL 1.


1.1

PRODUCT EXIT CONTROL PHOTOCELL (OPTIONAL C.220.021)


DESCRIPTION

The product exit photocell is an essential extra when an automatic weighing system is mounted after the machine, or when it is equipped with product conveyor systems which could stop, not allowing the machine to eject the wrapped product. For installation of this optional device request the drawing : D.222.D.01. For the electrical connection see diagram : E.222.D.100 1.2 OPERATION

PARAMETERS / VARIABLES INVOLVED: - Package parameter "Timing for the obscured product exit photocell ", (see chapter 40.4.2) Operation of this photocell is described in the flow chart represented here below. Remember that since this photocells intervention time must be programmed in each wrapping programme, this time must be determined with test no. 707 (VARIOUS TEST menu). The reading made must be increased by 1 or 2 units.

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The flow chart representing operation of the product exit photocell is shown here below

PRODUCT EXIT PTC - 1

NO

The relative package parameter is other than 0 [see chapter Programmed packages] ? YES

NO

Is the machine in cycle ? YES

NO

Prod. Exit PTC on ON (1 OBSCURED) for a longer time than programmed? YES WARNING 99

Start tally for stopping optional discharge

Is there a tray on the infeed PTC? NO Taly expired for stopping optional discharge [ see Variables description] ? NO

YES

INFEED clutch : on OFF (0)

YES

OPTIONAL discharge output on OFF (0)

NO

Product exit PTC on OFF (0 -FREE) ? YES OPTIONAL discharge output on ON (1)

INFEED clutch: on ON (1)

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A description of the errors reported by the display and linked to the topic follows.

Code

DESCRIPTION

CAUSE ALARM SITUATION

90

1. TURNING ON THE MACHINE: IF THE PRODUCT EXIT PHOTOCELL IS OBSCURED E90 PRODUCT EXIT 2. START: IF THE PRODUCT EXIT PHOTOCELL OBSCURED AT PHOTOCELL IS OBSCURED STARTING NOTE: AFTER 10 START COMMANDS, THE ALARM IS DISENGAGED

1.3

MALFUNCTIONS

In addition to the description seen above, another list of ERRORS possible CAUSES possible SOLUTIONS is presented in chapter no. 40. E90

2.
2.1

SIDE STRETCH DEVICE (OPTIONAL C.220.047 AND C.220.047.1)


DESCRIPTION

The side stretch device is an essential extra if the products to be wrapped are irregular in shape, and/or in cases of critical surrounding environment conditions, and/or when special film is being used. This optional is available in two different versions: C.220.047 for machines equipped with elevator E or E1 and prearranged for strokes E, E1 (max. tray width 320 mm)

C.220.047.1 for machines equipped with elevator A and prearranged for stroke A (max. tray width 407 mm) Both the clamp supports and the counterclamps are adjustable in length with optional C.220.047. This particular device offers flexibility and ease of adaptation to the type of product to be wrapped.

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The machine is already prepared, both mechanically and electrically, for installation of this device. For installation of the optional device C.220.047 request the drawing : D.222.H.01, while for optional C.220.047.1 request the drawing D.222.H.02. For the electrical connection see diagram : E.222.H.100. These clamps are controlled by an electromagnet (YA3) that through a lever rotates a shaft, on which the arms supporting the clamps are mounted. The minimum length of film to be used with the side stretch device is about 400 mm with optional C.220.047 and 500 mm with optional C.220.047.1. PARAMETERS / VARIABLES INVOLVED: - Package parameter "Side stretch device opening ", (see chapter 40.4.2) 2.2 MALFUNCTIONS

The errors shown on the display, other errors or malfunctions are described in chapter no. 40. 1041

3.
3.1

INTEGRATION FOR ELEVATOR TYPE A (OPTIONAL C.220.101 AND C.220.101.1)


DESCRIPTION

When the 55 Pi machine is equipped with this optional, it can wrap products up to the dimension of200 x 407 mm and 260x360 mm. To enable the machine to accept products having these dimensions, switch no. 4 of DS1 on board CPU AP7 must be positioned on ON and test no. 126 of the Variables Menu has to be correctly selected. See HELP. When the machine has selected switch no. 4 of DS1 on ON, its maximum productivity is 50 packages per minute. A 50 package per minute productivity is also obtained if switch no. 4 of DS1 is on OFF, but the selected elevator type in the programmed package is no. 3. For proper operation of the machine with this optional, it is necessary to programme a carriage position of no less than 7 up to machine no. 159 in the

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wrapping cycles, whereas the minimum programming of the carriage must be 10 from machine no. 160. NOTE: Always programme the correct machine number in order to allow it to be used trouble-free. When wrapping large products, it is advisable to use the lower wrapping speed in order to obtain the best wrapping results. PARAMETERS / VARIABLES INVOLVED : - Package parameter "Elevator type " (see chapter 40.4.2) - Variable no. 126 "ELEVATOR/FOLDER stroke type " (see chapter 40.4.3) - Switch 4 of switch bank DS1 (see above) 3.2 MALFUNCTIONS

The errors shown on the display, other errors or malfunctions are described in chapter no. 40. E19 NOTE: for proper operation of this optional, it is essential that the machine number set on the monitor (function no. 102) be the same as that shown on the name plate.

4.
4.1

PRINTED FILM CENTRING PHOTOCELL (OPTIONAL C.215.031)


DESCRIPTION

The printed film photocell is an optional device which can be installed on the machine to enable the wrapping of products with non-continuous, pre-printed film. The film can be automatically centred by design or marking on the product, without any adjustment to the machine. This optional can be used both with the standard reel and with the optional support for second reel C.220.042 on the 55 Pi. For installation of the optional device request the drawing: D.222.F.01 For the electrical connection see diagram: E.222.F.100.

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4.2

PRINTED FILM CHARACTERISTICS

Printing of the film with the markings/design of the customer and the relevant reference marks, should be done as shown in the enclosed drawing 9. The reel width W and the distance L between the reference marks should be such as to allow a proper wrapping of the product/tray. The printing should always be on the side of the film to the outside of the rolled reel, as well as to the outside of the wrapped product. 4.3 OPERATION

PARAMETERS / VARIABLES INVOLVED : - Package parameter "Film length " (see chapter 40.4.2) - Package parameter "Printed film tolerance " (see chapter 40.4.2) The wrapping of various products with printed film is carried out with the following procedure: Position the reel on carrier shaft 1 or 2, according to the reel placement plate. Position the reel in such a way that the photocell will read the reference marks on the printed film. If necessary, it is possible to adjust the horizontal position of the photocell. Insert the film into the machine, positioning it so that one of the reference marks is in the centre of the knife slot. Programme a length of film preceded by a 1 corresponding to the distance between the two reference markers in the wrapping cycle when the film is kept taut by the dandy roll. For example, type in 150 for a 50-cm length. Check that during unwinding, the perforation is always carried out near the reference mark. Should the reference mark tend to shift away from the cutting point, you can correct the films stopping on the knife in every wrapping programme with the parameter TOLERANCE FOR PRINTED FILM. See the programmed packages HELP. Every adjustment unit corresponds to about 9 mm of film advancing. 4.4 ERRORS AND MALFUNCTIONS

The errors shown on the display, other errors or malfunctions are described in chapter no. 40. E91, E92

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Lato stampa Printing side Druckseite Cote d impression Lado impreso

20

70 30

+1 /2B

=
L

Fig. 9

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5.

INFEED EXTENSION L=1 m (OPTIONAL C.220.005, C.220.005.1 and C.220.040) INFEED EXTENSION L=2m (OPTIONAL C.220.003, C.220.003.1 and C.220.040.1)

Since these extensions are none other than the extension of the machines standard infeed, refer to chapter 2, STANDARD INFEED UNIT, for information about their operation.

6.

IN-LINE OUTLET CONVEYOR (OPTIONAL C.220.009 L=850mm) (OPTIONAL C.220.009.1 L=1270mm)


DESCRIPTION

6.1

This outlet conveyor consists in loose rollers and can be connected after the sealing plate. For installation request the drawing: D.222.G.02

7.

MOTORIZED OUTLET CONVEYOR (OPTIONAL C.220.010 90 RIGHT) (OPTIONAL C.220.011 90 LEFT) (OPPIONAL C.220.012 180 RIGHT) (OPTIONAL C.220.013 180 LEFT)
DESCRIPTION

7.1

These optionals make evacuation of the wrapped trays/products easier by diverting them to the right or left of the machine and into the area of the plant the customer wants. For installation of the optional devices request drawing D.222.U.01 for optional C.220.010 and C.220.011, drawing D.222.U.02 for optional C.220.012, and drawing D.222.U.03 for optional C.220.013. The electrical connections, the same for all discharge types, are shown on wiring diagrams E.222.U.100a and E.222.U.100b. 7.2 OPERATION

PARAMETERS / VARIABLES INVOLVED:

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- Variable no. 128 "Timing adjustment for stopping discharge " (see chapter 40.4.3) Discharge starts following a START signal sent to the machine. It stops after: the STOP button on the display is pressed one of the machines moveable guards is opened the STOP button (emergency stop) is pressed the product outlet photocell is obscured for a length of time greater than is programmed in the wrapping cycle plus the time set in variable no. 128. 7.3 ERRORS AND MALFUNCTIONS

The errors shown on the display, other errors or malfunctions are described in chapter no. 40. NOTE. The XXXXbis errors are found at the end of the errors chapter. The errors concerned by this movement are : 1100bis

8.
8.1

AUTOMATIC CARRIAGE MOVEMENT (OPTIONAL C.220.026)


DESCRIPTION

The 55 Pi is equipped with an automatic carriage positioning system so that it can utilize and fully make use of all film lengths ranging from 280 to 550 mm. To activate the automatic carriage movement management, switch no. 5 of DS 1 on the board CPU AP7, must be put on the ON position. The carriage has 16 different positions that differ from each other by 7.5 mm. These positions are obtained with the combination of the signals of the four sensors SQ2, SQ3, SQ4 and SQ5, and the movement is given by a stepping motor M7 managed by the boards AP6 and AP8. The desired carriage position must be programmed in the relative wrapping cycle. The carriage places itself in the programmed position when each programme is selected. Depending on the type of elevator present on the machine (switch no. 4 of DS1 on AP7), the carriage assumes the following minimum positions in closing: Elevator type E or E1 (switch no. 4 on OFF): minimum position 1.

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Elevator type A (optional C.220.101 or C.220.101.1) (switch no. 4 on ON): minimum position 7 up to machine no. 159, position no. 10 from machine no. 160 and up. As regards what is illustrated above, it is of primary importance that you always enter the correct machine number with test no. 102 of the FUNCTIONS menu. In the event the optional C.220.102 is installed on the machine, the entire sensor unit must be moved towards the centre of the machine so that a 280mm-wide film can be used. The bored holes for these shifts are already present on the standard machine. Operation of the automatic carriage is described in the flow chart shown here below:

A description of the errors reported by the display and linked to the topic follows.

Code

DESCRIPTION

CAUSE ALARM SITUATION

54 55

ALARM IF, WITH AUTOMATIC CARRIAGE, AN INCORRECT SENSOR CONFIGURATION IS DETECTED DURING A E54 ONE OR MORE MOVEMENT (e.g. STARTING CARRIAGE SENSORS DOES NOT OPERATE CORRECTLY FROM POSITION 4 AND FINDING A CONFIGURATION CORRESPONDING TO 10 INSTEAD OF TO 3 OR 5 ) [See config. carriage sensors]
E55 AUTOMATIC CARRIAGE MOVEMENT IN ERROR

See AUTOMATIC CARRIAGE flow - PAGE 2

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The functions of these inputs are described in the flow chart described hereunder:

AUTOMATIC CARRIAGE - 1

YES

Is a REPHASING in progress ? NO

Has the programme been changed or has the current programme been modified ? YES

NO

Is the current CARRIAGE position different than that programmed ? YES

NO

Calculation, based on the CURRENT and on PROGRAMMED positions, of the direction and maximum displacement to carry out

CARRIAGE movement in the suitable direction

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NO Is the CURRENT POSITION equal to the PROGRAMMED position (see sensors table) ? YES Has the maximum possible displacement been reached ?

YES

It stops the CARRIAGE movement

ERROR 55

END

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A short list of constants / parameters linked to the topic follows. DESCRIPTION


Stepping motor speed

VALUE
500

UNIT
rpm

NOTE

Mechanical transmission

1.35

mm displacem./ motor rev.

