نافخه

EBS Ergon
Operator Interface Manual

Translation of the original instructions
Manual code: DM220210

Console: v. 16.00
Creation date: 22/09/2016
Summary
Summary
1 – MACHINE CONTROL 7
1.1 Operator panel description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Main page (maximum configuration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Warnings and signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Navigating bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Inserting the password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4 Procedure to start the machine and prepare it / production start . . . . . . . . . . . . . . . . . . . 14
1.5 Machine start procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.6 Machine emptying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.7 Machine switch-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.8 Format selection / format change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2 – DIRECT CONTROLS 17
2.1 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Grippers mechanical position (carousel infeed) / without blow-moulding . . . . . . . . . . . . . 18
2.3 Blowing air recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4 Bottles per mould / grippers mechanical position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5 Machine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.6 Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.7 Temperature control commands / preforms rejection and bottles rejection / lighting up
of service lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.8 Lots production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3 – MACHINE OPERATING MODES AND STATES 25

3.1 General information and operation description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 Normal operation mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
WITHOUT PRODUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
WITHOUT BLOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
PREFORMS EXPULSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
BOTTLES PER MOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3 Unloading state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.4 Emergency state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.5 On phase waiting state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.6 Pause state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.7 Stop state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.8 Oven heating state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.9 Production state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.10 Stand-by state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.11 Pre-heating state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.12 States for detecting machine indexes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
“Machine running with products” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3
Summary
“Production stop – external causes” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

“Production stop – internal causes” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
“Production stop – downstream problems” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
“Production stop – upstream problems” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4 – RESTART OF THE PRODUCTION AFTER AN ALARM 33

4.1 Preliminary controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.2 Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.3 Possible faults and problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
0001 ON SELECTING "POWER" ON THE OPERATOR'S PUSH-BUTTON PANEL,
THE POWER SUPPLY IS NOT ACTIVATED . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
0002 SERVO MOTORS DO NOT RESET IN THE STARTING POSITION . . . . . . . . . . . 35
0003 ALTHOUGH THE ANOMALY CAUSING THE ALARM SITUATION HAS BEEN
SUCCESSFULLY DEALT WITH, THE ALARM IS STILL ACTIVE ON THE
DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5 – SERVO MOTORS PHASE RECOVERY PROCEDURE 37

5.1 Premise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.2 Preliminary controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.3 Phase search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
COMPLETE PHASE SEARCH AFTER TURNING ON THE MACHINE . . . . . . . . . . . . . 38
COMPLETE PHASE SEARCH AFTER FORMAT CHANGE . . . . . . . . . . . . . . . . . . . . . . 39
INDIVIDUAL AXIS PHASE SEARCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6 – SERVO MOTORS PHASE SEARCH PROCEDURE 43

6.1 Premise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.2 Phase recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.3 Faults requiring the phase recovery procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7 – PROCEDURE TO ENABLE THE INVERTERS 47

7.1 Premise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.2 Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8 – PARAMETERIZATION 51
8.1 Parameters organization principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.2 Selection of the functional group and access to the parameters . . . . . . . . . . . . . . . . . . . 52
8.3 Support functions for the parameters setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Restoring the pre-existing values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Recommended range and safety range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Consulting the chronological list of the modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Display of the most frequently used parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8.4 How to create safety copies of the machine parameters . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.5 How to restore the machine parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8.6 How to print the parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8.7 Utility functions for the parameterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8.8 Other forms of parameterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8.9 Control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4
Summary
9 – STATISTICS VIDEO PAGE 67

9.1 Premise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
RECORDERS PUSH-BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Consultation of the recorder data by means of the push-button of the individual data
recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Push-buttons for a guided consultation of the statistics . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9.3 Saving of the recorded data on a flash memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
10 – ALARMS AND STATE MESSAGES 83

10.1 Managing alarms acknowledgement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
10.2 List of state messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
SUMMARY CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
10.3 List of alarm messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Summary chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10.4 Meaning of the alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
11 – CONSOLE MANAGER (CONMGR) – INSTALLATION AND USE 125

11.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
11.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
11.3 Minimum requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
11.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
11.5 Disinstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
11.6 Preparation of a spare Posyc with CONMGR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
11.7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
When you start the system, the programme does not start . . . . . . . . . . . . . . . . . . . . . . 128
No operator panel is found on the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
The active operator panel is not executed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
The operator panel that has been started signals some problems during the data
transfer to the process controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
12 – MACHINE COMMANDS 129

12.1 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
12.2 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
12.3 Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
12.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
ANALYTICAL TABLE OF CONTENTS 133
5
Summary
6
Machine control
1 MACHINE CONTROL
1.1 Operator panel description

The operator panel consists of:
MACHINE CONTROLS
START/UNLOAD push-button.
It starts the machine.
It assumes special functions depending on the modes the system operates.
STOP push-button
It stops the machine in phase. If it is pressed when the machine is at a standstill, it cancels the
alarm messages from the display, this will not occur if you activate the alarm acknowledgement
management. Therefore, refer to chapter 10"Alarms and state messages (page 83)" to under-
stand how the alarm acknowledgement management works.
POWER push-button.
It powers up the machine.
When the LED is ON, power is OFF.
When the LED is OFF, power is ON.
EMERGENCY push-button
Mushroom push-button to stop the machine in emergency.
In some applications, the standard push-buttons board includes the push-buttons “Warning sound”
and “Alarm reset”.
LUMINOUS COLUMN
The following models of luminous column are available:
• 5-colour luminous column (red, yellow, green, white, blue) with an integrated siren.
• 3-colour luminous column (red, green, blue) with an integrated siren.
7
Machine control
Explanations:
5-colour column 3-colour column State Description
This goes off just before the machine starts

running or following the stop of the machine
MACHINE START -
due to an alarm. ATTENTION: for some ver-
SIREN SIREN ALARM SIGNALS -
sions, it is possible to associate some cus-
STATE INDICATION
tomized acoustic signals with a certain type of
alarms.
It turns on when there are some alarms which

prevent the machine operation. Examples of
RED COLOUR RED COLOUR EMERGENCY
turn on conditions: - disabled power supply, -
open safety doors; - air lack
It turns on when there is a problem or an

anomaly related to the production. By press-
FLASHING RED COL- ing the START push-button, the machine can
YELLOW COLOUR PROBLEM
OUR start again. Examples of turn on conditions: -
product lack at the infeed. - Consumable ma-
terial reserve end.
GREEN COLOUR GREEN COLOUR RUNNING This is on when the machine is running.
This is on when the machine is in the PAUSE

state. Attention: the machine will re-start auto-
FLASHING GREEN matically, as soon as the causes determining
WHITE COLOUR PAUSE
COLOUR its stop in PAUSE are solved. Examples of
turn on conditions: - accumulation, - end of
product flow.
This is on when an action by the operator is

requested or to restore consumption products
BLUE COLOUR BLUE COLOUR ACTION REQUEST (cartons, glue, etc.) or just to start the ma-
chine again by pressing the START push-but-
ton.
8
Machine control
1.2 Main page (maximum configuration)
Warnings and signals
Shows the value of the service air (expressed in Bar) and the button to access functional
A unit parameterization.
Shows the value of the pre-blow moulding air (expressed in Bar) and the button to access
B functional unit parameterization.
Shows the value of the blow moulding air (expressed in Bar) and the button to access
C functional unit parameterization.
Partial counter with display of number of bottles produced and access to the machine's
D production indicators page, with option to reset the partial counters.
Shows machine encoder pulses (allows access to speed settings to SMI authorized
E personnel).
Shows machine speed, expressed in bottles per hour (allows access to speed settings to
F SMI authorized personnel).
G Shows energy consumption, related charts and count reset.
H Indicates scheduled maintenance (if this option is enabled).
9
Machine control
Section including manual increase or decrease of power of all the tunnel's lamps (in case
I temperature control is OFF) or temperature control set point increase or decrease (in case
temperature control is ON).
Shows pressure at machine inlet (if this option is enabled) and the button to access
J functional unit parameterization.
Shows preforms temperature at machine inlet and the button to access the
K parameterization of the temperature control functional unit.
Shows tunnel temperature and the button to access the parameterization of the
L temperature control functional unit.
Shows preforms temperature at tunnel exit and the button to access the parameterization
M of the temperature control functional unit.
Button for machine phase search/phase recovery.

Equivalent to preparing the machine as soon as it has been turned on or is displayed after
N an electronic axis problem in case of an emergency (phase search or phase recovery
request).
Button to access the page that shows all machine alarms and operating states, I/O states,
O downtime analyses and alarms history.
P Button to access the format change function.
Q Button to access the function that checks pressure inside the moulds.
Button to access the perform quality control function through the vision system (if this
R option is enabled).
When this button is active (colored), it may indicate the need for the acknowledgement of
machine alarms, or the mere presence of errors already seen by the operator.
S When this button is not active (white and black), there aren't any alarms.
For a detailed description of how alarms are acknowledged, please read the relating
paragraph 10.1"Managing alarms acknowledgement (page 83)".
Control to force the rejection of the bottles exiting from the blow moulder's carousel.
- Bottle rejection OFF - Bottle rejection ON
Control to force the rejection of the preforms entering the blow moulder's carousel.
- Preforms rejection OFF - Preforms rejection ON
10
Machine control
By pressing on the “SMIFORM” logo, you can see basic information about the machine,
V including the MACHINE SERIAL NUMBER, type of machine and the versions of the
programs installed in the machine.
Shows the number of preforms that are inside the machine and button to activate/
deactivate the opening of the preforms inlet gate.
- Separation opened - Separation closed

W
Machine luminous column indicating the machine's various states, luminous column
X parameterization button and button for disabling the siren.
Display of active alarms (refer to chapter 10"Alarms and state messages (page 83)").
Note: Machine alarms are displayed with the priority defined during design stages,
starting from the most serious ones;
The complete list is available in the “ALARMS” page, reached through button:
Y
This button is inside the main page.
Z Control for turning on and off the machine's service lamps.
1 Button for the direct access to the parametrisation of the lamps' panels
Button for the access to the configuration and visualisation of the machine's status
2 concerning OMAC standard
Button to access the oven's infeed/outfeed stars unit. You may access the:
- Mode for opening the gate (normal, without product or preforms rejection);
- Control for lowering the movable unit of the oven's infeed/outfeed stars;
- Parameterization of the motor of the oven's infeed/outfeed stars;
200 - Parameterization of preform loading system;
- Parameterization of the detection of the sensor that checks preform inlet into the
machine;
- Parameterization of option “preforms cleaning” through suction (if present in the
machine).
Button to access the oven unit. You may access the:

- Parameterization of lamps panels;
- Management of static relay alarms;
- Oven activation/deactivation via direct control;
- Parameterization of spindle release control (access restricted to SMI authorized
201
personnel);
- Parameterization of preform perpendicularity check;
- Parameterization of chain stretching check;
- Parameterization of oven driver (access restricted to SMI authorized personnel);
- Parameterization of drivers for oven ventilation.
11
Machine control
Button to access carousel infeed grippers unit. You may access the:
- Parameterization of carousel infeed grippers driver;
- Parameterization of carousel infeed rejection (access restricted to SMI authorized
personnel);
202 - Parameterization of the check for the grippers mechanical position and mechanical
phase;
- Control for activating/deactivating the “grippers mechanical position” check;
- Direct controls for the rejection of the heated preform sample (access restricted to SMI
authorized personnel).
Button to access the carousel unit. You may access the:

- Parameterization of the blow-moulding cycle.
- Calibration for the momentary activation/deactivation of the following units: stretch rod;
pre-blow-moulding; counter-mould; blow-moulding.
- Diagnostics of carousel safeties and check parameterization of bottom 1 and 2;
- Parameterization of blow-moulding cycle for every single mould and for activating/
203 deactivating the work cycle of every single mould;
- Functions and parameterization of blow-moulding air recovery (if present in the
machine);
- Controls and parameterization of carousel driver;
- Test section for solenoid valves involved in the blow-moulding cycle (this function
appears only when the machine is stopped).
- The “jog enable via pushbutton panel” is also present.
Button to access the carousel outlet grippers unit. You may access the:
- Parameterization of carousel outlet grippers driver;
- Parameterization of the check for the grippers mechanical position and mechanical
phase;
- “Bottle per mould” activation/deactivation (one bottle is ejected automatically for each
mould at activation);
- Control for activating/deactivating the check for the “grippers mechanical position”;
204 - Parameterization of bottle rejection at blow moulder exit (access restricted to SMI
authorized personnel);
- Parameterization of accumulation, obstruction and remote-controlled obstruction
functions (access restricted to SMI authorized personnel);
- Parameterization of belts at blow moulder exit (if present in the machine - access
restricted to SMI authorized personnel);
- Activation of combined management with external filler (if present in the machine -
access restricted to SMI authorized personnel).
12
Machine control
Navigating bar
Index of the operator panel pages or opening of the most frequently used functions (Fig.
4).
01 - Shows the page for accessing the I/O check and the electronic devices synoptic
panel.
03 - Shows the page of the alarms and the machine's operating states.
06 - Shows the page for the machine's main settings.
A 07 - Shows the page for the programme reset and exit.
08 - Shows a black screen with message: “YOU MAY NOW CLEAN THE SCREEN”.
Using a cloth (to clean PC and TV screens), you may now clean the Posyc screen.
09 - Shows the utilities page that contains these functions: Save/Restore parameters;
Print parameters; Language; Virtual keyboard; System settings; Manual-online;
Converter; Status display; Information; Deletion of temporary files.
Figure 4
B Enter password. Refer to paragraph 1.3"Inserting the password (page 14)".
C Back to the main page.
D To the next page or back to the preceding active pages.
13
Machine control
E It activates the in-line manuals
It sets the percentage size of the active video page.

F This function is normally deactivated as it is for the exclusive use of SMI technicians.
It shows, through a dropdown menu, the list of active video pages with the option for
G selecting the ones you want to see.
H REFRESHES the active video page.
I It closes the active video page.
1.3 Inserting the password

Press button B (PASSWORD) in the navigation bar to enter the password:
1 • Use the keyboard to key in the required password (default code is

127 for the “L1” operator, unless configured differently after machine in-
stallation).
2 • Confirms the entered Password.
1.4 Procedure to start the machine and prepare it / production

start
1 • Put the machine main switch “ON”. The operator interface panel will display the start of the op-
erating system and of the machine programme, in sequence.
2 • Check for the presence of the materials needed for the production (preforms hopper full of pre-
forms, caps hopper full of caps (when the Ecobloc machine is installed);
3 • Check that the emergency button is not pressed on the preforms loading system; then press
the “POWER” button on the same pushbutton panel;
4 • Check that the emergency button on the caps loading system (when the Ecobloc machine is
installed) is not pressed; then press the “POWER” button on the same pushbutton panel;
5 • Check that service air and high pressure air is present at the inlet of the pneumatic circuits.
6 • Set the cooling system (chiller) switch to “ON”
7 • Check for the presence of product provided by the customer for the filling cycle (when the
Ecobloc machine is installed);
14
Machine control
8 • Close the machine's doors. Check that the emergency button, located on the machine's oper-
ator panel, is not pressed, and then press the “POWER” button.
9 • Enter the password. Make sure the format is the right one. If not, change the format as ex-
plained in paragraph 1.8"Format selection / format change (page 16)".
10 • Press the “PHASE SEARCH (14)” button. The fully automatic phase search procedure begins;
NOTE: The “PHASE SEARCH (14)” button is visible only when you turn on the machine or when
you request the phase search of an electronic axis. However, a “PHASE SEARCH” button is always
present in the “MACHINE GENERAL” page, reached through the “MENU” button of the navigation
bar.
When the preforms and caps have filled the respective loading systems, you can start-up the
machine in pre-heating mode.
11 • Press the machine's START button. During the first minutes, the machine will run at the speed,
and remain in a pre-heating state, which allows the correct starting up and heating of the me-
chanical parts and also ensures the ideal microclimate inside the oven;
12 • Purge the taps to discharge the air from the pipes and to ensure the exchange of liquid inside
the tank (when the Ecobloc machine is installed);
13 • Once the automatic pre-heating procedure is over, the machine reaches its nominal speed and
is ready to open the gate and let the preforms enter the machine.
14 • Enable preform inlet by selecting button “gate open” (25) (it should turn from red to green).
NOTE: At first, it is advisable to let only a few preforms in (about forty) to be able to check the
quality of the blow-moulded bottle and also to check it has been filled to the correct level (when
the Ecobloc machine is installed);
1.5 Machine start procedure

If there are the right conditions, the machine will start when you press the push-button START.
1.6 Machine emptying

Stop the machine. The machine will stop automatically after processing all the product contained
inside.
1.7 Machine switch-off

1 • Remove all the products to empty the machine (see paragraph 1.6"Machine emptying
(page 15)").
2 • Press the EMERGENCY button on Posyc (machine operator panel).
3 • Press buttons:
- MENU in the navigation bar;
- PROGRAM RESET/CLOSE (07);
- POSYC SHUTDOWN (01).
4 • Wait for the PC to shut down (this condition is achieved when the screen turns black and this
message appears: “It is now safe to turn off your computer”).
5 • Switch the machine master switch and the cooling system (chiller) switches to "OFF".
15
Machine control
1.8 Format selection / format change

Press button “12” in the main page:
Now carry out the following steps:

1 • Press “FORMAT SELECTION” (01).
2 • Scroll through the list of formats in the Posyc memory and select the one to put into production.
3 • Confirm your selection.
4 • Now, please follow the directions from step 10 of paragraph 1.4"Procedure to start the machine
and prepare it / production start (page 14)".
16
Direct controls
2 DIRECT CONTROLS
2.1 Operating modes

The NORMAL (production) mode and the WITHOUT PRODUCT mode can be set in the main page,
through the following icons:
“WITHOUT PRODUCT” mode ”NORMAL” mode
The same function is provided in the INLET STARS unit page (200), accessed from the main page.
When selected, the gate through which the preforms enter the machine will open to allow
the preforms to enter, hence beginning the production cycle. NOTE: The gate will remain
A physically closed until the oven's ideal working temperature (pre-heating) is reached.
Then it will open physically and the preforms will begin to enter the machine.
When selected, the gate through which the preforms enter the machine remains closed,
B not allowing the preforms to enter but allowing the machine to run idle (without product)
after the “Start”.
When selected, the gate through which the preforms enter the machine will open to allow
the preforms to enter and, on reaching the expulsion piston, they will all be rejected before
C entering the oven. This procedure allows emptying the preforms loading system in case a
format change is performed.
Allows deactivating the machine emptying mode, requested at program start-up, in case
D any product is still inside the machine after closing the application during a production
cycle.
17
Direct controls
2.2 Grippers mechanical position (carousel infeed) / without

blow-moulding
In the CAROUSEL INFEED GRIPPERS unit page (202), you can access the following controls:
A Allows you to reject a few preform samples at oven outfeed to check their temperature.
2.3 Blowing air recovery

In the blowing air recovery unit page (06), accessed by selecting in the main page CAROUSEL
(203), you can access the following controls:
18
Direct controls
A Allows you to access the direct controls for the blowing air recovery.
B Allows you to activate/deactivate the blowing air recovery from the blow-moulding cycle.
Allows you to activate/deactivate the production of service air through the blowing air
C recovery from the blow-moulding cycle.
2.4 Bottles per mould / grippers mechanical position

In the CAROUSEL OUTFEED GRIPPERS unit page (204), accessed in the main page, you can
access the following controls:
A Allows you to reject a number of bottle samples for each mould present in the machine.
19
Direct controls
2.5 Machine speed

Press the MENU key in the flybar, MACHINE GENERAL (06) and then button MACHINE SPEED
(15) to access the page in which to set the rated or reduced speed.
2.6 Chiller
Press the MENU key in the flybar, MACHINE GENERAL and then button CHILLER, to access the
following control:
A Allows you to activate/deactivate chiller forcing.
20
Direct controls
2.7 Temperature control commands / preforms rejection and

bottles rejection / lighting up of service lamp
On the main page, you can enable or disable the two controls of the preforms
temperature, bymeans of the following icons:
- Activated control - Deactivated control

A
Corresponding to the following icons representing the functional group:
- Check for preform temperature - Outlet oven temperature

at machine infeed control
21
Direct controls
The following situations are achieved by selecting the icons listed below:
-Non-forced rejection of preforms(not active) -Non-forced rejection of bottles(not active)

Routine production condition. Routine production condition.
- Forced rejection of preforms (active). - Forced rejection of bottles (active).