For installation of the optional device request the drawing: D.222.E.01 For the electrical connection see diagram : E.222.E.100. PARAMETERS / VARIABLES INVOLVED : - Package parameter "Carriage opening ", (see chapter 40.4.2) - Switch 5 of switch bank DS1 (see above) 8.2 ERRORS AND MALFUNCTIONS In addition to the description seen above, another list of ERRORS possible CAUSES possible SOLUTIONS is presented in chapter no. 40. E51, E52, E53, E54, E55

9.
9.1

CUSTOMER BELT CONTROL PHOTOCELL (OPTIONAL C.220.018)


DESCRIPTION

This photocell is used to manage operation of a customers infeed felt not mechanically connected to the machines infeed. To activate this photocells control function, you must put switch no. 3 of DS 1 on the board CPU AP7 on the ON position. The photocell must be installed at the end of the customers belt (close to the beginning of the infeed of the 55 Pi machine) and its operation is indicated in the flow chart in chapter 35. For installation of the optional device request the drawing: D.222.N.01 For the electrical connection see diagram: E.222.N.100.

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SENSOR 1
0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0

SENSOR 2
0 0 1 1 1 1 0 0 0 0 1 1 1 1 0 0

SENSOR 3
0 0 0 0 1 1 1 1 1 1 1 1 0 0 0 0

SENSOR 4
1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0

Position
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Mod. 55pi - MAN.TEC. - Carro - SENSORI


Page 130 of 168

PARAMETERS / VARIABLES INVOLVED : - Variable no. 122 "Customer belt timing " (see chapter 40.4.3) - Switch 3 of switch bank DS1 (see above) 9.2 ERRORS AND MALFUNCTIONS

Since no error would be displayed on the monitor in the event this photocell malfunctions, test no. 223 should be used to check it.

10. OPTIONAL DEVICE FOR FRAGILE TRAYS (OPTIONAL C.220.029)


10.1 DESCRIPTION

This optional was made to wrap transparent trays or containers having a highly limited consistency (so-called fragile). The machine equipped with this optional can not be fitted out with the side stretch device. (C.220.047 C.220.047.1) The values of the folder and ejector clamps must be programmed with the value 0, whereas the value of the side stretch device, which in this optional move the brush, must be set based on the type of product to be wrapped. The recommended maximum dimensions of the trays/product are the following: length 195 mm x width 125 mm. For installation of the optional device request the drawing: E.222.V.01. For the electrical connection see diagram: E.222.H.100.

11. SUPPORT FOR SECOND REEL (OPTIONAL C.220.042)


11.1 DESCRIPTION

The second reel support was made to allow rapid film changeovers in those cases where products having different dimensions are wrapped, and therefore cannot be wrapped with the same film band. It is available for internal reel diameters of 111 mm and 75 mm. Refer to chapter 4, REEL SUPPORT, for information about its operation since it is analogous.

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For installation request the drawing: E.222.O.01. For the electrical connection see diagram: E.222.O.100. 11.2 ERRORS AND MALFUNCTIONS

The errors shown on the display, other errors or malfunctions are described in chapter no. 40. 1035, 1046,

12. REEL CARRIER FOR PRINTED FILM (OPTIONAL C.220.042.1)


12.1 DESCRIPTION

This optional allows small reels of printed film to be automatically placed on the packages during the packaging operation. The optional support for second reel C.220.042 cannot be installed on machines equipped with this optional. For installation request the drawing: D.222.O.02.

13. OPTIONAL DEVICE FOR PIZZA up to = 280 mm (OPTIONAL C.220.066)


13.1 DESCRIPTION

This optional was made for packaging round products supported by a stiff disk. To activate use of this optional, you must put switch no. 7 of DS 1 on the board CPU AP7 on the ON position. The optional side stretch device C.220.047/047.1 cannot be installed on machines equipped with this optional since the same optional is already integrated as it is considered vital for obtaining the ideal packaging. The maximum diameter of a product that can be wrapped is 280 mm. For installation request the drawing: E.222.Z.05. For the electrical connection see diagram: E.222.H.100. PARAMETERS / VARIABLES INVOLVED : - Switch 7 of switch bank DS1 (see above)

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14. OPTIONAL DEVICE FOR SMALL TRAYS (OPTIONAL C.220.102)


14.1 DESCRIPTION

The optional was made for packaging trays/products having smaller minimum dimensions than those indicated for the standard machine. It also allows a minimum reel band of 280 mm to be used instead of 330 mm, in this way improving the wrapping quality. To activate this function, switch no. 6 of DS 1 on board CPU AP 7 must be put on the ON position. The recommended minimum dimensions of the trays/product are the following : width 100 mm x length120 mm while the maximum dimensions are : width 160 mm x length 280 mm. For installation of the optional device request the drawing : D.220.Z.02 PARAMETERS / VARIABLES INVOLVED : - Switch 6 of switch bank DS1 (see above) NOTE: for proper operation of this optional, it is essential that the machine number set on the monitor (function no. 102) be the same as that shown on the name plate.

15. OPTIONAL DEVICE FOR NARROW AND LONG TRAYS (OPTIONAL C.220.105)
15.1 DESCRIPTION

The optional was made for packaging long and narrow trays/products. It also allows a minimum reel band of 280 mm to be used instead of 330 mm, in this way improving the wrapping quality. To activate this function, switch no. 6 of DS 1 on board CPU AP 7 must be put on the ON position. The recommended minimum dimensions of the trays/product are the following : width 100 mm x length160 mm while the maximum dimensions are : width 140 mm x length 350 mm For installation request the drawing: D.220.Z.01

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PARAMETERS / VARIABLES INVOLVED : - Switch 6 of switch bank DS1 (see above) NOTE: for proper operation of this optional, it is essential that the machine number set on the monitor (function no. 102) be the same as that shown on the name plate.

16. OPTIONAL DEVICE FOR INSERTING TRAYS AT 90 (OPTIONAL C.220.041)


16.1 DESCRIPTION

This optional allows you to connect the standard or optional infeeds with loading systems positioned at 90 with respect to the machines infeeds. The tray guide can be installed to the right or to the left of the optional device, depending on the customers needs. For installation request the drawing: E.220.Z.08

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Mod. 55Pi
0 E00 THE MACHINE IS STOPPED - PRESS START BUTTON TO RESTART 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 3048 Adjustment 6190 Safety micro switch enabled for short time due to vibrations; mechanical position of micro switches adjusted and operator instructed 6352 STOP button activated for short time due to vibrations; connections verified and operator instructed 3061 Utilization 6186 Machine waiting for START; operator instructed 1 E01 STOP BUTTON ON THE MACHINE I PRESSED 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6172 Hybrid IB3 faulty, hybrid replaced 6305 Input interface card AP6 damaged; card replaced 3047 STOP button 6282 STOP button SB1 enabled; STOP button disabled 6280 STOP button SB1 faulty; button replaced 2 E02 THE MACHINE HAS STOPPED DUE TO LACK OF PRODUCTS 3061 Utilization 6008 Machine stop does not happen, if variables n 121 is set to 0 6007 Machine stop due to products missing for a period time equal to the value contained in variables n 121; press START button 3 E03 STOP BUTTON ON THE EXTERNAL INFEED IS PRESSED 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6176 Hybrid IB7 faulty, hybrid replaced 6305 Input interface card AP6 damaged; card replaced 3047 STOP button 6283 STOP button SB2 enabled; STOP button disabled 6281 STOP button SB2 faulty; button replaced 5 E05 A STOP BUTTON IS PRESSED, A COVER IS OPEN OR A CONTACT IS DEFECTIVE 3005 Cover 6021 Cover open, Cover closed 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6305 Input interface card AP6 damaged; card replaced

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6311 Output interface card AP5 damaged; card replaced 3024 Fuses 6163 Fuse FU19 interrupted; fuse replaced 3033 Safety micro switch 6192 Safety micro switch faulty; micro switch replaced 6191 Safety micro switch is touching a cover even if it is closed; micro switch position adjusted 3047 STOP button 6280 STOP button SB1 faulty; button replaced 6281 STOP button SB2 faulty; button replaced 7 E07 MACHINE CPU HAS GOT A RESET 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6055 Machine earth connection is defective; connection restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 3050 Power network 6145 Frequent and quick network interruptions; inconvenient notified 3051 Electrostatic discharges 6301 Electrostatic discharges present; parts of machine in contact with film and insulated have been earthed 11 E11 PULSES FROM CAM PULSES SENSOR MISSING 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 6304 6171 6173 6310 6181 6311 6306 CPU AP7 card damaged; card replaced DAC AP10 card damaged; card replaced Hybrid IB1 faulty, hybrid replaced Hybrid IB4 faulty, hybrid replaced Input interface card AP6 damaged; card replaced Inverter AP3 faulty; inverter replaced Output interface card AP5 damaged; card replaced Power card AP1 damaged; card replaced

3022 Brake 6130 Cam brake YB3 is faulty; brake replaced 3023 Clutch 6149 Cam clutch YC4 faulty; clutch replaced 6150 Cam clutch YC4 is slipping; clutch cleaned and adjusted 3024 Fuses 6164 Fuses FU7 or FU8 interrupted; replaced 3030 Frequency converter 6181 Inverter AP3 faulty; inverter replaced 3036 Three-phase motor 6216 Motor M1 faulty; motor replaced 3037 Cam movement 6226 Cams movement hard; released movement 6225 Cams movement jammed; movement restored 3038 Ejector movement 6231 Ejector movement jammed; movement restored

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3039 Folder movement 6233 Folder movement jammed; movement restored 3040 Elevator movement 6238 Elevator movement jammed; movement restored 3048 Adjustment 6068 Toothed disk for synchronisation not integral ith his shaft; disk made integral 3053 Sensor 6329 Sensor SR3 faulty; sensor replaced 3060 Transformer 6358 Transformer TV3 faulty; transformer replaced 12 E12 PULSES FROM CAM POSITION SENSOR MISSING 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 6304 6171 6173 6310 6181 6311 6306 CPU AP7 card damaged; card replaced DAC AP10 card damaged; card replaced Hybrid IB1 faulty, hybrid replaced Hybrid IB4 faulty, hybrid replaced Input interface card AP6 damaged; card replaced Inverter AP3 faulty; inverter replaced Output interface card AP5 damaged; card replaced Power card AP1 damaged; card replaced

3022 Brake 6130 Cam brake YB3 is faulty; brake replaced 3023 Clutch 6149 Cam clutch YC4 faulty; clutch replaced 6150 Cam clutch YC4 is slipping; clutch cleaned and adjusted 3024 Fuses 6164 Fuses FU7 or FU8 interrupted; replaced 3030 Frequency converter 6181 Inverter AP3 faulty; inverter replaced 3036 Three-phase motor 6216 Motor M1 faulty; motor replaced 3037 Cam movement 6226 Cams movement hard; released movement 6225 Cams movement jammed; movement restored 3038 Ejector movement 6231 Ejector movement jammed; movement restored 3039 Folder movement 6233 Folder movement jammed; movement restored 3040 Elevator movement 6238 Elevator movement jammed; movement restored 3048 Adjustment 6068 Toothed disk for synchronisation not integral ith his shaft; disk made integral 3053 Sensor 6329 Sensor SR3 faulty; sensor replaced 3060 Transformer 6358 Transformer TV3 faulty; transformer replaced

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14 E14 CAM BRAKE IS SLIPPING TOO MUCH 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6171 Hybrid IB1 faulty, hybrid replaced 6305 Input interface card AP6 damaged; card replaced 3022 Brake 6130 Cam brake YB3 is faulty; brake replaced 6131 Cam brake YB3 is slipping; brake cleaned and adjusted 3053 Sensor 6330 Sensor SR4 faulty; sensor replaced 15 E15 PULSES FROM THE MAIN SENSOR MISSING 3006 Motor belt 6023 Motor belt broken; belt replaced 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 6171 6310 6311 CPU AP7 card damaged; card replaced Hybrid IB1 faulty, hybrid replaced Input interface card AP6 damaged; card replaced Output interface card AP5 damaged; card replaced

3048 Adjustment 6068 Toothed disk for synchronisation not integral ith his shaft; disk made integral 3053 Sensor 6327 Sensor SR1 faulty; sensor replaced 16 E16 CAM FREQUENCY INVERTER DEFECTIVE 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6172 Hybrid IB3 faulty, hybrid replaced 6305 Input interface card AP6 damaged; card replaced 3030 Frequency converter 6181 Inverter AP3 faulty; inverter replaced 3036 Three-phase motor 6216 Motor M1 faulty; motor replaced 3060 Transformer 6358 Transformer TV3 faulty; transformer replaced 17 E17 THE MAIN MOTOR SPEED IS NOT STABLE 3016 Electronic 6304 DAC AP10 card damaged; card replaced 6171 Hybrid IB1 faulty, hybrid replaced 3030 Frequency converter 6181 Inverter AP3 faulty; inverter replaced 3053 Sensor 6327 Sensor SR1 faulty; sensor replaced 18 E18 PROGRAMMED DATA IN BATTERY RAM HAVE BEEN LOST 3011 Electrical connections 6054 Electrical connections are defective; connections restored