All preforms at outfeed All bottles at carousel outfeed
will be rejected. will be rejected.
- Service lamp on - Service lamp off.
22
Direct controls
2.8 Lots production

By pressing the button in the main screen:
followed by the selection of buttons LOTS PRODUCTION (04) and then SETTINGS (04), you will
access the LOTS PRODUCTION direct control.
Allows you to activate/deactivate the lots production.

If active, the machine will automatically count a specific number of packs set via
A parameters and then the machine will stop at the end of the lot, displaying a message to
warn that the lot is finished.
23
Direct controls
24
Machine operating modes and states
3 MACHINE OPERATING MODES AND STATES
3.1 General information and operation description

The system object of this document is a continuous cycle industrial machine, which blowmoulds
plastic containers. The machine is equipped with two special push-buttons on the operator interface
terminal which allow its starting (START push-button) and its stopping (STOP push-button).
Furthermore,special mushroom-head push-buttons to stop the machine in an emergency situation
are present.
The various motions are obtained by brushless electrical motors. It is possible that several
mechanical members are driven by the same motor by the appropriate mechanical transmissions.
Please bear in mind that, in this text, the movements performed by the brushless type motors will
be called electronic axes or servo motors depending on cases and context.
For the control of the machine an electronic-computer system is used, which carries out the
programs for process control and for interaction with the assigned personnel. This system can be
subdivided into a process control system, an operator interface terminal and a series of alternate
and continuous current frequency converters used to control the electrical motors present.
From an operational point of view, the machine, by means of the infeed conveyour belt, carries the
preforms inside itself. The preforms are divided, heated and blown according to the pre-set
operating cycle, thus obtaining the shaped bottles to be conveyed to the machine outlet for
subsequent processes.
The control system, apart from allowing the carrying out of the operating cycle of the individual
mechanical members which make up the machine, is able to evaluate the entity of the flow of the
incoming product and to stop it if the upstream system does not supply enough product. It is
furthermore able to, in the latter case, to implement the automatic restart of the machine into
production if the incoming product has become sufficient again.
The control system also monitors the state of the machine outlet, in order to stop it if there were
accumulations of bottles due to the stop of the downstream system. Also in this case, the
production will re-start automatically as soon as the accumulation is solved.
Individual faults are pointed out by special display messages on the operator interface terminal.
The operator is supposed to carefully deal with the kind of alarm which has been activated.
Once the problem has been solved, the alarm shown on screen will be cancelled by pressing the
STOP push-button. At this point the selection of the START push-button will re-start the machine.
Schematically, when a fault shows up, this causes:
- Stop of the machine,
- Display of the related warning message on the terminal,
- Action by the assigned personnel to read the solution of the fault and its cancellation from the
alarms list by starting again the machine using the START push-button (which functions as a
“reset” push-button in this case) or through the alarm acknowledgement procedure (if active).
For any further information, please refer to chapter 10"Alarms and state messages (page 83)".
25
It is useful to know that the control system subdivides all the faults which might concern the
machine into two groups, the following table shows their characteristics.
EMERGENCY TYPE FAULTS PROBLEM TYPE FAULTS
These are faults which cause the immediate stop of

the machine and require some special procedures,
in order to solve the problem. Please refer to chapter
10"Alarms and state messages (page 83)" in order These are faults which cause the stop of the machine
to know the procedures to be followed. The origin of in a PHASE STOP and which may require an action
these faults can be mechanical, electric or electron- of reset by the operator. This group includes the warn-
ic. This group includes, for instance, all the faults de- ings concerning the production process and supply of
riving from the activation of the machine safety consumption materials.
systems. In some cases the seriousness of the fault
can cause the disconnection of the power supply of
the machine.
The machine foresees several operating modes, which can be selected through a special page of
the operator panel:
- Normal mode;
- Mode without product;
- Without blowing;
- Preforms expulsion;
- Expulsion forcing at carousel infeed
- Expulsion forcing at carousel outfeed
- Bottles expulsion due to mould.
The following pages will be dedicated to the explanation of these operating modes of the
machine. It is also very important to consider the operating modes of the infeed conveyor belt, due
to its special function as a controller of the machine feeding.
3.2 Normal operation mode

This is the typical operation mode of the machine. By pressing the push-button START, the
machine starts running and keep on running until the product at the machine inlet is finished or a
condition of stop occurs (the push-button STOP is pressed or an anomaly occurs)
WITHOUT PRODUCT
If you select this mode, you interrupt the preforms feeding. The machine is on, but in pause state,
until you select the normal mode and the different sequences of preforms processing are activated
(preforms discards, blowing cycle, etc.).
WITHOUT BLOWING
By selecting this mode, the machine continues producing, but the blowing command is not enabled
for two seconds, so that the bottle is formed only by the pre-blowing cycle.
PREFORMS EXPULSION
By selecting this mode, the machine rejects the oven inlet preforms until the inlet magazine is
empty.
26
BOTTLES PER MOLD

In the main page, press the zone concerning the BLOWING-WHEEL OUTFEED GRIPPERS (204),
then press the button BOTTLES PER MOLD (01):
By pressing one of the push-buttons representing one of the molds in the machine, you can reject
a certain number of bottles from the mold. The number of rejected bottles is set by the parameter.
3.3 Unloading state

Once the emergency conditions are solved, you must proceed to unloading the preforms present
in the machine, because they are no longer adequate for the machine processing.
The machine leaves the emergency state and enters the stop state, after solving the problems that
had occurred.
By pressing the push-button START, the machine starts running without carrying out the working
cycle operations, with the expulsion devices activated and the preforms feeding stopped.
3.4 Emergency state

In this state the machine is powered-on and stationary due to a fault.
Depending on the severity of the fault, the machine will exit from this state either automatically if
the PROBLEM type fault is restored or solved, or after carrying out specific recovery procedures
(e.g.: Phase recovery of electronic axes) if the fault is the EMERGENCY type.
The following two cases are possible if the ALARM occurs while the machine is running:
- A PROBLEM type fault occurred. In this case the control system stops the machine according
to the STOP IN PHASE procedure described below, in the paragraph that deals with the STOP
state.
- An EMERGENCY type fault occurred. In this case the control system stops the machine imme-
diately but maintains synchronization between major and minor movements.
If the machine switches to this state when there is no product inside, the machine will enter the
STOPPED state after problems have been solved.
27
But if product was present when the machine entered the alarm state, the machine will switch to
the UNLOADING state.
This will allow product to be removed from the machine without subjecting it to any type of
processing.
3.5 On phase waiting state

This is the state which the machine enters as soon as it is switched on through the main switch and
the power supply push-button (POWER) on the operator terminal has been pressed, or after an
emergency that caused an electronic axis to move from its phase position.
The machine leaves this state and enters the STOP state as soon as the system phase search or
the phase search of the axis in wrong phase position is carried out.
3.6 Pause state

In this state the machine keeps on running, with the preforms heating lamps active at the necessary
power to maintain the oven temperature near the working temperature; in this way, you are able to
immediately re-start the production, as soon as the pause conditions are not active.
The PAUSE state is expressely reasoned out in order to guarantee the machine automatic
operation, taking into consideration the operating states of the upstream and downstream systems
and the consequent variability of the product flow at the machine inlet and outlet.
In general, the possible pause conditions are:
- End of product flow
- Outlet accumulation
- Oven temperature below the minimum working temperature
- The next system is present, but not activated
However, four parameters are available that allow the technician to choose in which state the
machine should work in case one of these conditions occurs.
If the parameter is set to 1, the machine will reach the PAUSE state but if set to 0 the machine will
stop in STOP condition.
Format parameters are available in section “Machine specifications”, namely:
- Pause due to next system off;
- Pause due to oven heating;
- Pause due to lack of product at the inlet;
- Pause due to accumulation at outfeed.
- Pause due to remote-controlled accumulation.
The machine can enter the PAUSE state only if it was in the PRODUCTION state previously. As
soon as there are the right conditions to activate the PAUSE state, the preforms flow at the inlet is
stopped, the processing of the preforms present in the machine is stopped and the white light of
the lighting column is switched on.
If any anomalies occur during the PAUSE state, the machine leaves that state and enters the
ALARM state. If you press the push-button STOP, the machine will enter the STOP state.
A maximum time of permanency in the PAUSE state is set by a parameter; after the time has
expired, the machine will enter the STAND-BY state.
28
3.7 Stop state

This state consists in the situation where the machine is not running, but it is ready to do so,
although this cannot happen in an automatic manner (as in fact it happens for the PAUSE state and
STAND-BY).
The machine reaches this condition:
- After pressing the STOP button on the operator pushbutton panel;
- Coming from a MACHINE UNLOADING state caused by a fault that was solved later on.
In the first case, the changing of the system from the PRODUCTION state to that of STOP takes
place according to the procedure called “PHASE STOP procedure”. This procedure allows you to
stop the machine (almost emptied of the product) in an optimal position (called STOP IN PHASE),
set by special system parameters.
Once the control system has detected that it is necessary for the machine to enter the STOP state,
it stops the preforms feeding, concludes the processing of the product already in the machine; then
it stops the machine in STOP IN PHASE, after waiting the time set by the special parameters.
Please remember that all operations related to the phasing of the electronic axes present on the
machine (therefore, to the synchronization of the movements) must be carried out with the machine
in the STOP state.
3.8 Oven heating state

This state precedes the passage to the PRODUCTION state, after the push-button START has
been pressed, in order to re-start the machine. It has the function of restoring the optimal working
conditions before the processing of the preforms at the inlet starts.
These conditions consist in reaching the speed rate and the pre-set temperature value inside the
oven. Once the machine reaches these conditions, the machine will enter the PRODUCTION state.
3.9 Production state

It is the state corresponding to the machine running. The preforms are picked up at the inlet and
processed according to the established cycle. When you press the push-button STOP, the machine
will enter the corresponding operation state, thus stopping the preforms feeding and concluding the
processing of the preforms already in the machine.
By contrast, if an emergency occurs, the machine will the EMERGENCY state.
During the production, if the preforms flow is not regular or there is an outlet accumulation, the
machine will enter the PAUSE state.
3.10 Stand-by state

This state follows the PAUSE state after the maximum time of permanency has expired. It is similar
to the PAUSE state, but with the oven power in configuration of energetic saving. Once the
conditions that caused the machine to enter the pause state have been solved, the machine will
enter the OVEN HEATING state, in order to restore the production conditions. The introduction of
a new collector model, requiring a continuous consumption of air during the rotation in order to
avoid overheating the gaskets, implied a modification of the stand-by state management.
This modification consists in creating a stand-by state with the machine at a standstill, which the
machine would enter after a certain time of permanency in the present stand-by state. The
conditions of production re-starting do not change.
29
3.11 Pre-heating state

This state is displayed if the pre-heating procedure is active, which means starting the machine at
a speed lower than the nominal one (usually between 50 and 60% of the nominal speed) to allow
the mechanical parts to start-up when the machine starts running at the beginning of the work shift.
This mode can be disabled in the follow page, accessed via MENU – MACHINE GENERAL (06) –
MACHINE HEATING (17):
3.12 States for detecting machine indexes

For the purpose of reporting machine operations statistically, the following additional machine
states have been added:
“Machine running with products”

In this state, the machine can operate in two conditions:
- In normal production: the machine is producing bottles;
- In preforms processing end: the machine is emptying due to a stop condition.
The display of this alarm indicates that the production report will record the time during which the
machine is in production.
“Production stop – external causes”

In this state, the machine can be running or at a standstill and can not produce any bottles.
This is due to the malfunction of external devices of the machine or to special operating modes set
by the operator (mode without product).
production is interrupted due to external problems.
“Production stop – internal causes”

In this state, the machine can be at a standstill and can not produce any bottles.
This is due to internal malfunctions, such as an emergency due to a lowered mold bottom or inverter
communication failure. The display of this alarm indicates that the production report will record the
time during which the production is interrupted due to internal problems.
30
“Production stop – downstream problems”

This is due to the presence of alarms, such as “Outlet accumulation” or “Next system off”.
production is interrupted due to problems on downstream devices
“Production stop – upstream problems”

This is due to the presence of the alarm “Product flow end”.
production is interrupted due to problems on upstream devices (the lack of preforms on the hopper
depends on the machine operator who should load the product at the inlet).
31
32
Restart of the production after an alarm
4 RESTART OF THE PRODUCTION AFTER AN ALARM
4.1 Preliminary controls

Make sure that:
• Power supply is avaiable;
• Operating compressed air is avaiable;
• That the machine did not shutdown due to any serious faults;
• Safety micros are not active;
• All emergency push-buttons are released.
4.2 Start-up procedure

After removing the causes which generated the alarm or emergency situation, proceed as follow:
1 • Switch on the power in case it is off, by pressing the POWER push-button in the interface PC.
2 • If phase-recovering of the servo-motors is required, perform the relative “PHASE RECOVERY”
procedure. For any further information, refer to Chapter 6"Servo motors phase search proce-
dure (page 43)".
3 • If the servomotors need the phase search procedure, perform the relative “PHASE SEARCH”
procedure. For any further information, refer to Chapter 5"Servo motors phase recovery pro-
cedure (page 37)".
4 • If the servomotors need the enable procedure, perform the relative “ENABLE” procedure. For
any further information, refer to Chapter 7"Procedure to enable the inverters (page 47)".
5 • Press the push-button STOP or RESET in order to reset the alarms. In case alarm acknowl-
edgement is active, perform the procedure to acknowledge. For any further information, refer
to Chapter 10"Alarms and state messages (page 83)".
6 • Operate the machine by pressing the START push-button on the interface PC.
The alarms currently installed on the machine are duly shown in the apposite display on the main
page.
ATTENTION: if the priority management system is active, some alarms may not be made
immediately visible on the main page, as they would be shown only when all the anomalies ranked
higher in the alarms priority list have been successfully dealt with.
In any case, to get to know the real situation of all active problems, it is advisable to refer to the
ALARMS section, which in accessed in the main page by pressing any point of the machine layout
and then the button shown in the figure located on the outside of the machine image:
More specifically, this page provides the detailed classification of all the alarms that are
concurrently affecting the machine at any level. The ALARMS section is also meant for the
consultation of all the latest attended alarms that interested the machine. It is thus possible to keep
a record of the anomalies that caused the machine production to stop, even though no alarms are
simultaneously show as active.
33
The structure of the active alarms classification page is shown in the figure below:
This display lists the alarms due to mistaken or missing settings, which are necessary to
A the machine start-up or normal production process. Among these, for example, is the case
in which the hot-melt glue unit has not been switched on.
This display lists the alarm due to the normal dynamics of the expendable materials (glue,
B cartons, ecc.) during production.
This display lists the alarms whose causes can be attributed to the mechanics of the
C machine. For example all alarm that need recovery are part of this category.
This display lists the alarms whose causes can be attributed to the electronic part of the
D machine. For example the brushless driver block, or the activation of the thermal overload
protections that are present in the machine are part of this category.
This display lists the alarms solved lately by the last start of the machine. If an interruption
E of the machine running occurs without visualized active alarms found, this display will
allow you to find the causes of the interruption.
This display lists the status messages. These messages provide information about the
F movement and operation of the machine and its parts.
34
4.3 Possible faults and problems

The cases that may appear are the following:
0001 ON SELECTING "POWER" ON THE OPERATOR'S PUSH-BUTTON PANEL, THE

POWER SUPPLY IS NOT ACTIVATED
Carry out the relevant electrical verifications paying attention to check the safeties electrical circuit
leading to the Pilz-Pnoz.
0002 SERVO MOTORS DO NOT RESET IN THE STARTING POSITION

A. Check the servomotors.
B. Read the servomotors instruction manual to clear the alarm.
0003 ALTHOUGH THE ANOMALY CAUSING THE ALARM SITUATION HAS BEEN
SUCCESSFULLY DEALT WITH, THE ALARM IS STILL ACTIVE ON THE DISPLAY
The causes of this anomalous situation can be:
A. The condition has not been correctly restored. In this case it is necessary to check the restore
procedure.
B. Sometimes you must press the STOP button. In these cases, this button in regarded as an
operator "acknowledgement" of the fault, or acknowledging alarms if alarm acknowledge-
ment management is active. It would also be useful to refer to 10"Alarms and state messag-
es (page 83)".
C. The condition has been correctly restored but the machine control system has not shown the
solved intervention. In this case, with help of electic wiring diagram, check the sensor ac-
quirement chain that allows the control system to monitor the alarm situation that is present.
Note: More information about what caused the alarm, and the solutions that should be adopted, is
provided in chapter 10"Alarms and state messages (page 83)", which describes each alarm
specifically.
35
36
Servo motors phase recovery procedure
5 SERVO MOTORS PHASE RECOVERY PROCEDURE
5.1 Premise
This chapter indicates the necessary operations to perform the PHASE SEARCH PROCEDURE of
electronic axes (brushless servo motors) present in the machine. It is an integral part of the START
UP PROCEDURE OF THE MACHINE and its purpose is to reset the synchronisation of the
individual servo motor.
From an operational point of view, the PHASE SEARCH procedure causes the electronic axis to
carry out a variable number of positioning cycles, during which, thanks to the reading of the special
phase sensor, its position is determined at zero, which means synchronisation with the main
movement of the machine.
For this operation, it is necessary to remove all products from the area of the functional unit
concerned by the PHASE SEARCH PROCEDURE.
If the whole machine needs the phase search, it is necessary to remove all products. Principally the
PHASE SEARCH PROCEDURE can be utilized in two situations.
The first is fundamental as it resets the synchronisation of all the electronic axes every time the
machine is started up or at every pack format change. The second situation occurs less frequently
and is strictly linked to maintenance operations. In this case, the phase search procedure resets
the synchronisation of each electronic axis and checks its correct functioning. Still the phase search
procedure is activated when PHASE - RECOVERY has not proved effective.
In order to facilitate its use in the former situation, a single push-button has been devised,
identifiable as "SYSTEM PHASE SEARCH" push-button. Its selection operates an automatic
procedure independent of any further intervention from the operator, which is meant to carry out
the phase search procedure for all the electronic axes and any existing automatic format change
devices the machine may be provided with. Once this procedure has ended, the machine is ready
for production.
ATTENTION: the push-buttons “SYSTEM PHASE SEARCH”, present in the video pages specified
here below, might not be available, if the operator password is not present.
If a single operating device is in error, though, it is possible to start its phase search procedure
through the page dedicated to each axis. As regards the video page at the bottom of the list
(electronic axis), the following pages will provide some indications taking as an example the phase
search procedure for the OVEN CONVEYOR. The same indications are to be held valid for any
other functional group run by brushless servomotors.
In some applications, after pressing the push-button Phase search, a window is displayed,
indicating that it is necessary to carry out the machine “start” procedure, in order to operate the
command “Phase search”.
5.2 Preliminary controls

These indications assume that the machine is turned on, with the power supply connected and with
the air in the pneumatic circuit present.
WARNINGS:
- If the PHASE SEARCH procedure has to be carried out it is necessary to
remove product from the machine in the electronic axis zone concerned.
- If the whole machine needs the phase search procedure it is necessary to
remove all product from the machine.
37
Remember that, during the normal conduction of the machine in production, it is possible to reset
the electronic axes from their error condition by the PHASE RECOVERY function. In this manner,
you can reset the machine without having to empty it. Of course, after a phase recovery you will
have to empty the blow-moulder because the product it contains can no longer be used for
production.
Restoring the synchronism of the individual electronic axes, as well as any automatic format
change devices in the machine, achieved by means of a PHASE SEARCH, takes place according
to the parameters of the currently selected format.
5.3 Phase search

COMPLETE PHASE SEARCH AFTER TURNING ON THE MACHINE
Access this function via the operator panel's main page.
On pressing the button shown below:
you will see the page in which to activate the complete procedure for phase searching all the
electronic axes.
Always in the main page, using the fly-bar MENU button, you can access the MACHINE GENERAL
page that contains the PHASE SEARCH button, as shown in the following figure:
Button for activating the complete phase search.