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3016 Electronic 6303 CPU AP7 card damaged; card replaced 6010 Faulty RAM battery; RAM replaced 3050 Power network 6145 Frequent and quick network interruptions; inconvenient notified 3051 Electrostatic discharges 6302 Electrostatic discharges present; parts of machine insulated have been earthed 19 E19 THE SPEED IS HIGHER THAN ALLOWED ONE 3048 Adjustment 6318 Please select a correct wrapping programme 6279 Wrapping programs with speed lower than 51 cycles per minutes are necessary 20 E20 PULSES FROM INFEED PULSE SENSOR MISSING 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 6304 6172 6173 6310 6311 6306 CPU AP7 card damaged; card replaced DAC AP10 card damaged; card replaced Hybrid IB3 faulty, hybrid replaced Hybrid IB4 faulty, hybrid replaced Input interface card AP6 damaged; card replaced Output interface card AP5 damaged; card replaced Power card AP1 damaged; card replaced

3024 Fuses 6164 Fuses FU7 or FU8 interrupted; replaced 3030 Frequency converter 6182 Inverter AP4 faulty; inverter replaced 3036 Three-phase motor 6217 Motor M2 faulty; motor replaced 3048 Adjustment 6068 Toothed disk for synchronisation not integral ith his shaft; disk made integral 3053 Sensor 6334 Sensor SR8 faulty; sensor replaced 3060 Transformer 6358 Transformer TV3 faulty; transformer replaced 21 E21 THE INFEED MOTOR SPEED IS NOT STABLE 3016 Electronic 6304 DAC AP10 card damaged; card replaced 6172 Hybrid IB3 faulty, hybrid replaced 3030 Frequency converter 6182 Inverter AP4 faulty; inverter replaced 3053 Sensor 6334 Sensor SR8 faulty; sensor replaced 22 E22 INFEED FREQUENCY CONVERTER DEFECTIVE 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6174 Hybrid IB5 faulty, hybrid replaced 6310 Input interface card AP6 damaged; card replaced 3036 Three-phase motor 6217 Motor M2 faulty; motor replaced

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3060 Transformer 6358 Transformer TV3 faulty; transformer replaced 23 E23 ONE OR TWO UNWRAPPED TRAYS WERE FOUND ON THE INFEED INSIDE THE MACHINE ???????? 3061 Utilization 6356 Eventual products at machine internal must be eliminated; product eliminated 6351 START button pressed without opening the infeed cover 24 E24 INFEED PHOTOCELL IS OBSCURED OR DEFECTIVE 3007 Belts 6029 Infeed belts slanting; belts arranged 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6310 Input interface card AP6 damaged; card replaced 3021 Photocell 6098 6099 6120 6119 Photocell AP11 is defective, photocell replaced Photocell AP12 is defective, photocell replaced Photocells AP11 or AP12 are dirty, photocells cleaned Photocells AP11 or AP12 are not aligned, photocells aligned

30 E30 ZERO-SETTING MOVEMENT OF THE UPPER EJECTOR FAILED 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6171 Hybrid IB1 faulty, hybrid replaced 6310 Input interface card AP6 damaged; card replaced 3031 Mechanics 6232 Upper ejector movement hard; released movement 3053 Sensor 6319 Sensor SQ1 faulty; sensor replaced 40 E40 PULSES FROM UNWINDING SENSOR MISSING 3007 Belts 6027 Separation movement belt broken; belt replaced 6028 Unwinding movement belt broken; belt replaced 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 6170 6171 6310 CPU AP7 card damaged; card replaced Hybrid IB0 faulty, hybrid replaced Hybrid IB1 faulty, hybrid replaced Input interface card AP6 damaged; card replaced

3022 Brake 6133 Centering brake YB2 is faulty; brake replaced 3023 Clutch 6151 Centering clutch YC3 faulty; clutch replaced 6153 Centering clutch YC3 is sliding; clutch cleaned and adjusted

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3048 Adjustment 6067 Toothed disk for unwinding sensor activation SR2 not integral with shaft; toothed disk made integral 3053 Sensor 6328 Sensor SR2 faulty; sensor replaced 41 E41 FILM CENTRING MOVEMENT HAS FINISHED TOO LATE 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6170 Hybrid IB0 faulty, hybrid replaced 6311 Output interface card AP5 damaged; card replaced 3022 Brake 6133 Centering brake YB2 is faulty; brake replaced 6134 Centering brake YB2 is not adjusted; brake adjusted 3023 Clutch 6151 Centering clutch YC3 faulty; clutch replaced 6153 Centering clutch YC3 is sliding; clutch cleaned and adjusted 3058 Unwinding 6241 Unwinding movement hard or mechanical jammed: released movement 42 E42 ZERO-SETTING MOVEMENT OF FILM LENGTH MOTOR FAILED 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 6075 6174 6310 6311 CPU AP7 card damaged; card replaced Driver AP9 is defective; driver replaced Hybrid IB5 faulty, hybrid replaced Input interface card AP6 damaged; card replaced Output interface card AP5 damaged; card replaced

3031 Mechanics 6237 Film length reel movement hard; released movement 3034 Motor 6215 Film length motor M8 faulty; motor replaced 3053 Sensor 6325 Sensor SQ7 faulty; sensor replaced 44 E44 FILM MISSING IN THE DISTRIBUTOR OR FILM PRESENCE SENSOR DEFECTIVE 3001 Film tension device 6230 Film tension device movement faulty; movement arranged 6210 Film tension spring broken; spring replaced 6211 Film tension spring not adjusted; spring adjusted 6212 Film tension spring too much loaded; spring released 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3012 Knife 6060 Knife is cutting too much; knife height adjusted 6229 Knife movement hard; released movement 6228 Knife movement with mechanical clearance; movement restored

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6056 Knife out of phase; knife phase adjusted 3014 Distributor 6072 Distributor not adjusted; distributor adjusted 6298 Film presence reel is not running free; released reel movement 6299 Film presence reel with sliding surface; reel surface cleaned 3016 Electronic 6303 6075 6170 6171 6310 6311 3019 Film 6094 Film broken; film reinserted in machine 6084 Film is advancing badly; film advancing arranged 6011 Film reel ended; replaced 3022 Brake 6125 Reel brake YB5 defective; brake replaced 6124 Reel brake YB5 not adjusted; brake cleaned and adjusted 3048 Adjustment 6015 Sensor activation cam of film presence sensor not integral with the roller; cam got integral with reel 3053 Sensor 6331 Film presence sensor SR5 faulty; sensor replaced 3057 Reel Support 6349 Reel support does not turn freely; released movement 45 E45 EXCESS OF NOT-USED FILM OR FILM RETAINER PHOTOCELLS OBSCURED - NO MACHINE START IF UPPER RIGHT COVER IS NOT OPENED 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 6313 Photocell cables shields are not connected with earth on control board side; connections restored 3016 Electronic 6303 6310 6110 6111 6308 6309 3019 Film 6093 Film not in use has obscured the photocells AP15 and AP16; film eliminated 3058 Unwinding 6046 Unwinding belts not in position; belts positioned 6047 Unwinding belts too long, out of reels grooves; tightened belts 46 E46 EXCESS OF NOT-USED FILM OR FILM RETAINER FIX PHOTOCELLS OBSCURED - NO MACHINE START IF UPPER RIGHT COVER IS NOT OPENED 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 6313 Photocell cables shields are not connected with earth on control board side; connections restored CPU AP7 card damaged; card replaced Input interface card AP6 damaged; card replaced Photocell AP15 is dirty, photocell cleaned Photocell AP16 is dirty, photocell cleaned Photocell card AP15 damaged; card replaced Photocell card AP16 damaged; card replaced CPU AP7 card damaged; card replaced Driver AP9 is defective; driver replaced Hybrid IB0 faulty, hybrid replaced Hybrid IB1 faulty, hybrid replaced Input interface card AP6 damaged; card replaced Output interface card AP5 damaged; card replaced

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3016 Electronic 6303 6310 6111 6309 3019 Film

CPU AP7 card damaged; card replaced Input interface card AP6 damaged; card replaced Photocell AP16 is dirty, photocell cleaned Photocell card AP16 damaged; card replaced

6091 Film not in use has obscured the photocell AP16; film eliminated 3058 Unwinding 6046 Unwinding belts not in position; belts positioned 6047 Unwinding belts too long, out of reels grooves; tightened belts 47 E47 EXCESS OF NOT-USED FILM OR FILM RETAINER CARRIAGE PHOTOCELLS OBSCURED NO MACHINE START IF UPPER RIGHT COVER IS NOT OPENED 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 6313 Photocell cables shields are not connected with earth on control board side; connections restored 3016 Electronic 6303 6310 6110 6308 3019 Film 6092 Film not in use has obscured the photocell AP15; film eliminated 3058 Unwinding 6046 Unwinding belts not in position; belts positioned 6047 Unwinding belts too long, out of reels grooves; tightened belts 48 E48 FILM LENGTH MOTOR PULSE SENSOR DEFECTIVE 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 6075 6171 6310 6311 CPU AP7 card damaged; card replaced Driver AP9 is defective; driver replaced Hybrid IB1 faulty, hybrid replaced Input interface card AP6 damaged; card replaced Output interface card AP5 damaged; card replaced CPU AP7 card damaged; card replaced Input interface card AP6 damaged; card replaced Photocell AP15 is dirty, photocell cleaned Photocell card AP15 damaged; card replaced

3034 Motor 6219 Motor M8 does not turn; motor replaced 3053 Sensor 6333 Film length sensor SR6 dirty; sensor cleaned 6332 Film length sensor SR6 faulty; sensor replaced 51 E51 EXTRA-STROKE CARRIAGE AND ELEVATOR NOT CORRECTLY SET 3048 Adjustment 6053 Switch SW1-4 e/o SW1-7 in contrast with SW1-6; switches restored 52 E52 CARRIAGE OPENING IS TOO NARROW FOR ELEVATOR TYPE A OR TYPE 280 mm CONFIGURATION - WARNING: PLEASE VERIFY THE MACHINE NUMBER ! 3061 Utilization 6264 Carriage position too small; carriage more opened 6262 Carriage position; from series 16 included must be superior to 9 6263 Carriage position; until series 15 included must be superior to 6

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6271 Wrapping program under use not correct; operator instructed 6272 Wrapping program; from series 16 included one with a carriage opening wider than 9 must be selected 6273 Wrapping programme; until series 15 included it must be selected one with a carriage opening of more than 6 53 E53 YOU CANNOT USE THIS PROGRAMME BECAUSE THE CARRIAGE IS TOO NARROW 3061 Utilization 6317 Please select a wrapping programme with a carriage opening wider or equal to 10. 54 E54 ONE OR MOTE CARRIAGE SENSORS ARE WORKING INCORRECTLY 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6174 Hybrid IB5 faulty, hybrid replaced 6310 Input interface card AP6 damaged; card replaced 3053 Sensor 6338 Carriage sensors SQ2, SQ3, SQ4 and SQ5; one or more are dirty; sensors cleaned 6320 Sensor SQ2 faulty; sensor replaced 6321 Sensor SQ3 faulty; sensor replaced 6322 Sensor SQ4 faulty; sensor replaced 6323 Sensor SQ5 faulty; sensor replaced 55 E55 AUTOMATIC CARRIAGE MOVEMENT FAILURE - THE CARRIAGE DID NOT REACH THE POSITION 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 6074 6174 6310 CPU AP7 card damaged; card replaced Driver AP8 is defective; driver replaced Hybrid IB5 faulty, hybrid replaced Input interface card AP6 damaged; card replaced

3031 Mechanics 6227 Carriage movement hard; released movement 6000 Carriage stop rings not in correct position; rings correctly positioned 3034 Motor 6218 Motor M7 faulty; motor replaced 3053 Sensor 6338 Carriage sensors SQ2, SQ3, SQ4 and SQ5; one or more are dirty; sensors cleaned 6320 Sensor SQ2 faulty; sensor replaced 6321 Sensor SQ3 faulty; sensor replaced 6322 Sensor SQ4 faulty; sensor replaced 6323 Sensor SQ5 faulty; sensor replaced 60 E60 THE LEFT UPPER COVER IS OPEN; CLOSE IT 3005 Cover 6021 Cover open, Cover closed 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored

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3016 Electronic 6303 CPU AP7 card damaged; card replaced 6175 Hybrid IB6 faulty, hybrid replaced 6310 Input interface card AP6 damaged; card replaced 3033 Safety micro switch 6195 Micro switch SB3 faulty; micro switch replaced 6196 Micro switch SB3 not adjusted; micro switch adjusted 61 E61 THE RIGHT UPPER COVER IS OPEN; CLOSE IT 3005 Cover 6021 Cover open, Cover closed 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6175 Hybrid IB6 faulty, hybrid replaced 6310 Input interface card AP6 damaged; card replaced 3033 Safety micro switch 6197 Micro switch SB4 faulty; micro switch replaced 6198 Micro switch SB4 not adjusted; micro switch adjusted 62 E62 THE ELEVATOR DOOR IS OPEN; CLOSE IT 3005 Cover 6021 Cover open, Cover closed 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6175 Hybrid IB6 faulty, hybrid replaced 6310 Input interface card AP6 damaged; card replaced 3033 Safety micro switch 6199 Micro switch SB5 faulty; micro switch replaced 6200 Micro switch SB5 not adjusted; micro switch adjusted 63 E63 THE FILM INSERTION DOOR IS OPEN. CLOSE IT 3005 Cover 6021 Cover open, Cover closed 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6175 Hybrid IB6 faulty, hybrid replaced 6310 Input interface card AP6 damaged; card replaced 3033 Safety micro switch 6201 Micro switch SB6 faulty; micro switch replaced 6202 Micro switch SB6 not adjusted; micro switch adjusted 64 E64 THE LOWER DOOR IS OPEN. CLOSE IT 3005 Cover 6021 Cover open, Cover closed 3011 Electrical connections

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6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6175 Hybrid IB6 faulty, hybrid replaced 6310 Input interface card AP6 damaged; card replaced 3033 Safety micro switch 6203 Micro switch SB7 faulty; micro switch replaced 6204 Micro switch SB7 not adjusted; micro switch adjusted 65 E65 LOWER INFEED COVER OPEN. CLOSE IT 3005 Cover 6021 Cover open, Cover closed 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6175 Hybrid IB6 faulty, hybrid replaced 6310 Input interface card AP6 damaged; card replaced 3033 Safety micro switch 6207 Micro switch SB9 faulty; micro switch replaced 6208 Micro switch SB9 not adjusted; micro switch adjusted 66 E66 EXTENDING ROD MICROSWITCH ACTIVE 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6172 Hybrid IB3 faulty, hybrid replaced 6310 Input interface card AP6 damaged; card replaced 3032 Switch 6189 Elastic rod was enabled, disabled elastic rod 6205 Micro switch SB8 faulty; micro switch replaced 6206 Micro switch SB8 not adjusted; micro switch adjusted 67 E67 INFEED COVER OPEN. PLEASE CLOSE 3005 Cover 6066 Infeed cover open; cover closed 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6175 Hybrid IB6 faulty, hybrid replaced 6310 Input interface card AP6 damaged; card replaced 3032 Switch 6193 Micro switch SB10 faulty; micro switch replaced 6194 Micro switch SB10 not adjusted; micro switch adjusted 70 E70 KNIFE SENSOR HAS NOT SWITCHED DURING ZERO-SETTING MOVEMENT 3011 Electrical connections 6054 Electrical connections are defective; connections restored

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6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 6075 6172 6310 CPU AP7 card damaged; card replaced Driver AP9 is defective; driver replaced Hybrid IB3 faulty, hybrid replaced Input interface card AP6 damaged; card replaced

3031 Mechanics 6229 Knife movement hard; released movement 3034 Motor 6213 Knife motor faulty; motor replaced 3053 Sensor 6326 Sensor SQ8 faulty; sensor replaced 71 E71 KNIFE SENSOR HAS NOT SWITCHED DURING CUTTING MOVEMENT 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 6075 6172 6310 CPU AP7 card damaged; card replaced Driver AP9 is defective; driver replaced Hybrid IB3 faulty, hybrid replaced Input interface card AP6 damaged; card replaced

3031 Mechanics 6229 Knife movement hard; released movement 3034 Motor 6213 Knife motor faulty; motor replaced 3053 Sensor 6326 Sensor SQ8 faulty; sensor replaced 73 E73 OPTION N 1 DEVICE ALARM 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6176 Hybrid IB7 faulty, hybrid replaced 6310 Input interface card AP6 damaged; card replaced 3061 Utilization 6069 Device connected with optional input 1 is in error; disable this device 74 E74 OPTION N 2 DEVICE ALARM 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6176 Hybrid IB7 faulty, hybrid replaced 6310 Input interface card AP6 damaged; card replaced 3061 Utilization 6070 Device connected with optional input 2 is in error; disable this device 75 E75 OPTION N 3 DEVICE ALARM 3011 Electrical connections 6054 Electrical connections are defective; connections restored

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6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6176 Hybrid IB7 faulty, hybrid replaced 6310 Input interface card AP6 damaged; card replaced 3061 Utilization 6071 Device connected with optional input 3 is in error; disable this device 84 E84 CARRIAGE PHOTOCELL IS OBSCURED OR DEFECTIVE 3007 Belts 6029 Infeed belts slanting; belts arranged 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6310 Input interface card AP6 damaged; card replaced 3021 Photocell 6100 6101 6122 6121 Photocell AP13 is defective, photocell replaced Photocell AP14 is defective, photocell replaced Photocells AP12 or AP13 are dirty, photocells cleaned Photocells AP13 and AP14 are not aligned, photocells aligned

85 E85 THE PRODUCT ON THE INFEED IS TOO LONG OR INCORRECTLY POSITIONED 3000 Infeed 6246 Pack does not advance correctly; pack advancing arranged 3007 Belts 6030 6031 6037 6035 Infeed belts are slipping; belts tightened Infeed belts deformed; belts arranged Infeed belts not enough tightened; belts tightened Infeed belts too long; belts tightened

3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 6313 Photocell cables shields are not connected with earth on control board side; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6310 Input interface card AP6 damaged; card replaced 3021 Photocell 6100 6107 6106 6101 6109 6108 Photocell AP13 is defective, photocell replaced Photocell AP13 is dirty, photocell cleaned Photocell AP13 is not aligned, photocell aligned Photocell AP14 is defective, photocell replaced Photocell AP14 is dirty, photocell cleaned Photocell AP14 is not aligned, photocell aligned

3046 Programming 6264 Carriage position too small; carriage more opened 6277 Programming of maximum acceptable pack width wrong; programming corrected 6006 Tray stop on elevator too anticipated; tray stop position modified 3048 Adjustment 6343 Elevator not in phase; phase of elevator corrected 6344 Elevator too high when in the stand position; height adjusted

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3061 Utilization 6065 6245 6244 6270 6362

Foreign bodies present in the machine internal; bodies eliminated Pack too wide; recommended to use a smaller tray Packs too close on infeed; operator instruction Product is overhanging from the tray; operator instructed Trays inclined on infeed; operator instructed

86 E86 THE CARRIAGE PHOTOCELL IS OBSCURED DURING ELEVATOR RISE 3000 Infeed 6246 Pack does not advance correctly; pack advancing arranged 3007 Belts 6030 6031 6037 6035 Infeed belts are slipping; belts tightened Infeed belts deformed; belts arranged Infeed belts not enough tightened; belts tightened Infeed belts too long; belts tightened

3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 6313 Photocell cables shields are not connected with earth on control board side; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6310 Input interface card AP6 damaged; card replaced 3021 Photocell 6100 6107 6106 6101 6109 6108 Photocell AP13 is defective, photocell replaced Photocell AP13 is dirty, photocell cleaned Photocell AP13 is not aligned, photocell aligned Photocell AP14 is defective, photocell replaced Photocell AP14 is dirty, photocell cleaned Photocell AP14 is not aligned, photocell aligned

3046 Programming 6264 Carriage position too small; carriage more opened 6277 Programming of maximum acceptable pack width wrong; programming corrected 6006 Tray stop on elevator too anticipated; tray stop position modified 3048 Adjustment 6343 Elevator not in phase; phase of elevator corrected 6344 Elevator too high when in the stand position; height adjusted 3061 Utilization 6020 6065 6245 6244 6270 6362 Carriage too much closed; carriage position adjusted Foreign bodies present in the machine internal; bodies eliminated Pack too wide; recommended to use a smaller tray Packs too close on infeed; operator instruction Product is overhanging from the tray; operator instructed Trays inclined on infeed; operator instructed

87 E87 CARRIAGE PHOTOCELL HAS BEEN OBSCURED TOO LATE 3007 Belts 6032 External infeed belts not enough tightened; belts tightened 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 6313 Photocell cables shields are not connected with earth on control board side; connections restored

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3016 Electronic 6303 CPU AP7 card damaged; card replaced 6310 Input interface card AP6 damaged; card replaced 3021 Photocell 6100 6107 6106 6101 6109 6108 Photocell AP13 is defective, photocell replaced Photocell AP13 is dirty, photocell cleaned Photocell AP13 is not aligned, photocell aligned Photocell AP14 is defective, photocell replaced Photocell AP14 is dirty, photocell cleaned Photocell AP14 is not aligned, photocell aligned

3061 Utilization 6038 Infeed belts durty are obscuring the infeed photocells; operator instructed 6269 Product is falling after been read by the infeed photocell; operator instructed 88 E88 CARRIAGE PHOTOCELL HAS BEEN OBSCURED TOO EARLY 3007 Belts 6033 Internal infeed belts not enough tightened; belts tightened 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 6313 Photocell cables shields are not connected with earth on control board side; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6310 Input interface card AP6 damaged; card replaced 3021 Photocell 6100 6107 6106 6101 6109 6108 Photocell AP13 is defective, photocell replaced Photocell AP13 is dirty, photocell cleaned Photocell AP13 is not aligned, photocell aligned Photocell AP14 is defective, photocell replaced Photocell AP14 is dirty, photocell cleaned Photocell AP14 is not aligned, photocell aligned

89 E89 PRODUCT DETECTED BY CARRIAGE PHOTOCELL BUT NOT BY THE INFEED-ONE 3000 Infeed 6037 Infeed belts not enough tightened; belts tightened 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 6313 Photocell cables shields are not connected with earth on control board side; connections restored 3013 Machine condition 6045 Internal infeed belts dirty; belts cleaned 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6310 Input interface card AP6 damaged; card replaced 3021 Photocell 6100 6107 6106 6101 6109 6108 Photocell AP13 is defective, photocell replaced Photocell AP13 is dirty, photocell cleaned Photocell AP13 is not aligned, photocell aligned Photocell AP14 is defective, photocell replaced Photocell AP14 is dirty, photocell cleaned Photocell AP14 is not aligned, photocell aligned

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3061 Utilization 6250 Parts of the product are falling on infeed; operator instructed 90 E90 EXIT PRODUCT PHOTOCELL OBSCURED AT START 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3013 Machine condition 6289 Reflector broken; reflector cleaned 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6172 Hybrid IB3 faulty, hybrid replaced 6310 Input interface card AP6 damaged; card replaced 3021 Photocell 6112 Photocell B1 is defective; photocell replaced 6114 Photocell B1 is dirty, photocell cleaned 6113 Photocell B1 is not aligned, photocell aligned 3048 Adjustment 6113 Photocell B1 is not aligned, photocell aligned 91 E91 PRINTED FILM PHOTOCELL DEFECTIVE 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3013 Machine condition 6289 Reflector broken; reflector cleaned 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6172 Hybrid IB3 faulty, hybrid replaced 6310 Input interface card AP6 damaged; card replaced 3021 Photocell 6115 Photocell B2 is defective; photocell replaced 6117 Photocell B2 is dirty, photocell cleaned 6116 Photocell B2 is not aligned, photocell aligned 3048 Adjustment 6118 Photocell B2 is not adjusted, photocell adjusted 92 E92 - REGISTRATION MARK OF PRINTED FILM NOT FOUND 3019 Film 6314 Film signal not readable; reel replaced 3048 Adjustment 6285 Photocell ray too powerful; ray power reduced 3061 Utilization 6090 Film not aligned with photocell; film aligned 910 W10 - The clutch of the cam is slipping too much 3023 Clutch 6149 Cam clutch YC4 faulty; clutch replaced 6150 Cam clutch YC4 is slipping; clutch cleaned and adjusted 921 W21 - The infeed conveyor switch is on position 0. Put it on position 1. 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic

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6303 CPU AP7 card damaged; card replaced 6172 Hybrid IB3 faulty, hybrid replaced 6310 Input interface card AP6 damaged; card replaced 3052 Selector 6315 Infeed selector SA1 faulty; selector replaced 6316 Infeed selector SA1 on position "0"; placed on position "1" 922 W22 - The clutch of the infeed is slipping too much 3023 Clutch 6146 Infeed clutch YC5 faulty; clutch replaced 6148 Infeed clutch YC5 is dirty; clutch cleaned 6147 Infeed clutch YC5 is slipping; clutch adjusted and cleaned 930 W30 - The upper ejector has been disabled. If necessary adjust its height manually 3018 Upper ejector 6288 Upper ejector function reactivated 945 W45 - Film retainer photocells obscured. REMOVE UNUSED FILM 3007 Belts 6048 Unwinding belts too long; belts tightened 3021 Photocell 6123 Photocells film overrun AP15 or AP16 enabled; function verified 3061 Utilization 6253 Film pieces has obscured the film overrun photocell; film pieces removed 951 W51 - The carriage is not in the programmed position of the utilized packaging programme 3004 Carriage 6018 Carriage not in the programmed position; carriage placed in the programmed position 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6174 Hybrid IB5 faulty, hybrid replaced 6310 Input interface card AP6 damaged; card replaced 3053 Sensor 6338 Carriage sensors SQ2, SQ3, SQ4 and SQ5; one or more are dirty; sensors cleaned 6320 Sensor SQ2 faulty; sensor replaced 6321 Sensor SQ3 faulty; sensor replaced 6322 Sensor SQ4 faulty; sensor replaced 6323 Sensor SQ5 faulty; sensor replaced 954 W54 - Carriage sensors are not switching in the correct sequence 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6174 Hybrid IB5 faulty, hybrid replaced 3053 Sensor 6338 Carriage sensors SQ2, SQ3, SQ4 and SQ5; one or more are dirty; sensors cleaned 6320 Sensor SQ2 faulty; sensor replaced 6321 Sensor SQ3 faulty; sensor replaced

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6322 Sensor SQ4 faulty; sensor replaced 6323 Sensor SQ5 faulty; sensor replaced 980 W80 - One or more channels on infeed photocells not working 3021 Photocell 6098 Photocell AP11 is defective, photocell replaced 6103 Photocell AP11 is dirty, photocell cleaned 6102 Photocell AP11 is not aligned , photocell aligned 6099 Photocell AP12 is defective, photocell replaced 6105 Photocell AP12 is dirty, photocell cleaned 6104 Photocell AP12 is not aligned, photocell aligned 981 W81 - One or more channels on carriage photocells not working 3021 Photocell 6100 Photocell AP13 is defective, photocell replaced 6107 Photocell AP13 is dirty, photocell cleaned 6106 Photocell AP13 is not aligned, photocell aligned 6101 Photocell AP14 is defective, photocell replaced 6109 Photocell AP14 is dirty, photocell cleaned 6108 Photocell AP14 is not aligned, photocell aligned 990 W90 - Temperature probe on sealing plate broken (open circuit) 3056 Probe 6347 Probe damaged; probe replaced 991 W91 - Temperature probe on sealing plate broken (open circuit) 3056 Probe 6347 Probe damaged; probe replaced 992 W92 - The sealing plate does not reach the programmed temperature 3041 Sealing plate 6287 Resistances broken; resistances replaced 993 W93 - Sealing plate temperature is exceeding the programmed one 3016 Electronic 6303 CPU AP7 card damaged; card replaced 3056 Probe 6347 Probe damaged; probe replaced 994 W94 - The sealing plate has not yet reached the programmed temperature. Please wait 3041 Sealing plate 6287 Resistances broken; resistances replaced 6256 Sealing plate not yet in temperature; please wait 995 W95 - Product stopped on the infeed because of error of the device connected with the option input 1. PLEASE WAIT UNTIL MACHINE STARTS AGAIN 3026 Optional inputs 6003 Equipment connected with optional device 1 input faulty; working condition restored 996 W96 - Machine stopped on the infeed because of error of the device connected with the option input 2. PLEASE WAIT UNTIL MACHINE STARTS AGAIN. 3026 Optional inputs 6004 Equipment connected with optional device 2 input faulty; working condition restored 997 W97 - Machine stopped on the infeed because of error of the device connected with the option input 3. PLEASE WAIT UNTIL MACHINE STARTS AGAIN. 3026 Optional inputs 6005 Equipment connected with optional device 3 input faulty; working condition restored

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999 W99 - Product stopped on the infeed because of exit product photocell obscured too long time. PLEASE WAIT UNTIL MACHINE STARTS AGAIN 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6172 Hybrid IB3 faulty, hybrid replaced 6310 Input interface card AP6 damaged; card replaced 3021 Photocell 6112 Photocell B1 is defective; photocell replaced 3061 Utilization 6177 Inclination of outlet conveyor with idle rolls too low; inclination increased 6243 Packs moving slowly at machine exit; transfer time of packs reduced 1000 UNWINDING TOO TIGHT AND TRAYS SQUASHED 3010 Film transport belts 6049 Film transport belts bright; belts replaces 6050 Film transport belts not enough tightened; belts tightened 3042 Folder 6082 Folder stop too forward; folder positioned at 3mm from the conveyor rollers 3044 Clamps 6236 Clamps movement hard; released movement 6259 Clamps too closed in the stand position; clamps opened 3046 Programming 6001 Clamps opening too late; opening time of clamps modified 3061 Utilization 6086 Film excessive quantity under the belts; film position modified 6271 Wrapping program under use not correct; operator instructed 1001 TENSION FILM DEVICE BANGS AGAINST THE FILM DEVIATION REELS 3001 Film tension device 6210 Film tension spring broken; spring replaced 6209 Film tension spring not enough loaded; spring loaded 6014 Sensor activation cam of film tension device not adjusted; cam adjusted 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 6170 6174 6310 6311 3022 Brake 6140 6139 6143 6142 CPU AP7 card damaged; card replaced Hybrid IB0 faulty, hybrid replaced Hybrid IB5 faulty, hybrid replaced Input interface card AP6 damaged; card replaced Output interface card AP5 damaged; card replaced Reel 1 brake YB5 is mechanical jammed; Reel 1 brake YB5 is mechanical jammed; Reel 2 brake YB6 is mechanical jammed; Reel 2 brake YB6 is mechanical jammed; brake replaced movement released brake replaced movement released

3053 Sensor 6324 Film tension sensor SQ6 faulty; sensor replaced 1002 TENSION FILM DEVICE BANGS DOWNWARDS

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3001 Film tension device 6014 Sensor activation cam of film tension device not adjusted; cam adjusted 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 6170 6174 6310 6311 3019 Film 6012 Reel not integral with his support; reel locked 3022 Brake 6141 6144 6126 6127 Reel 1 brake YB5 is faulty; brake replaced Reel 2 brake YB6 is faulty; brake replaced Reel brake YB5 does not brake; brake adjusted Reel brake YB6 does not brake; brake adjusted CPU AP7 card damaged; card replaced Hybrid IB0 faulty, hybrid replaced Hybrid IB5 faulty, hybrid replaced Input interface card AP6 damaged; card replaced Output interface card AP5 damaged; card replaced

3053 Sensor 6324 Film tension sensor SQ6 faulty; sensor replaced 1003 FILM WITH HOLES AT THE BOTTOM OF THE TRAYS 3010 Film transport belts 6049 Film transport belts bright; belts replaces 6050 Film transport belts not enough tightened; belts tightened 3016 Electronic 6170 Hybrid IB0 faulty, hybrid replaced 3048 Adjustment 6353 Sealing plate temperature too high; temperature reduced 3054 Folders 6342 Folders too lucid; folders replaced 6341 Folders too lucid; folders roughed 3055 Elevator 6158 Mushrooms bright; mushrooms made rough 6161 Mushrooms weared: faulty mushrooms replaced 3056 Probe 6348 Probe ST1 damaged; probe replaced 3061 Utilization 6088 Film insufficient quantity under the belts; carriage position modified 6271 Wrapping program under use not correct; operator instructed 1004 FILM TAILS UNDER THE TRAYS 3010 Film transport belts 6049 Film transport belts bright; belts replaces 6050 Film transport belts not enough tightened; belts tightened 3044 Clamps 6236 Clamps movement hard; released movement 6259 Clamps too closed in the stand position; clamps opened 3046 Programming 6001 Clamps opening too late; opening time of clamps modified 6185 Film length is excessive, film length reduced 3048 Adjustment

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6087 Film excessive quantity under the belts; carriage position modified 6089 Film got caught between central and side folders; distance between these parts modified 6013 Reel not in correct position: reel repositioned 3054 Folders 6342 Folders too lucid; folders replaced 6341 Folders too lucid; folders roughed 3055 Elevator 6158 Mushrooms bright; mushrooms made rough 6161 Mushrooms weared: faulty mushrooms replaced 3061 Utilization 6095 Film under use is too wide; narrower film used 6271 Wrapping program under use not correct; operator instructed 1005 KNIFE IS WORKING BUT SOME TIMES WITHOUT CORRECT FILM PERFORATION 3012 Knife 6062 Knife is weared; knife replaced 3048 Adjustment 6063 Knife contrast too high; height adjusted 6061 Knife is too low; knife height corrected 1006 DISPLAY NOT SWITCHING ON 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6307 Display card AP17 damaged; card replaced 1007 FILM IS NOT CORRECTLY ADVANCING 3001 Film tension device 6210 Film tension spring broken; spring replaced 6211 Film tension spring not adjusted; spring adjusted 6212 Film tension spring too much loaded; spring released 3012 Knife 6183 Knife blade weared; knife replaced 3013 Machine condition 6073 Distributor with dirty parts in contact with film;parts cleaned 3014 Distributor 6297 6296 6265 6290 3019 Film 6083 Film too much electrostatic; earth connection of parts in contact with film restored 3022 Brake 6125 6129 6124 6128 Reel brake YB5 defective; brake replaced Reel brake YB5 is not adjusted; brake adjusted Reel brake YB5 not adjusted; brake cleaned and adjusted Reel brake YB6 does not work; brake adjusted Distributor contrast reel springs not adjusted; springs adjusted Distributor contrast reel with broken springs; springs replaced Pressure of distributor contrast reel is not constant; pressure adjusted Rubberized reels damaged; reels replaced

3046 Programming 6274 Film separation correction programming not correct; programming arranged 3048 Adjustment

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6020 Carriage too much closed; carriage position adjusted 6019 Carriage too much opened; carriage position adjusted 3053 Sensor 6324 Film tension sensor SQ6 faulty; sensor replaced 3057 Reel Support 6349 Reel support does not turn freely; released movement 3058 Unwinding 6254 6040 6039 6041 6042 Film pieces under the belts; film removed under the belts Film transport belts missing; missing belts assembled Film transport belts out of position; positioned the belts Film transport belts too long; belts tightened Film transport belts weared; belts replaced

3064 Film's fan 6365 Fan M4 or M5 does not run; connections restored 6363 Fan M4 or M5 does not run; fan replaced 1008 FILM IS TOUCHING THE FOLDERS DURING THE CENTERING PHASE 3010 Film transport belts 6049 Film transport belts bright; belts replaces 6050 Film transport belts not enough tightened; belts tightened 3012 Knife 6059 Knife is not cutting enough; height adjusted 3024 Fuses 6162 Fuse FU11 interrupted; fuse replaced 3049 Relay 6286 Relay K2 faulty; relay replaced 3054 Folders 6341 Folders too lucid; folders roughed 3065 Fans 6365 Fan M4 or M5 does not run; connections restored 6363 Fan M4 or M5 does not run; fan replaced 1009 FILM GOES OUT OF DISTRIBUTOR DURING TRANSPORTATION PHASE 3012 Knife 6060 Knife is cutting too much; knife height adjusted 3014 Distributor 6072 Distributor not adjusted; distributor adjusted 6267 First distributor reel damaged; reel replaced 6268 First distributor reel dirty; reel cleaned 1010 FILM CENTERING DEFECTIVE, FEEDING TOO ADVANCED 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 6170 6171 6310 6311 CPU AP7 card damaged; card replaced Hybrid IB0 faulty, hybrid replaced Hybrid IB1 faulty, hybrid replaced Input interface card AP6 damaged; card replaced Output interface card AP5 damaged; card replaced

3022 Brake 6133 Centering brake YB2 is faulty; brake replaced 6134 Centering brake YB2 is not adjusted; brake adjusted

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6135 Centering brake YB2 is slipping; brake cleaned 3048 Adjustment 6275 Centering correction programming not correct; centering corrected 6276 Film separation correction programming not correct; programming arranged 3053 Sensor 6067 Toothed disk for unwinding sensor activation SR2 not integral with shaft; toothed disk made integral 6336 Unwinding sensor SR2 faulty: sensor replaced 1011 FILM CENTERING DEFECTIVE, FILM KEEPING BEHIND 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3012 Knife 6061 Knife is too low; knife height corrected 6062 Knife is weared; knife replaced 3016 Electronic 6303 6170 6171 6310 6311 CPU AP7 card damaged; card replaced Hybrid IB0 faulty, hybrid replaced Hybrid IB1 faulty, hybrid replaced Input interface card AP6 damaged; card replaced Output interface card AP5 damaged; card replaced

3023 Clutch 6151 Centering clutch YC3 faulty; clutch replaced 6153 Centering clutch YC3 is sliding; clutch cleaned and adjusted 6152 Centering clutch YC3 not adjusted; clutch adjusted 3048 Adjustment 6275 Centering correction programming not correct; centering corrected 6276 Film separation correction programming not correct; programming arranged 3053 Sensor 6336 Unwinding sensor SR2 faulty: sensor replaced 1012 FILM IS ROLLING UP THE FIRST DISTRIBUTOR REEL 3001 Film tension device 6212 Film tension spring too much loaded; spring released 3012 Knife 6060 Knife is cutting too much; knife height adjusted 3014 Distributor 6295 Distributor contrast reel dirty; reel cleaned 6266 Pressure of distributor contrast reel is too high; springs' pressure reduced 1013 FILM NOT SEALED UNDER THE TRAYS 3016 Electronic 6170 Hybrid IB0 faulty, hybrid replaced 3041 Sealing plate 6255 Sealing plate faulty; sealing plate replaced 3048 Adjustment 6354 Sealing plate temperature too low; temperature increased 3056 Probe 6348 Probe ST1 damaged; probe replaced 1014 SEPARATION BRAKE OR CLUTCH DOES NOT RUN 3011 Electrical connections 6054 Electrical connections are defective; connections restored

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6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6170 Hybrid IB0 faulty, hybrid replaced 6311 Output interface card AP5 damaged; card replaced 3022 Brake 6136 Film separation brake YB1 is faulty; brake replaced 6138 Film separation brake YB1 is not adjusted; brake adjusted 6137 Film separation brake YB1 is slipping; brake cleaned 3023 Clutch 6154 Film separation clutch YC1 faulty; clutch replaced 6156 Film separation clutch YC1 is not adjusted; clutch adjusted 6155 Film separation clutch YC1 is slipping; clutch cleaned 1015 ELEVATOR MUSHROOMS ARE BREAKING 3054 Folders 6340 Folders too low; height adjusted 3055 Elevator 6344 Elevator too high when in the stand position; height adjusted 6157 Mushrooms badly fitted; mushrooms fitted 6159 Mushrooms not positioned in right direction ; mushrooms position corrected 1016 FILM DISTRIBUTOR DOES NOT OPEN 3003 Knife safety cam 6017 Knife safety cam not correctly positioned; cam adjusted 3012 Knife 6058 Knife not in zero position; knife repositioned 6057 Knife not in zero position; pressed START button 1017 INFEED MOTOR IS RUNNING BUT EXTERNAL INFEED BELTS ARE STANDSTILL 3008 Toothed belts 6025 External infeed movement toothed belt broken; belt replaced 3009 Flat belts 6036 Infeed belts missing; missing belts fitted 6037 Infeed belts not enough tightened; belts tightened 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6311 Output interface card AP5 damaged; card replaced 3024 Fuses 6146 Infeed clutch YC5 faulty; clutch replaced 3025 Gears 6178 Gears for infeed extension motion faulty; gears replaces 6179 Gears for infeed extension motion not adjusted; gears replaces 1018 INFEED MOTOR IS RUNNING BUT INTERNAL INFEED BELTS ARE STANDSTILL 3008 Toothed belts 6026 Internal infeed movement toothed belt broken; belt replaced 1019 MACHINE DOES NOT START BY PRESSING THE START BUTTON 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored

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3016 Electronic 6303 6304 6307 6311

CPU AP7 card damaged; card replaced DAC AP10 card damaged; card replaced Display card AP17 damaged; card replaced Output interface card AP5 damaged; card replaced

3059 Keyboard 6350 Keyboard faulty; replaced 1020 MACHINE DOES NOT POWER ON 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 6051 Main switch connections are defective; connections restored 6187 Network voltage not present; connection restored 3016 Electronic 6303 6307 6311 6306 CPU AP7 card damaged; card replaced Display card AP17 damaged; card replaced Output interface card AP5 damaged; card replaced Power card AP1 damaged; card replaced

3024 Fuses 6166 Fuses FU15 and FU16 interrupted; replaced 6167 Fuses FU17 and FU18 interrupted; replaced 6169 Fuses FU9 and FU10 interrupted; replaced 3029 Main switch 6180 Main switch QS1 faulty; replaced 3045 Rectifier bridge 6261 Rectifier bridge V2 faulty; replaced 3060 Transformer 6357 Transformer TV1 faulty; transformer replaced 1021 MISSING OF SUPPLY TENSION ON INVERTERS 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6306 Power card AP1 damaged; card replaced 3020 Filter 6096 Filter E2 is defective, filter replaced 6097 Filter E3 is defective, filter replaced 3024 Fuses 6164 Fuses FU7 or FU8 interrupted; replaced 3030 Frequency converter 6181 Inverter AP3 faulty; inverter replaced 6182 Inverter AP4 faulty; inverter replaced 3060 Transformer 6358 Transformer TV3 faulty; transformer replaced 1022 MISSING OF SUPPLY TENSION ON STEPPER MOTORS 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6311 Output interface card AP5 damaged; card replaced

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3024 Fuses 6167 Fuses FU17 and FU18 interrupted; replaced 3045 Rectifier bridge 6261 Rectifier bridge V2 faulty; replaced 3060 Transformer 6357 Transformer TV1 faulty; transformer replaced 1023 MISSING OF SUPPLY TENSION ON CPU AND DISPLAY 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3024 Fuses 6166 Fuses FU15 and FU16 interrupted; replaced 3060 Transformer 6357 Transformer TV1 faulty; transformer replaced 1024 MISSING OF SUPPLY TENSION ON BRAKES, CLUTCHES AND SOLENOIDS 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6311 Output interface card AP5 damaged; card replaced 3024 Fuses 6165 Fuses FU13 and FU14 interrupted; replaced 3045 Rectifier bridge 6260 Rectifier bridge V1 faulty; replaced 3060 Transformer 6357 Transformer TV1 faulty; transformer replaced 1025 MISSING OF SUPPLY TENSION ON SENSORS AND PHOTOCELLS 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6310 Input interface card AP6 damaged; card replaced 1026 INFEED MOTOR DOES NOT START BY PRESSING THE START BUTTON 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 6304 6307 6311 CPU AP7 card damaged; card replaced DAC AP10 card damaged; card replaced Display card AP17 damaged; card replaced Output interface card AP5 damaged; card replaced

3030 Frequency converter 6182 Inverter AP4 faulty; inverter replaced 3034 Motor 6217 Motor M2 faulty; motor replaced 3059 Keyboard 6350 Keyboard faulty; replaced 1027 MAIN MOTOR DOES NOT START BY PRESSING THE START BUTTON

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3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 6304 6307 6311 CPU AP7 card damaged; card replaced DAC AP10 card damaged; card replaced Display card AP17 damaged; card replaced Output interface card AP5 damaged; card replaced

3030 Frequency converter 6181 Inverter AP3 faulty; inverter replaced 3034 Motor 6216 Motor M1 faulty; motor replaced 3059 Keyboard 6350 Keyboard faulty; replaced 1028 MAIN OR INFEED MOTOR DOES NOT RUN WITH THE PROGRAMMED SPEED 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6304 DAC AP10 card damaged; card replaced 6311 Output interface card AP5 damaged; card replaced 3030 Frequency converter 6181 Inverter AP3 faulty; inverter replaced 6182 Inverter AP4 faulty; inverter replaced 1029 STEPPER MOTORS ARE RUNNING IN OPPOSITE DIRECTION 3011 Electrical connections 6022 Cable for motor connection has some wires inverted; connections arranged 6052 Electrical connections between the cards are defective; connections restored 3035 Stepper motor 6022 Cable for motor connection has some wires inverted; connections arranged 1030 STEPPER MOTORS SOMETIMES ARE RUNNING IN OPPOSITE DIRECTION 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6074 Driver AP8 is defective; driver replaced 6075 Driver AP9 is defective; driver replaced 6310 Input interface card AP6 damaged; card replaced 3035 Stepper motor 6213 Knife motor faulty; motor replaced 1031 MAIN OR INFEED MOTOR DOES NOT START AND ON THE INVERTERS DISPLAY "OH2" APPEARS 3011 Electrical connections 6054 Electrical connections are defective; connections restored 3034 Motor 6251 Thermoregulator for motor protection interrupted; motor replaced 1033 KNIFE MOVEMENT DOES NOT WORK 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced

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6075 Driver AP9 is defective; driver replaced 6310 Input interface card AP6 damaged; card replaced 6311 Output interface card AP5 damaged; card replaced 3035 Stepper motor 6224 Stepper motor M9 faulty; motor replaced 1034 FILM REEL LENGTH MOVEMENT DOES NOT WORK 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 6075 6310 6311 CPU AP7 card damaged; card replaced Driver AP9 is defective; driver replaced Input interface card AP6 damaged; card replaced Output interface card AP5 damaged; card replaced

3035 Stepper motor 6223 Stepper motor M8 faulty; motor replaced 3067 Film length screw 6367 Film length drive screw not lubricated; screw lubricated 1035 REEL SUPPORT MOVEMENT BRAKE DOES NOT WORK 3001 Film tension device 6014 Sensor activation cam of film tension device not adjusted; cam adjusted 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 6170 6174 6310 6311 CPU AP7 card damaged; card replaced Hybrid IB0 faulty, hybrid replaced Hybrid IB5 faulty, hybrid replaced Input interface card AP6 damaged; card replaced Output interface card AP5 damaged; card replaced

3022 Brake 6141 Reel 1 brake YB5 is faulty; brake replaced 6144 Reel 2 brake YB6 is faulty; brake replaced 3053 Sensor 6324 Film tension sensor SQ6 faulty; sensor replaced 1036 UPPER EJECTOR MOVEMENT DOES NOT WORK 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 6074 6310 6311 CPU AP7 card damaged; card replaced Driver AP8 is defective; driver replaced Input interface card AP6 damaged; card replaced Output interface card AP5 damaged; card replaced

3035 Stepper motor 6221 Stepper motor M6 faulty; motor replaced 3066 Ejector screw 6366 Ejector drive screw not lubricated; screw lubricated 1037 TEFLON BELT BREAKS 3048 Adjustment

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6242 Belt not aligned; belt aligned 1038 SEALING PLAT DOES NOT WARM UP 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 6311 6306 6312 CPU AP7 card damaged; card replaced Output interface card AP5 damaged; card replaced Power card AP1 damaged; card replaced Relay card AP2 damaged; card replaced

3024 Fuses 6168 Fuses FU4, FU5 and FU6 interrupted; replaced 3041 Sealing plate 6257 Sealing plates, one is faulty; replaced 1039 EXIT CLAMP DOES NOT WORK 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3015 Solenoid 6077 Solenoid YA2 is defective; solenoid replaced 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6173 Hybrid IB4 faulty, hybrid replaced 6311 Output interface card AP5 damaged; card replaced 1040 FOLDER CLAMP DOES NOT WORK 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3015 Solenoid 6076 Solenoid YA1 is defective; solenoid replaced 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6173 Hybrid IB4 faulty, hybrid replaced 6311 Output interface card AP5 damaged; card replaced 1041 SIDE CLAMPS DO NOT WORK 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3015 Solenoid 6078 Solenoid YA3 is defective; solenoid replaced 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6173 Hybrid IB4 faulty, hybrid replaced 6311 Output interface card AP5 damaged; card replaced 1042 FILM SEPARATION POINT TOO FAR BEHIND 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced

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6170 6171 6310 6311

Hybrid IB0 faulty, hybrid replaced Hybrid IB1 faulty, hybrid replaced Input interface card AP6 damaged; card replaced Output interface card AP5 damaged; card replaced

3023 Clutch 6154 Film separation clutch YC1 faulty; clutch replaced 6156 Film separation clutch YC1 is not adjusted; clutch adjusted 6155 Film separation clutch YC1 is slipping; clutch cleaned 3048 Adjustment 6300 Film length reel not rightly positioned; reel restored 6276 Film separation correction programming not correct; programming arranged 3053 Sensor 6332 Film length sensor SR6 faulty; sensor replaced 6325 Sensor SQ7 faulty; sensor replaced 6336 Unwinding sensor SR2 faulty: sensor replaced 1043 FILM SEPARATION POINT TOO ADVANCED 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 6170 6171 6310 6311 CPU AP7 card damaged; card replaced Hybrid IB0 faulty, hybrid replaced Hybrid IB1 faulty, hybrid replaced Input interface card AP6 damaged; card replaced Output interface card AP5 damaged; card replaced

3022 Brake 6136 Film separation brake YB1 is faulty; brake replaced 6138 Film separation brake YB1 is not adjusted; brake adjusted 6137 Film separation brake YB1 is slipping; brake cleaned 3048 Adjustment 6300 Film length reel not rightly positioned; reel restored 6276 Film separation correction programming not correct; programming arranged 3053 Sensor 6332 Film length sensor SR6 faulty; sensor replaced 6325 Sensor SQ7 faulty; sensor replaced 6336 Unwinding sensor SR2 faulty: sensor replaced 1044 ELEVATOR DOES NOT REACH THE CORRECT HIGH POSITION 3055 Elevator 6252 Cam idle pin subsided; cam idle pin replaced 6184 Elevator control lever of elevator with game; lever replaced 6359 Elevator control lever unibal faulty; unibal replaced 1045 ELEVATOR DOES NOT STOP IN THE CORRECT LOW POSITION 3022 Brake 6130 Cam brake YB3 is faulty; brake replaced 6132 Cam brake YB3 is not adjusted; brake adjusted 6131 Cam brake YB3 is slipping; brake cleaned and adjusted 3055 Elevator 6252 6009 6184 6343 Cam idle pin subsided; cam idle pin replaced Elevator adjustment rod not adjusted; rod adjusted Elevator control lever of elevator with game; lever replaced Elevator not in phase; phase of elevator corrected