A This window appears: MACHINE COMPLETE PHASE-SEARCH.
Reply “YES” so that all phases will be searched in all brushless motors.
38
COMPLETE PHASE SEARCH AFTER FORMAT CHANGE

The machine's complete phase search may also be accessed through the FORMAT SELECTION
button in the main page, and is shown in the following image:
allows you to access the page below that contains the button to perform the machine's complete
phase search.
B Button for activating the complete phase search
The page below will open for each of the examples for accessing the complete phase search:
By pressing the “YES” button, the machine's complete phase search procedure will be carried out.
Wait until the phase search procedure is over.
The figure below shows the info page displayed by the operator panel during this operation: it
indicates the electronic axes undergoing the phase search.
39
ATTENTION: executing the complete phase search procedure, essential for running the machine
after turning it on, entails the following conditions:
• Machine empty, without product;
• Power ON;
• Air in the pneumatic circuit;
• The electronic axes should not be affected by mechanical locking;
• Ensure that the phase sensors of the electronic axes, which must undergo the phase search,
are efficient both in terms of operation and calibration (positioning);
• Ensure that the parameters that define the electronic axes, which must undergo the phase
search, are consistent and valid;
• The phase search of the individual electronic axes will take place according to the parameters
of the currently selected format;
40
INDIVIDUAL AXIS PHASE SEARCH

You can access the PHASE SEARCH function of an individual axis from the detailed page of the
individual electronic axis involved. Information is provided referring to the electronic oven conveyor.
The detailed page of the individual electronic axis appears by pressing the associated zone in the
machine synoptic panel, present in the operator panel's main page (in this specific case, that of the
oven conveyor (201), and then selecting (A)):
A Access to (motor) axis management page.
B Button for requesting the motor phase search (in the example, the oven chain).
41
42
Servo motors phase search procedure
6 SERVO MOTORS PHASE SEARCH PROCEDURE
6.1 Premise
This chapter indicates the necessary operations to perform the PHASE RECOVERY of electronic
axes (brushless servo motors) present in the machine. This procedure is necessary every time one
or more servo motors block, due to an error (positioning, voltage, internal anomaly).
It allows you to reset the servo motor synchronisation with the main movement of the machine,
without requiring its complete phase search. In this way the resetting of the error conditions of the
electronic axes is possible without having to remove the product from the machine.
From an operational point of view, the PHASE RECOVERY procedure determines a shifting of the
electronic axes from the position it is blocked into that which, theoretically, puts it back into
synchronism with the main machine movement. For obvious reasons, PHASE RECOVERY proves
to be effective when the movement that the axes must carry out is within certain limits. If PHASE
RECOVERY does not permit resetting of the axis, it is necessary to perform its PHASE SEARCH.
In some applications, after pressing the PHASE RECOVERY button, a window appears to warn the
operator about the need to carry out the machine Start procedure to be able to run the command.
The PHASE RECOVERY can be activated through the following screen pages dedicated to
individual functional units.
The next pages will provide information and will use, as an example, the running of the PHASE
RECOVERY procedure for the OVEN. The indications provided are valid for any other functional
unit based on brushless servo motor present in the machine. For more technical details (both
theoretical and practical) please refer to the manual file dedicated to the individual functional units.
These indications presume that the machine has been switched on and that the power supply has
been connected.
WARNINGS:
Make sure there is no jammed or overturned product that can obstruct the electronic axes
movement during PHASE RECOVERY.
43
6.2 Phase recovery

The phase recovery of the axis can be carried out by touching the machine area on the main
screen, which shows the affected axis.
Example of a oven chain phase recovery, by pressing button (201).
44
and then (A), the following screen will appear:
Activates the TUNNEL'S PHASE RECOVERY procedure.

01
This button is shown only if the conditions exist, necessary to perform a “Phase recovery”.
Activates the TUNNEL'S PHASE SEARCH procedure.

02
This button is shown only if the machine is stationary.
Example of a TUNNEL Phase Recovery caused by alarm “Excessive position deviation” due to the
jamming of a preform between the oven and the inlet stars.
1 • In the main page you can see there is a problem in area “201”, which contains a triangle mean-
ing there is a fault, and the alarms window displays messages “Phase recovery request” and
“Divider bars stop”. “Oven problem”
2 • Visually check the extent of the problem (the example shows a preform wedged between the
inlet stars and the oven).
3 • Select area “201” in the main page; now press the button in the oven window (A); Press button
“MOT. FORWARD” to try to clear the area
4 • The oven will move forward to try to free the jammed preform.
5 • Press the EMERGENCY button
6 • Open the door and free the preform.
7 • Close the door, pull out the EMERGENCY button and press the POWER-ON button.
8 • Press button “PHASE RECOVERY” 01”
9 • The oven repositions itself in the correct working position.
Now you may continue by pressing the START button, to allow the machine to resume the
production cycle.
45
6.3 Faults requiring the phase recovery procedure

The machine's control program points out the necessity to perform the PHASE RECOVERY
operation on the display dedicated to the alarm messages. When the alarm message PHASE
RECOVERY REQUEST appears followed by the name of the individual electronic axis present in
the machine it is necessary to proceed in this way. From an operational point of view the main
causes which may lead to the necessity to perform the PHASE RECOVERY procedure are listed
here below:
1 • The product that is wedged between one electronic axis and the next generated an emergency
due to no product alignment.
2 • Mechanical block or friction that causes the electronic axis standstill in ways similar to the ones
described in the previous point.
3 • Manual shifting of the electronic axis (please remember that this is possible only with power
switched off) during operations to release the jammed product.
4 • Loss of control of the electronic axis position due to causes not referable to the ones indicated
in the previous points.
5 • Higher current use than that expected by the motor or the driver.
If the phase recovery procedure does not end correctly, you can retry. You may need to perform
the phase search of the axis if the axis does not resume the correct working position.
WARNINGS:
In the case of the inlet stars “Phase recovery”, a warning message asks the operator to
remove the product from this area because the mechanical unit will go down to let the
motor run. Product presence at the end of the Phase recovery procedure could damage
other mechanical parts when the I/O stars movable unit goes back up.
46
Procedure to enable the inverters
7 PROCEDURE TO ENABLE THE INVERTERS
7.1 Premise
This chapter outlines the operations required to ENABLE the electronic axes driven by the
machine's inverters (asynchronous servomotors).
This operation is an integral part of the MACHINE'S SWITCHING-ON PROCEDURE and its task
is to enable the individual servomotor so that it is suitable for the production process.
From an operational viewpoint, the ENABLE procedure activates the inverter.
To make it as easy as possible to use this procedure for the first case, there is a single button called
“MACHINE COMPLETE PHASE SEARCH”, which activates an automatic procedure and that will
phase-search all the electronic axes and any automatic format change devices in the machine,
without any operator intervention. At the end of this procedure, the machine will be ready to
produce.
Below are listed the inverter-driven electronic axes:
- Preforms lifter (in the preforms loading system)
WARNINGS: the “MACHINE COMPLETE PHASE SEARCH” buttons, which are in the video pages
specified below, may not be available in the absence of the operator password.
But in the case of a specific faulty inverter, you can perform the enable through the page dedicated
to each axis.
Concerning the latter option, the following pages provide instructions, taking as an example the
ENABLING for the PREFORMS LIFTER.
Keep in mind that that specified applies to any other functional unit that is based on asynchronous
motors.
In some applications, after pressing the Phase Search button a window appears to warn the
operator to carry out the machine Start procedure to be able to issue the command.
For any further technical in-depth examination (both theoretical and practical), you should refer to
the sheet in the manual dedicated to individual functional units.
47
7.2 Enable
As soon as the machine is switched on, the inverter-driven electronic axes are enabled as outlined
in paragraph 5.3"Phase search (page 38)".
The foregoing enable can also be accessed via the detailed page of the individual electronic axis.
The information provided refers to the lifter of the preforms loading system. The lifter's detailed
page can be accessed via the machine inlet section (200):
A Access to the page that manages the preforms loading system.
B Access to the page that manages the preforms lifter inverter
C Button that enables lifter inverter and preforms directing device rollers
48
D Button that requests a motor enable.
49
50
Parameterization
8 PARAMETERIZATION
The parameters of the machine are essential for its operation, that is why the control program sets
special mechanisms to limit the access to authorized personnel only and special verifications on
the insertion of values formally and technically acceptable.
Despite this, unsuitable modifications might cause, in the most serious cases, the bad operation of
the machine.
Before proceeding to the modification of the parameters, carry out a backup of them through the
special functions of the control program. This will make the resetting of the machine's previous
parameters possible, if the brought modifications are not correct or not satisfactory.
The modification of the parameters of the brushless servomotors determines the application of the
phase search procedure, with the consequent necessity to have no product in the zone interested
by their movement. The direct and subjective parameter modifications that set the movement
profile of the servomotors are to be avoided. It is necessary to refer only to the special values
theoretically calculated and available in the machine database.
The modification of the parameters of a format not in use will not be immediately effective on the
machine operation. Be very careful to this kind of modification, because some faults might occur
when such formats are enabled. In the same way, the parameters concerning the configuration of
the machine or of an axis (for example the sercos address of a device) will be transferred to the
process control PC only at the next re-start of the system.
The lower level parameterization that makes the brushless servomotors, the SERCOS devices, the
alternate current frequency converters and the present thermo-regulators operational on the
machine must be maintained and verified in case they are replaced with a possible spare part.
In all the situations in which the use of a removable disk is required, make sure it DOES NOT
contain computer virus infection.
8.1 Parameters organization principles