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1046 REEL SUPPORT DOES NOT TURN CORRECTLY 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 6170 6174 6310 6311 3022 Brake 6140 6139 6143 6142 CPU AP7 card damaged; card replaced Hybrid IB0 faulty, hybrid replaced Hybrid IB5 faulty, hybrid replaced Input interface card AP6 damaged; card replaced Output interface card AP5 damaged; card replaced Reel 1 brake YB5 is mechanical jammed; Reel 1 brake YB5 is mechanical jammed; Reel 2 brake YB6 is mechanical jammed; Reel 2 brake YB6 is mechanical jammed; brake replaced movement released brake replaced movement released

3053 Sensor 6324 Film tension sensor SQ6 faulty; sensor replaced 3057 Reel Support 6239 Reel support 1 movement hard; released movement 6240 Reel support 2 movement hard; released movement 1047 KEYBOARD DOES NOT WORK 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6303 CPU AP7 card damaged; card replaced 6307 Display card AP17 damaged; card replaced 3059 Keyboard 6350 Keyboard faulty; replaced 1048 INCORRECT EXIT OF TRAYS ON THE EXIT REEL 3010 Film transport belts 6049 Film transport belts bright; belts replaces 6050 Film transport belts not enough tightened; belts tightened 3018 Upper ejector 6080 Upper ejector too high; ejector height adjusted 3042 Folder 6082 Folder stop too forward; folder positioned at 3mm from the conveyor rollers 3043 Exit clamp 6234 Exit clamp movement hard; released movement 6258 Exit clamp too closed in his stand position; clamp opened 3046 Programming 6002 Exit clamp opening too late; opening time of clamp modified 3061 Utilization 6086 Film excessive quantity under the belts; film position modified 6271 Wrapping program under use not correct; operator instructed 1049 TRAYS DO NOT MOVE CORRECTLY ON THE ELEVATOR 3007 Belts 6043 End infeed belts missing; assembled the missing belts 6044 End infeed belts not enough tightened; belts tightened 3055 Elevator

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6344 Elevator too high when in the stand position; height adjusted 1050 INCORRECT POSITIONING OF TRAYS ON THE ELEVATOR 3000 Infeed 6030 Infeed belts are slipping; belts tightened 3046 Programming 6284 Pack straightening on elevator not correct; pack straightening modified 3055 Elevator 6344 Elevator too high when in the stand position; height adjusted 1051 TRAYS TIPPING OVER WHEN EJECTED 3010 Film transport belts 6049 Film transport belts bright; belts replaces 6050 Film transport belts not enough tightened; belts tightened 3018 Upper ejector 6080 Upper ejector too high; ejector height adjusted 3042 Folder 6082 Folder stop too forward; folder positioned at 3mm from the conveyor rollers 3043 Exit clamp 6234 Exit clamp movement hard; released movement 6258 Exit clamp too closed in his stand position; clamp opened 3046 Programming 6002 Exit clamp opening too late; opening time of clamp modified 3061 Utilization 6086 Film excessive quantity under the belts; film position modified 6271 Wrapping program under use not correct; operator instructed 1052 TRAYS BREAKING DURING WRAPPING 3010 Film transport belts 6049 Film transport belts bright; belts replaces 6050 Film transport belts not enough tightened; belts tightened 3044 Clamps 6236 Clamps movement hard; released movement 6259 Clamps too closed in the stand position; clamps opened 3046 Programming 6001 Clamps opening too late; opening time of clamps modified 6249 Wrapping parameters not correct; parameters modified 3048 Adjustment 6345 Elevator too low; height of elevator adjusted 6013 Reel not in correct position: reel repositioned 3055 Elevator 6081 Elevator phase not correct; phase arranged 6346 Elevator too small for the product to be wrapped; elevator replaced 6188 Mushrooms on elevator not present; missing mushrooms added 3061 Utilization 6088 Film insufficient quantity under the belts; carriage position modified 6271 Wrapping program under use not correct; operator instructed 3063 Trays 6361 Bad trays quality; use of better trays quality recommended 1053 SQUASHED TRAYS DURING THE FILM FOLDING 3010 Film transport belts 6049 Film transport belts bright; belts replaces 6050 Film transport belts not enough tightened; belts tightened

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3019 Film 6085 Film quality is bad: better film use recommended 3042 Folder 6294 6293 6292 6291 Folder reel bent; Folder reel bent; Folder reel lucid; Folder reel lucid; reel replaced reel straightened reel replaced reel roughed

3044 Clamps 6235 Clamp movement not free; released movement 3046 Programming 6264 Carriage position too small; carriage more opened 6355 Clamps opening times too high; opening times anticipated 3055 Elevator 6345 Elevator too low; height of elevator adjusted 6160 Mushrooms not straightened while the elevator goes down; mushrooms adjusted 3061 Utilization 6271 Wrapping program under use not correct; operator instructed 3063 Trays 6361 Bad trays quality; use of better trays quality recommended 1054 ELECTRONIC BOARD'S FAN DOES NOT RUN 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3016 Electronic 6311 Output interface card AP5 damaged; card replaced 6306 Power card AP1 damaged; card replaced 3065 Fans 6364 Fan faulty: replaced 1055 FILM'S FANS DO NOT RUN 3011 Electrical connections 6054 Electrical connections are defective; connections restored 6052 Electrical connections between the cards are defective; connections restored 3024 Fuses 6162 Fuse FU11 interrupted; fuse replaced

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PART 3 ENCLOSURES

x x x

x x

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Infeed sensor Unwinding sensor


New code from series no. 30 F.220.F.106 F.220.A.102 F.220.F.110 Description Sensor Sensor cam Support for sensor Old code until series no. 29 1.34.C72.01 F.220.A.036 F.220.F.050

Sensor for film detection


New code from series no. 30 F.220.F.106 F.220.F.109 F.220.G.033 Description Sensor Sensor disk Support for sensor Old code until series no. 29 1.34.C72.01 F.220.F.072 -

Film length sensor


New code from series no. 30 F.220.F.106 F.220.F.107 F.220.F.108 F.220.F.111 Description Sensor Sensor cam Support for sensor Transversal support Old code until series no. 29 1.34.C72.01 F.220.F.096 F.220.F.097 F.220.F.037

There are three replacement sets for the machines prior to series no. 30 so that, should a problem arise with an old sensor type, this can be replaced with the one of new type. The codes for the above-mentioned replacement sets are the following: Code M.220.A.102 M.220.F.112 M.220.G.033 Description Infeed and unwinding sensor Film length sensor Sensor for film detection

These replacement sets are composed by the new sensors, the parts and the relevant bolts and nuts necessary for their mounting as well as by a drawing giving the instructions and showing where to drill the holes (where necessary) for the mounting of the new sensors. The drawing number corresponds to the relevant replacement set.

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2. INFEED ASSEMBLY In order to solve the oxidation problems noticed on some components of the machine standard infeed assemblies as well as on those sold as options, two modifications have been carried out which are: 1. starting from series no. 30 included, the roller code no. F.220.A.006 and the relevant bearing (subject to oxidation) with code no. 2.25.012.06, have been replaced by the roller code no. M.220.A.006. The new roller is in fact complete of two plastic moulded bushings which replace the bearings. 2. Starting from series no. 36 included, the retaining rings made of hardened steel (subject to oxidation) have been replaced by those made of stainless steel. Starting from series no. 30 included, the product guides of the standard infeed assembly have been shortened by 165mm. This modification has been made in order to avoid possible displacements of the trays when they moved on the belts in the speed changing area. These displacements were caused by that 165mm piece of guide which has now been eliminated. The new parts take following identification codes: New code from series no. 30 F.220.A.100 F.220.A.101 Description Product guide, right Product guide, left Old code until series no. 29 F.220.A.071 F.220.A.072

3. TRANSVERSAL SUPPORT FOR THE CARRIAGE POSITION SENSORS Starting from series no. 30 included, the sensors transversal support with code no. F.220.F.027 has been replaced by the new transversal support with code no. F.220.F.105. On the new transversal support, the holes for the fixing of carriage sensors in the extrastroke position (carriage more closed) used when small trays are wrapped, have been modified. Up to machine series no. 29, with the carriage in the extra-stroke position, the sensors had to be relocated by 48mm. With the above-mentioned modification valid from machine series no. 30, the sensors are to be relocated only by 26mm.

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The purpose of this modification is to permit to use the carriage positions 1, 2 and 3. This is something which originally was not advised as the wrapping of the products did not look fine enough because of the fact, that the elevator was too close to the carriage. 4. KNIFE ASSEMBLY In order to ease its mounting and its maintenance, starting from series no. 30 included the knife structure has been thoroughly re-designed. The structure of the new assembly, essentially composed by a stainless steel support obtained through laser cut, fine folding and weldering, include more parts which previously had to be assembled manually. The new parts take following identification codes: New code from series no. 30 F.220.G.031 F.220.G.034 F.220.G.032 F.220.G.033 Old code until series no. 29 Knife support F.220.G.001-G.004-G.005F.220.V.005 Reinforcement of knife guide F.220.G.002 Support Support for film detection sensor Description

5. UNWINDING ADJUSTMENT ASSEMBLY Starting from series no. 36 included, the same concept as that studied for the knife assembly (see chapter 5) has been adopted for the unwinding adjustment assembly, that is we have re-designed this assembly in order to ease its mounting and maintenance. The new structure includes now some parts which previously had to be assembled manually. It is essentially composed of a support of stainless steel sheet obtained through laser cut, fine folding and weldering. The new parts take following identification codes: New code from series no. 36 F.220.F.113 F.220.F.114 F.220.V.139 Description Transversal support Rectangular mobile support Carter Old code until series no. 35 F.220.F.111-F.108-F.036 F.220.V.004-V.007 F.220.F.033 F.220.V.011 *

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* The carter code no. F.220.V.011 has been replaced due to the different holes now being necessary for the mounting of the end stroke device code no. 1.56.51B.03 on the transversal support code no. F.220.F.113. 6. COVER ASSEMBLY To ease its disassembly during the maintenance operations, starting from series no. 30 included it has been decided to divide the knife cover F.220.V.067 into two separate covers. More precisely: a) F.220.V.136 b) F.220.V.137 Cleanout guard Knife guard

Always starting from series no. 30 included, the bulkhead shaft F.220.V.111 has been replaced by the shaft having the code no. F.220.V.138. This change has also been implemented with the purpose to ease the mounting as well as the maintenance operations. In fact, the previous shaft was fixed to the sides of the cover code no. F.220.V.093 by means of screws and washers, whereas the new one is fixed only with a dowel in the reinforcement code no. F.220.V.128 located in the middle of the cover. 7. MACHINE PROGRAMME A new programme version is installed in the machine starting from machine series no. 30 included. This programme version includes a further small series of modifications and improvements. This programme up-date was anyway necessary due to the mechanical implementation of the carriage extra-stroke (see chapter 3). Starting from series no. 30 included, the new programme version takes following identification code: New code no. F.220.I.612 (date 29.01.01) Description EPROM machine programme Old code number F.220.I.612 (date 28.06.00)

We list hereafter the differences between the new version and the previous-one.