The parameters are divided into:
They define the machine structure and composition. The electrical diagram and the
GENERAL mechanical documentation are the main sources for these parameters. These pa-
rameters apply to all formats.
They depend on the type of production (format/receipt). Among them, we can find
the parameters setting the production speed and the servomotors profile move-
ment. In general, their value is fixed through experimental procedures during the
commissioning and installation phase, according to the product and to the con-
sumption material in use during the production. However, there are some format
FORMAT
parameters with a value defined in a theoretical way, such as the parameters de-
fining the servomotors movement. Their values are provided in an electronic form,
directly in the database, thus making the whole profile range available, for the en-
abled formats. Do not modify the parameters in a subjective and direct way, be-
cause the servomotor will not operate correctly.
According to the password you enter, it will be possible to display and modify only the enabled
parameters.
51
Parameterization
8.2 Selection of the functional group and access to the

parameters
Access the parameters via the page containing the machine layout (“COMMANDS” page).
Therefore, simply touch the synoptic panel that represents the machine, in the main page. Then,
by pressing each area of the machine shown in the page displayed to the operator, he/she will be
able to see, if possessing the required login rights, the buttons for consulting the format and general
parameters menus.
Since that stated applies to any functional unit, let's assume you consult the parameters of
the OVEN. Any devices with operational autonomy, but still dependent on a specific
functional unit, are managed through the screen pages dedicated to it.
To access the parameters, simply touch the machine area containing the oven in the main page
(button 201) and then go to the “OVEN” screen, button (A).
This is the page shown to the operator:
By pressing buttons (20) and (21) you can access the general and format parameters,
respectively.
52
Parameterization
• FORMAT PARAMETERS IN USE

By pressing button (21) in the previous figure, you will see the parameters menu in which to change
the parameters.
When this menu opens, you can view the parameters relating to the format being used, i.e. the one
that is currently active in the machine, but you also have the option to go to parameters having a
different format, by selecting it among those available. The page looks like this:
A Name of the parameter.
B Unique number that identifies the parameter.
C Indicates that the format "in editing" is the one used.
Name of the format to which the parameters are referred. When you open the page, the
D displayed format is the one in use.
E It selects a different format.
F It saves the parameters modifications without shutting down the page.
Change the individual parameter by placing the selection bar on it and pressing [ENTER].
Now enter the value (highlighted by the cursor that appears on the parameter) through the
numeric keyboard on the screen. In order to delete the previous value, use button [DEL]. The
value-entry stage ends by pressing [ENTER] again. The value-entry stage ends by pressing
[ENTER] again; then save the change through the SAVE button.
53
Parameterization
The functions of the other buttons are as follows:
Push-buttons [UP] and

They move the selection bar.
[DOWN]:
Push-button [ESC]: It stops the value digitization phase and cancels the modifications.
It allows you to begin and to conclude the phase of digitization of a

Push-button [ENTER]:
new value.
Push-button [HOME] e [END]: They position the cursor at he beginning or at the end of the value.
Push-button [<] e[ >]: They move the cursor.
Push-button [0]..[9], [.] , [+/-]: They cancel a character
Push-button [0]..[9], [.] , [+/-]: They allow you to write the parameter value.
After pressing [ENTER], the value will be accepted and recorded only if it is within the validation
range. Otherwise, it will be displayed in red; if you decide to shutdown the video page by pressing
[EXIT], the wrong value will not be recorded and the pre-existing one will be valid (even if it has
been cancelled by pressing [DEL]).
• FORMAT PARAMETERS NOT CURRENTLY IN USE

When the operator presses the "FORMAT SELECTION" - (E) button in the previous screen, he/she
accesses the next page, in which to select a different format by choosing it among those available
(the one in use is highlighted in red).
1 Take note of the currently selected format.
Select the format to be modified through the push-buttons “Up” and “Down” or by directly
2 pressing the format name.
3 Confirm the selected format.
A It cancels the selection of the format.
54
Parameterization
If you select a different format, the following video-page for the parameters modification will be
displayed:
The message “In editing” means that the format is NOT the one in use and the modified
A parameters will be saved only in the database.
B Name of the format of which you are modifying the parameters.
In case of parameters of a format not in use, the rows of the parameters table will be
C displayed in grey.
The push-button “SAVE” saves the modified parameters, without having to shut down the video
page. The parameters that have been modified but not yet saved are displayed in a different colour
than the original one.
A Data modified after opening the page or after the last saving procedure.
B It saves the parameters modifications without shutting down the page.
55
Parameterization
If you shut down the page without saving the data, the following message will be displayed:
A Name of the format of which you modified the parameters.
B It saves the modified parameters in the database.
C It shuts down the page without saving the parameters.
D It goes back to the parameters modification page.
Until you do not select one of the above options, the other pages and the FLYBAR are disabled.
The above message is displayed also when you modify the parameters of a format, but you do not
save them, before selecting another format.
• GENERAL PARAMETERS
This is the page that allows you to consult or modify the general parameters.
From an operational point of view, the instructions for the format parameters are valid.
General parameters can either be edited or not, depending on the specific machine area and the
entered password.
56
Parameterization
8.3 Support functions for the parameters setting

Restoring the pre-existing values
The push-button “Undo” cancels every modification and restores the pre-existing values displayed
when you opened the page. By contrast, the push-button “Redo” restores the modifications
cancelled by pressing “Undo”. The modifications are cancelled or restored in the same order as
they had been carried out and with reference to all parameters of the menu, not to the individual
parameter. By selecting another format, the list of the “Undo” and “Redo” operations will be
cancelled and will be ready for the modifications of the format you have just selected.
A “Undo” cancels the last modification
B “Redo” restores the cancelled modification
Recommended range and safety range

In case of very important parameters, three confirmations are requested, before recording the
modification.
The user is informed about the importance of the parameter and is required to confirm the
modification:
57
Parameterization
The value must be within the recommended range (usually more restrictive than the displayed
range):
If the modification is confirmed, the parameter value will be displayed in orange.

The system makes sure that the value does not modify the parameter beyond a safety range, in
order to reach the limit values gradually.
Consulting the chronological list of the modifications
A Access to the chronological list of the modifications of the selected parameter.
58
Parameterization
By pressing this push-button, the following list will be displayed:
A Time interval taken into consideration in the chronological list.
Parameter type (Configuration, System, Format). In case of a format parameter, it

B indicates what format is taken into consideration.
C List of the modifications.
Display of the most frequently used parameters
The presence of the bar means that the most recently modified parameters are displayed.
A If you press the bar, you obtain a complete display of the parameters.
59
Parameterization
8.4 How to create safety copies of the machine parameters

The JADA operator interface programme JADA gives you the possibility to create some copies of
the parameters, either on the flash memory of the operator PC or on a floppy disk. In the first case,
the copy is unique, because the last one replaces the previous one.
By contrast, with the backup on a floppy it is possible to create more than one safety copy, but a
different floppy disk is to be used for each copy.
In this case, it is important to indicate the following basic information on the label of each floppy disk:
- Serial number to which the safety copy is referred;
- Date of creation of the safety copy;
- JADA programme version.
Below is the procedure for SAVING the machine parameters (database), which should be carried
out after entering the work level (at least L2 Maintenance technician, see paragraph 1.3"Inserting
the password (page 14)").
1 Select “MENU” and then “UTILITIES” in the main page.
2 Press button “SAVE/LOAD PARAMETERS (01)”
Press button "SAVE PARAMETERS ON HARD DISK

3 (01)”; this step allows you to store the parameters in
Posyc's flash memory for any future emergency use.
60
Parameterization
Insert the USB stick into the Posyc exactly where you
4 want to save the copy of the machine's parameters
(database)
Press button “SAVE PARAMETERS ON

5 REMOVABLE DISK (03)”.
6 Confirm your decision to save on a removable disk.
Once done, confirm by pressing OK and remove the

7 stick. Now the machine parameters have been saved
on the USB stick you used.
NOTE: In any case, it is recommended to use floppy disks that DO NOT contain any computer virus
infection.
It is very important to create safety copies (both on the flash memory and on a floppy disk) at the
end of the installation phase and anyway after every updating procedure carried out by the control
programme.
In some cases, the floppy disk is replaced by a Key memory with the same functions. In order to
make the most of this device, the database must be saved in a directory called DXXXX, where
XXXX indicates the serial number.
61
Parameterization
8.5 How to restore the machine parameters

Besides the saving function, the JADA programme offers the possibility to restore the parameters
from the safety copy, available either in the flash memory or on the floppy disk.
In both cases, it is very important that the safety copy refers to the version of the programme
currently in use. Otherwise, avoid the parameters restoring.
Below is the procedure for RESTORE the machine parameters (database), which should be carried
out after entering the work level (at least L2 Maintenance technician, see paragraph 1.3"Inserting
the password (page 14)").
Select "MENU" and then "UTILITIES" in the main

1 page.
2 Press button “SAVE/LOAD PARAMETERS (01)”
Press button "PARAMETERS LOAD FROM HARD

3 DISK (02)"; this step allows you to restore the last
database saved on HARD DISK.
62
Parameterization
But if you wish to restore the parameters saved in the

USB stick, insert the USB stick into Posyc where the
4 copy of the machine parameters is stored (database)
(they are in a folder called, for example,
DPC13999IS9999).
Press button "PARAMETER LOAD FROM

5 REMOVABLE DISK (04)"
Confirm your decision to restore parameters from a

6 removable disk.
Once done, confirm by pressing OK and remove the

7 stick. Now the machine parameters stored in the stick
are those being used in the machine.
NOTE: In any case, it is recommended to use floppy disks that DO NOT contain any computer virus
infection.
63
Parameterization
8.6 How to print the parameters

The JADA programme includes the possibility to print the parameters in electronic form on a file in
ASCII format, recorded on a floppy disk. This file can be consulted and printed on paper through
any text edition programme (word processor). It is recommended to use floppy disks that DO NOT
contain any computer virus infection.
Below is the procedure to PRINT the machine parameters (database), which should be carried out
after entering the work level (at least L2 Maintenance technician, see paragraph 1.3"Inserting the
password (page 14)").
Select "MENU" and then "UTILITIES" in the main

1 page.
2 Press button "PARAMETER PRINTING (02)".
Insert the USB stick into the Posyc exactly where you
3 want to save the copy of the printable parameters.
64
Parameterization
Press button "COMPLETE (04)", which allows you to

4 have all machine parameters in text format. You are
asked whether to print to file or via a printer.
Remove the stick once the print creation count is over.

Now the parameters are stored in the stick in text
5 format so that they may be viewed on a PC and
printed.
ATTENTION: this set of parameters is only in text format and, as such, is not a file which can be
used to RESTORE parameters from a removable disk.
8.7 Utility functions for the parameterization

In order to make the parameterization easier, especially during the setting phase, the JADA
programme allows you to automatically load the parameters which define the movement profile of
the servomotors carrying out electronic cams and to copy the parameters from a format to another
one.
The programme also offers the function “EDIT NOME FORMATI”, in order to modify the formats/
receipts name.
8.8 Other forms of parameterization

Besides the above mentioned parameters, there are the low-level parameters, referring to the
electronic devices. Among them, we can find:
- The setting of the identification address of the SERCOS devices;
- The parameters for the setting of the motors for the SERCOS servomotors;
- The parameters for the setting of the frequency converters;
- The settings for the installation of the programmes on the operator PC.
For the SERCOS parameters please refer to the manual files or to the devices manuals for further
information. The electrical manuals provide some instructions concerning the utilization parameters
of each device. As for the servomotors and the frequency converters (if any), the utilization
parameters are indicated in the electrical manuals. Therefore, it is possible to proceed with the
configuration of a spare part, during the installation.
As for the frequency converters and the thermoregulation devices, if any, it is possible to
programme them directly form the operator PC. Contact SMI customer service (+39 0345 40111)
for info on how to program the devices.
65
Parameterization
8.9 Control mode

As stated above, the parameters are recorded in a database of the POSYC. At power-on, the
operator panel program starts the process controller and transfers the configuration parameters,
the system parameters and those of the selected format.
This procedure is carried out also when you select a new format, but only as far as format
parameters are concerned.
Any modification of the parameters is recorded in the database; in case of system parameters or
of format parameters of the format in use, the new values are immediately and automatically
transferred to the process controller, so as to be immediately effective.
By contrast, the modification of most configuration parameters will be effective only after the next
start of the machine.
Likewise, the editing of parameters of one of the formats not currently in use will be effective only
when that format will be set and used on the machine.
66
Statistics video page
9 STATISTICS VIDEO PAGE
9.1 Premise
Starting from JADA version 5.71, a video page is available for the recording of the machine
operation data chronologically.
The data are available in a standard format (TXT CVS, font ‘|', “pipe”, as a separator) so as to be
immediately accessible through consultation on the operator terminal (by means of Cartesian
diagrams, pie charts and Pareto charts); they can also be processed by means of dedicated
programmes (such as, for example, MS-Excel).
Even though the data subject to recording can vary according to the machine model, the basic
records will include:
• The machine efficiency index;
• The machine hourly production estimate;
• The count and lasting time of each individual machine alarm;
• The count and lasting time of each individual machine state.
For further details, please refer to the following files in the “Maintenance technician manual”:
For the use of the statistics for diagnostic purposes, for example to find
Diagnostic functions
the production stop causes;
Statistical function For the use of the statistics in order to check the machine performance.
Statistics screen page - enabling

For the installation and activation of the statistics on the machine.
and configuration
WARNINGS:
The correct data recording procedure can be guaranteed only if the system date and time are not
altered in any way.
Therefore, make sure that the system date and time are correctly set before operating the machine.
It is understood that any interference with the machine operating mode will deprive all the data
previously recorded of their usefulness, although the relative files will be kept available on the disk
after being renamed with a new extension (.del).
It is also necessary to configure the “International settings” correctly, so as to avoid any future
modification. In POSYC, the default setting has the selection of the English language (UNITED
KINGDOM)
Please check the settings before operating the machine, as a subsequent variation could seriously
interfere with the correct data recording procedure.
67
9.2 Description
The statistics video page is automatically operated when the operator panel programme starts and
the data recording starts, too.
In order to view it, open the dropdown menu on the navigation bar and select item 2) - STATISTICS
CONTROL , as shown in the figure:
It consists of the push-buttons of the recorders enabled in the machine and of the push-button for
the guided consultation; it can not be shut down, nor refreshed.
The following paragraphs will show the different functionalities that can be accessed via the
STATISTICS CONTROL page.
68
RECORDERS PUSH-BUTTONS
Each push-button represents the recorder of the function indicated by the denomination and allows
you to consult the recorded data and save them; the corresponding led indicates the recorder state:
Stand-by (led off), Correct functioning (green led on), Incorrect functioning (intermittent red led). As
regards the incorrect functioning mode, every time an anomaly occurs the led will be flashing and
a warning page will be displayed, indicating the recording section concerned with the problem and
its causes.
A Led indicating the recorder state.
B Access to the functions operating the recorder.
The data of the recorders which can be consulted are shown by the buttons present in this screen,
and are as follows:
ALARMS TIME (01) ENERGETIC CONSUMPTION (07)
ALARMS COUNT (02) BLOWING WHEEL SAFETY (10)
EFFICIENCY (03) PREFORMS TEMPERATURE (11)
HOURLY OUTPUT (04) PRODUCTION ANALISYS (12)
STATES TIME (05) FILLER: ANALOG VALUE (14)
STATES COUNT (06)
69
Consultation of the recorder data by means of the push-button of the individual data
recorder
If you press one of the buttons of the recorders provided, for example, the displayed screen will be
similar to the following one:
01 If you press "STATISTICS", data will be saved in a removable mass storage.
02 If you press "GRAPH" you can consult data recorded up to that time.
The recording sections transcribe the data on the operator's terminal hard disk and classify them
into files identifiable as <year_month_day>. These files are then grouped into a specific folder and
ordered following their specific year. According to the frequency with which they have been
updated, they will be described as:
- Dailies (one-day recording)

- Weeklies (one-week recording)
- Monthlies (one-month recording)
- Six-monthlies (six-months recording)
- Yearlies (one-year recording)
70
After pressing "GRAPH", the page that opens will ask you to enter the required time period and the
quantity (or the different quantities) you intend examining.
Select the time period you are going to examine. The options range from one day to a
A multi-year period of time.
If you select item "Free" in choosing the period, the period of time to take into account can
B be entered by specifying the detection start and end day and time.
Select the data recovery mode. Here are the available possibilities:
• Total: the graphic will display the sum of the values of the entities during the period.
C • Data selection: it allows you to select one or more entities from the list D.
• All data: all entities are automatically taken into consideration.
Here is the list of the entities, from which you can select the entity to be displayed in the
D graphic. It is possible to select more than one entity, if necessary.
E Select the format, among those available, the graph of which you want to view
F Press the push-button CONFIRM, in order to display the graphic.
G Press CANCEL in order to exit without displaying the graphic.
71
• Display of the total data (Total mode)

After the confirmation of the data entered on the previous video page, if you selected the "Total"
data recovery mode, the following display will appear.
The consultation of the total data allows you to point out the most important entities, for example
the alarms that lasted longer or that occurred more frequently during the selected period. The data
will be displayed by means of a pie chart or a Pareto chart.
It tabulates the statistic data recovered according to the research data previously entered.
A The table pages can be consulted by means of the navigating bar B
B It is the navigating bar which allows you to consult the tabulated data.
C It saves the table A on a file in html format
D Chart legend.
The consultation of the table allows you to check the entity of the events, grouped under the item
“others” (due to lack of space), at the bottom of the diagram.
72
• Display of the required data for frequencies (Selection mode)

The consultation of the data divided per frequencies allows you to highlight the state of the entities
during a selected period and to check the concurrences and the precise moment when certain
values have occurred. For example, after checking the alarms that have occurred most frequently
(thanks to the "Total mode"), you can check their activation in order to check any concurrences.
From a graphic point of view, the data will be displayed by a Cartesian diagram (with the date of
acquisition in the abscissa and the value of the entity in the ordinate) or by a histogram.
The choice of the graph will appear if items "Select Data" or "All data" were selected in the previous
screen where you selected the period. The presented page will be as follows:
It tabulates the statistic data recovered according to the research data previously entered.
A The table pages can be consulted by means of the navigating bar B.
B It is the navigating bar which allows you to consult the tabulated data.
C It saves the table A on a file in html format.
D It graphically displays the data indicated in the table (Cartesian diagram)
E It graphically displays the data indicated in the table (histogram)
F Displays data, shown in the table, in graphical format (bars)
73
If you selected the Cartesian diagram:
A Diagram legend.
The red triangle indicates that the recording was sometimes interrupted (for example:
B machine switch-off).
By means of these push-buttons, you can modify the display period by drawing the left
C limit (date of beginning) and the right limit (date of end) nearer to each other.
If you selected the histogram:
A Diagram zoom, in order to enlarge the selected area.
74
Push-buttons for a guided consultation of the statistics

The STATISTICS CONTROL page will also contain button PRODUCTION SUMMARY (08), as
shown in the figure.
The page displayed after pressing the indicated button will be as follows:
75
The table outlines the guided consultations that can be accessed via this page:
(01) MACHINE UTILIZATION
(02) MACHINE PERFORMANCE (KPI)
(03) DOWNTIME ANALYSIS
(04) PRODUCTION ANALISYS
Whichever type of guided consultation was chosen, a page will open before displaying the graph,
requesting you to quickly select the period of time to be taken into account, as shown in the figure:
In any case, you have the choice of entering a time period different from those proposed, by
pressing the PERIOD SELECTION (08) button: as such, the next page will open with a keyboard
for entering detection start and end day and time.
Once you selected the period, the corresponding graphic will be displayed.
For the details, refer to the next paragraphs, which show the pages of the guided consultations that
can be accessed via the aforementioned buttons.
76
• Machine utilization (01)

It allows you to check how the machine has been used during the selected period, highlighting the
macro-causes which determined production losses: internal causes (machine malfunction),
external causes (for example, the start push-button has not been pressed), upstream causes (lack
of raw materials), downstream causes (accumulations).
• Machine performance (KPI) (02)

It allows you to check the state of the following “key performance indexes”, typically used for
evaluating the performance of industrial systems:
Utilization index It indicates how long the machine has been used
It indicates how long the machine has been available for the pro-
Availability index
duction
It indicates the relation between the actual machine production

Performance index
and the potential machine production
It indicates the discards quantity (this index is available only if the