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7.1 THE PROGRAMME HAS BEEN SUITED TO THE NEW MECHANICAL MEASURES OF CARRIAGE EXTRA-STROKE. Up to SERIES no. 29 included the sensors are moved by 48mm. Starting from SERIES no. 30 included, the sensors are moved by 26mm (purpose: be able to use also positions 1, 2 and 3 which in the previous version couldn't be reached due to mechanical interference). 7.2 TEST OF FILM LENGTH MOTOR and UPPER EJECTOR: the first movement is stopped respectively at 35cm and 27mm instead of 37cm and 37mm. The subsequent movements are increased respectively by 4cm and 20mm, as usual. 7.3 OPERATION WITH REDUCED INFEED SPEED: by setting the variable 126 "elevator/folder stroke type" to the value 2 (Elevator type E1), the infeed speed is reduced to about 85% compared with the standard set speed (leaving anyway the production rate unchanged). The purpose of this is to reduce the instability problems of the narrow trays when they are on the infeed. WARNING: it is possible, in case of particularly unstable products, to use this type of operation also with the standard elevator type E (i.e. with variable 126 set to 1). In this case you need to set the value 2 to the parameter "ELEVATOR TYPE" in the relevant wrapping programme. Pay attention, in this case, to avoid to set values greater than 20 in the parameter "PACK LINING-UP as otherwise there is the risk to get the tray bumping against the elevator while moving down. NOTE 1: while the maximum product dimension, when the variable 126 is equal to 2, is 200 mm (for ELEV. E1), in the second case described here-above the maximum product dimension is 230 mm (for standard ELEV. E). NOTE 2: in both cases of 'INFEED reduced speed' operation, the INFEED speed displayed on the machines parameters screen is the real one (i.e., if 50 cycles / min. is the target speed, the value displayed is approx. 41.5). 7.4 MODIFICATIONS TO OPERATION WITH EXIT PRODUCT PHOTOCELL AND OPTIONAL INPUTS The time interval between the photocell that gets free or the option input that switches to off (0) and the product that restarts from the infeed photocell, has been reduced (from 3-4 sec. to less than 1 sec.). Before the product on the infeed restarts due to the photocell getting free or the optional input switching to off (0), all optional inputs (if programmed) and the exit product photocell are tested to be off (0 / off).

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7.5 'FILM LENGTH CHANGE' SELECTION BY OPERATOR MENU: the infeed is now stopped during the film length motor movement. 7.6 RESTART AFTER ERROR 85 86 (WITH CAM ZEROSETTING) The time interval between the Start and the actual start of the infeed belt movement has been reduced (from 6-7 sec. to 3-4 sec.). NOTE: all CAM zerosettings are carried out now at 35 cycles / min. instead of 25 cycles / min. 7.7 BEHAVIOUR OF THE SMALL AND COUNTERSUNK TRAYS WITH THE EXTRASTROKE CARRIAGE As far as their positioning on the elevator is concerned, there has been an improvement in the behaviour of the first two packages in a series of packages. 7.8 UPPER EJECTOR DEFECTIVE AT MACHINE POWER-UP: the programme has been changed so that, if error 30 sorts out at the first zero-setting after the machine power-up (upper ejector not moving), the OPER menu will be displayed in order to be able to disable the ejector itself. 7.9 DISABLING THE EXIT PRODUCT PHOTOCELL: with the new programme version, 10 consecutive start commands with obscured photocell are needed to disable the photocell. With the previous version, 10 start commands during the whole day were enough. 7.10 INFEED CONVEYOR STOP SWITCH TURNED TO 0 WITH A PRODUCT JUST STARTED (OR THAT IS GOING TO START) FROM THE INFEED PHOTOCELL With the new programme version, the product ends the wrapping cycle. With the previous programme version, the product was stopped causing the error 87 to appear.

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8. NEW OPTIONS 8.1 C.220.040 Narrow infeed extension (section 1) This option enables to increase by 2 metres the space available to the operator to place the trays/products to be wrapped. It is to be connected directly to the standard infeed of the machine from which it is driven as this option hasnt an own motor. The main feature of this narrow infeed extension is its overall width of only 290mm. The max. width of the trays/products to be wrapped is therefore limited to 280mm (the trays have anyway to be placed on the infeed extension in the width sense). This option has been developed to fulfil the special requirements of certain packing installations, as for example the apples packing sector. Thanks to its reduced overall dimensions, the task of the operators is eased as no unnecessary and wrong body movements have to be done. This section is delivered complete with two supporting legs, a side guide for the centring of the trays and a Stop push-button which can both be mounted either on the left or right side. It is furthermore also adjustable in height to enable to feed the machine with products having an height up to 200mm. To further extend this infeed, please refer to the option C.220.040.1 This option can be installed to machines starting from series no.1. For its mechanical installation, please refer to the drawing no. D.222.A.01. 8.2 C.220.040.1 Narrow infeed extension (sections 2 / 3)

This narrow infeed extension of 2 metres can be connected after the narrow infeed extension of section 1 (option C.220.040) enabling in this way to further increase the space available to the operators to place the trays/products to be wrapped. The maximum possible length of all extension sections together that can be connected to the machine is 6 metres, including section 1. This infeed extension has the same general features as those of the option C.220.040. This option can be installed to machines starting from series no.1. For its mechanical installation, please refer to the drawing no. D.222.A.02. 9. ENCLOSURES Following the above-mentioned points, we enclose here-with the modified or extended chapters of the spare parts manual code no. Y.221.002 of the 55Pi machine. Additional sets of this spare parts manual, both for your internal use as well as for your customers, can be ordered as spare part by stating the above-mentioned code number.

fffffffff

44
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This modification, besides granting compliance to the maximum allowed levels of emissions set by the 89/336/EEC Directive, it also permits to use the above-mentioned switches provided that the power curve is of type D. The modification consists in the replacement of the two metal spacers of the condensers board by two spacers made of plastic having code no. 6.34.04004 and in the addition of two wires code no. F.220.I.136 and F.220.I.137 for the connection of the condensers board to the earth bar. For the machines belonging to the series prior to no.36 and which are connected to power mains protected by differential switches, it is possible to ask for the necessary pieces to perform the above-mentioned modification by ordering them under the code no. M.220.I.136 along with drawing no. E.220.I.05 for their mounting. NB. The modification can be performed on all power boards code no. E.220.I.05 having the condensers board mounted on the two metallic spacers. For those boards on which only a commercial net filter is mounted (with a metallic box), the modification must not be performed. 2. MACHINE PROGRAMME

Starting from machine series no.36 included, a new software version containing a small series of modifications and improvements is being installed (point 1 here-under is quite important). Starting from machine series no.36 included, the identification code of new software version is as follows: New code no. F.220.I.613 (date 08.08.01) Description EPROM programme Old code no. machine F.220.I.612 (date 29.01.00)

We list you here-after the main differences between the new programme version and the previous-one: 1. MACHINE STOPS CAUSED BY ERROR 71 (KNIFE) HAVE BEEN DRASTICALLY REDUCED The torque to the step motor is forced through the programme at the beginning of the movement and is taken away (always through programme) when the movement is really over.

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REMARK: for the reasons mentioned here-above, we suggest to install this software version on machines already installed and of prior series on which a high number of error 71 has been noticed without any clear reason (for example hardware, connections, etc.). 2. TWO PROBLEMS WHICH WERE BROUGHT IN FROM SERIES 30 HAVE BEEN REMOVED (WHICH ANYWAY COULD HAVE APPEARED VERY SELDOM): 2.1 With product parameter elevator type = 2 or with the variable stroke type = 2, if the sum of the product parameter pack lining-up and the machine parameter infeed behaviour is higher than 35, it could happen that a pack is stopped at the infeed photocell, without moving anymore. 2.2 If the machine stops with an error different from those between no.85 and no.89 (including STOP and COVERS) and if by the subsequent machine START the cam performs a zero-setting and something darkens the CARRIAGE photocell causing the error no.86 to appear, when a new START is given the machine restarts at the zero-setting speed (35 cycles) and not at the set-one. This problem is noticed if the machine runs at high speeds, for example higher than 45 cycles per minute. 3. IT EXISTS THE POSSIBILITY TO REDUCE THE SO-CALLED LEAF FROM 30mm to 10mm (i.e. THE QUANTITY IN MILLIMETERS OF THE PRODUCT THAT CAN DARKEN THE INFEED PHOTOCELL IN ORDER TO DETECT A PRODUCT). THE PRODUCT PARAMETER BLIND WINDOW FOR TRANSPARENT TRAYS MUST BE SET TO VALUE 1. REMARK: the parameter keeps its original function if the values are between 10 and 200. In other words: value 0 value 1 value 2 - 9 blind window disabled and product detected after 30mm blind window disabled and product detected after 10mm blind window enabled (VALUE FORCED TO 10) and product detected after 30mm blind window enabled (TO THE SET VALUE) and product detected after 30mm

value 10 - 200

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The pulley F.220.C.013 has therefore also undergone a modification in the bearing seat. This to allow the mounting of a larger bearing capable to absorb heavier loads. This modification has been done to avoid any possible dangerous flection caused by an excessive tensioning of the toothed belt giving the motion to the machine film unwinding system. In certain cases these flections could in fact generate an earlier wear of the shaft, pulley and bearing. The new items starting from series no. 63 take following code numbers: Old code number F.150.C.002 F.220.C.013 2.25.020.05 Description Shaft Toothed pulley Z=21 Bearing d30 Bearing d20 New code number F.220.C.026 F.220.C.027 2.25.030.07

Should there be the need to replace the SHAFT and the PULLEY on an 55Pi model machine up to series no. 62 (included), the assembly kit to order is M.220.C.026. This includes the shaft F.220.C.026, the pulley F.220.C.027 and the relevant bearings 2.25.030.07. Should there be the need to replace ONLY the SHAFT on an 55Pi model machine up to series no. 62 (included) or on a previous machine model 55, the assembly to order is M.220.C.002. This includes the shaft F.150.C.002 and a spacer (see drawings M.150.C.002 here-with enclosed).

2.2

Machine upper cover Starting from machine series no. 63, the right upper cover F.220.V.080 and the lower damper coupler F.220.V.041 have been modified to avoid possible cracks at the hollow area on the cover edges. These latter were made to allow the cover to close down correctly. On the new cover there is now no hollow area and the couplers C.220.V.041 have been modified. The new cover has the same code number as the previous one (i.e. F.220.V.080) whereas the lower damper coupler F.220.V.041 takes the new code F.220.V.142. Should there be the need to replace the upper cover F.220.V.080 on a machine model 55Pi up to series no. 62 (included), the assembly to order is M.220.V.142 which includes the cover, the new couplers and bolts & nuts for their mounting. On the enclosed drawing no. M.220.V.142 we have also drawn the new holes to be drilled on the machine sides for the mounting of the new parts.

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2.3

Protection cover for infeed clutch Starting from machine series no. 63, a protection cover is mounted on the clutch located under the machine infeed to protect it from water sprinkles or from other liquids being used during the cleaning operations. This protection cover has the code number F.220.A.105. This cover can also be mounted on machines series previous to the no. 63 where oxidation problems on the clutch have been noticed. The holes to be drilled are shown on the figure here-below.

30

120

93 8 45 195

2.4

Cams of the inductive sensors Starting from machine series no. 63, the material used to manufacture the cams F.220.A.102, F.220.F.107 and F.220.F.109 has been changed to AISI303 (stainless steel) compared to the material used on previous machine series (AlMgSi1 aluminium). The manufacturing material has been changed because the AISI303 is a more suitable material than AlMgSi1 for the correct functioning of these sensors. The code number of these cams do not change and are therefore interchangeable with those of previous series.

3xM4

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2.5

Tensioning spring of the sealing plate belt Starting from series no. 63, the tensioning spring F.112.U.071 of the sealing plate belt has been replaced by a new type with code number F.220.U.056. Compared to the previous type which was made of galvanized steel, the new spring is made of stainless steel. Furthermore, its strength has been increased to guarantee a better traction of the sealing belt in its rotation movement avoiding in this way possible slipping when heavy products are transported. As a spare part, please ask for the new spring F.220.U.056. Please ALWAYS replace both springs in order to have the same tension on both sides of the sealing belt. Shouldnt this be done, there will be for sure side-skidding and breakages of the belt.

2.6

Protection against oxidation To solve oxidation problems noticed on some aluminium parts of machines working in burdensome environments, starting from series no. 63 some aluminium parts have undergone anodising. The parts are: film unwinding rollers film tensioning rollers infeed roller

The new parts keep the same code numbers. They are therefore interchangeable with the previous ones.

3.

Outlet conveyors: options C.220.010, C.220.011, C.220.012, C.220.013 Starting from series no. 63, the above-mentioned options are manufactured following engineering design and have therefore undergone structural changes. The main changes are: the conical rollers arent any longer made in aluminium casting but are now made of plastic by injection molding solving in this way oxidation and cleaning problems. More suitable material and surface treatments have been used to manufacture some parts subject to oxidation.

I 41058 VIGNOLA (MO)


COMUNICAZIONE TECNICA N TECHNICAL COMMUNICATION N COMMUNICATION TECHNIQUE N TECHNISCHE MITTEILUNG Nr. COMUNICACION TECNICA N DEL DATE DU VOM FECHA

CH 6933 MUZZANO (TI)


PAGINA PAGE PAGE SEITE PAGINA

W 0184

23.07.02

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The straight sections complete with belts are now designed to be adjustable in height. This modification allows the conveyors to better fit to other equipment to attach to them. The straight sections complete with belts have also been extended allowing a better accessibility to the machine (for example for cleaning operations, film reel change, machine maintenance purposes, etc.). Please find here-with enclosed the drawing no. 10.311 showing the new layout of the outlet conveyors.

4.

Enclosed drawings no. M.150.C.002 no. M.220.V.142 no. 10.311