Quality index
discards counter is present).
It is a synthetic index, obtained by multiplying the availability in-

Overall equipment affectiveness
dex, the performance index and the quality index.
77
The graphic allows you to check the time intervals when the value of an index has been below a
pre-set value. Once you have got the time intervals, you can make an analysis of the downtime or
of the duration of the machine states during these intervals and then you can determine the main
causes that have reduced the performance.
• Downtime analysis (03)

It allows you to highlight the alarms that have lasted longer or have been activated most frequently
during the selected period, thus identifying immediately the zones to be improved.
You may reach the configuration page of this analysis by pressing button in the
“COMMANDS” page, followed by the “DOWNTIME ANALYSIS” (03) button.
78
• Production analisys (04)
79
9.3 Saving of the recorded data on a flash memory

The files of the recorded data can be selected according to their year of reference from the list
displayed on the video page and then saved on compact flash.
During the saving procedure, the multifunction bar (flybar) and all pages previously opened will be
disabled; in order to re-activate them, press “Exit” in order to stop the saving procedure.
To access the backup page, simply press the "STATISTICS" button, after selecting the recorder in
which you intend backing up data.
In order to save one or more files, make sure that the compact flash has been connected to the
system; then select the year of reference and press “Open”. Then select the required file from the
displayed list and press “Save”.
The following page might be displayed as follows:
1 Select the year.
2 Select the “Open” button to access the selected folder.
A Folder created by the statistical procedure.
80
The following page might be displayed as follows:
3 Select the file needed.
4 Press the push-button “Save”.
B Return to previous folder.
At this point, an apposite message will show the procedure in progress. The confirmation of the
saving procedure outcome will follow after this. The files will be saved in zip format and grouped
into a folder with the name of the recording section from which the files were extracted.
81
82
Alarms and state messages
10 ALARMS AND STATE MESSAGES
10.1 Managing alarms acknowledgement

The alarm acknowledgement procedure was provided to allow the operator to inform the system to
have acknowledged the active alarms. In general, alarms can be divided into 4 categories:
1) The first category includes all the less important alarms for which operator acknowledgement
need not be carried out.
2) The second category includes all problems that the system acknowledges automatically as soon
as the alarm is cleared: these are not serious anomalies and the procedure is carried out only for
statistical purposes.
3) The third category includes all alarms that must be acknowledged; if necessary, the main page
will display an alarm indicating the need to perform that operation. In addition, the state of the button
for accessing the acknowledgement page will be the one shown in the following figure. However,
the acknowledgement request does not affect the production, which can resume even if signals
remain active.
4) The fourth category is similar to the third except that you cannot resume continued production
until all alarms have been acknowledged and solved. Therefore, in this last case, this procedure is
an integral part in solving the problem: in the presence of an alarm, the operator must solve the
cause that generated it and acknowledge it before resuming production.
In order to access the page in which alarms are acknowledged, press the following button (located
on the right of the alarm display in the main page):
If the alarm acknowledgement request is active, the button's color turns to the one shown in the
image on the left; when there aren't any alarms to be acknowledged, the button remains gray, as
shown in the image on the right.
In both cases, on pressing this button you can access the page shown in the figure below.
83
Allows you to select the alarms you want to acknowledge: to do so, press the line
corresponding to the alarm present within the box. The first time you press this button the
A check mark will appear in the box (selected alarm); to deselect the alarm simply press this
button again. To select all the alarms, you can enter the check mark directly in the title
(otherwise press "SELECT AND ACKNOWLEDGE ALL (04)").
Indicates the alarm's unique code (useful in case of diagnostics, especially if you are not
B familiar with the language active on the operator panel).
C Date and time when the alarm occurred.
D Acknowledgement request state. Refer to the explanation of the LEGEND button (01).
E Complete description of the alarm message.
This is the group to which the alarm belongs. Each alarm belongs to one of the following
groups:
1 - Faults;
F 2 - Warnings;
3 - Problems;
4 - Emergencies;
84
Legend (01) - To help the operator understand whether or not an alarm should be acknowledged,
the different stages are shown in different colors with acronyms (shown in the "State" column - (D)).
Each alarm can have the following states:
ACTIVE alarm: this alarm is

present and the operator must
E RED
inform the system to have ac-
knowledged the alarm.
ACKNOWLEDGED alarm: this

alarm is still active and the oper-
ER ORANGE
ator has already acknowledged
it.
01 Alarm RESOLVED BEFORE IT

WAS ACKNOWLEDGED: this
EU GREEN alarm occurred and was solved
without the operator having the
chance to acknowledge it.
Alarm ACKNOWLEDGED and

RESOLVED: this alarm oc-
curred, was solved and ac-
knowledged by the operator.
ERU GRAY
ATTENTION: the standard dis-
play mode entails not showing
alarms of this type in the table
but only in the historical report.
Print (02) - Saves the print on the removable disk (if absent, select the disk in which to
save).
02 Before performing this operation, insert a stick to choose where to save data. The figure
shows the windows in which to save with the folders and the path where data will be
saved. A folder called DPCXXXXX will be created (according to serial number), inside
which another folder will be created, called Chronology Alarms.
03 Acknowledgement (03) - Acknowledges the alarms selected in column (A).
85
04 Select and acknowledge all (04) - Acknowledges all the alarms shown in the table.
05 Solving steps (05) - When available, you can see the procedure for solving the alarm.
Historical alarms (06) - Opens the page in which the alarms historical report is available:
06
J - Indicates the time interval referred to in the historical report. You can change the
date and time from one end of the range to the other by means of the SELECTION (01)
button.
Selection (01) - Opens the page in which to change historical report start and end date
and time:
Print (02) - Allows you to print the list of alarms displayed in the historical report table. The
print modes are the same ones described for the active alarms; the only difference
consists in the save path that in this case is:
D<SERIAL N.> ChronologyAlarmsHistoryHis_Date_Time.zip.
Legend (03) - Shows the same legend as for the active alarms.
Alarm (04) - The flashing of this button means that in the meantime the acknowledgement
page was refreshed with new alarms. Press this button to refresh the historical report
table.
86
10.2 List of state messages

SUMMARY CHART
Below there is a status messages table.
These messages provide information about the movement and operation of the machine and its
parts.
N. MESSAGE MEAN NOTE
In order to start working, the ma-

The machine was just turned on
1 Wait for phase search chine's axes need the search for
and needs a total phase search.
their zero position.
Any type of emergency problem

(DRIVER STALLED, THERMAL
CIRCUIT BREAKERS tripped,
Indicates that the machine is af-
2 Emergency problem etc.), or alarm, which requires a
fected by an anomalous situation.
machines stop, is active, and the
maachine is waiting for the problem
to be solved.
Indicates that the machine is While the machine was working, it

3 Machine stop
STOPPED. switched to the STOP state.
The machine must reach a work-

ing temperature and a preset The oven's temperature is not the
4 Oven warning up speed from the time the START set one and the machine's speed is
button is pressed to the beginning not the working one.
of the preforms process.
The machine has reached all the

Indicates that the machine is pro-
5 Machine producing required operating conditions to
ducing.
process the product.
After an emergency, any product

Indicates that the machine is in
inside the machine must be reject-
6 Machine unloading the MACHINE UNLOADING
ed because it is no longer suitable
state.
to be blow-moulded
Any type of emergency problem

(JAM AT OUTPUT, DI AXES
Indicates that the machine is af-
PHASE SEARCH REQUEST sig-
fected by an anomalous situation
7 Problem: start inhibited nal, etc.) or alarm, which requires a
that determines the disabling of
machines stop, is active, and the
the possibility of STARTING it.
machine is waiting for the problem
to be solved .
After a certain amount of time t that

the machine is PAUSED, set via a
Indicates that the machine is in
8 Machine in standby parameter, the oven switches to a
standby.
lower power state called STAND-
BY.
87
Since machine working conditions

are lacking, the preforms inlet is
Indicates that the machine is closed. The machine automatically
9 Machine paused
paused. reopens the inlet as soon as the
problems that caused it to pause
have been cleared.
From the production state, the pre-

forms closes on pressing the STOP
With inlet closed, the processing
End of preforms process in button. Before stopping the ma-
10 of all the preforms in the machine
the machine chine, the processing of the pre-
ends.
forms still inside the machine is
terminated.
The machine is running with the

11 Operating without product You chose to work without product.
preforms inlet closed.
The machine is running at a

System running at re- You chose to work at reduced
12 speed that is slightly slower than
duced speed speed.
the nominal one.
The machine unloads preforms at

You chose to work in “preforms re-
13 Preforms emptying at inlet oven inlet to empty the hopper at
jection” mode.
inlet.
The machine has been designed,

A data-sampling phase is detect-
Detection of machine pro- from a software point of view, with a
14 ed while the machine was produc-
ducing sampling system that allows you to
ing.
save a report during the production.
A data-sampling phase is detect- The machine has been designed,

Detection of production ed while the machine was not pro- from a software point of view, with a
15
stopped – external causes ducing due to problems related to sampling system that allows you to
machine external events. save a report during the production.
A data-sampling phase is detect- The machine has been designed,

Detection of production ed while the machine was not pro- from a software point of view, with a
16
stopped – internal causes ducing due to problems related to sampling system that allows you to
machine internal events. save a report during the production.

Detection of production ed while the machine was not pro-
from a software point of view, with a
17 stopped – downstream ducing due to problems related to
sampling system that allows you to
problems events that occurred downstream
of the machine.

Detection of production ed while the machine was not pro-
from a software point of view, with a
18 stopped - upstream prob- ducing due to problems related to
sampling system that allows you to
lems events that occurred upstream of
the machine.
88
The machine is running in a oven

Machine pre-heating ac- The machine is running and un- heating phase and at reduced
19
tive dergoing mechanical pre-heating. speed to allow the mechanical
parts to start regularly.
In case the Ecobloc is present The sanitation procedure of the fill-

(blow moulder and filler mono- er's hydraulic circuit is in progress
20 Sanitation in progress
bloc), this means that filler sanita- (provided the filler is present in
tion is in progress. monobloc with the blow moulder)
89
10.3 List of alarm messages

Summary chart
The following indicates the complete chart related to the machine's alarm messages. The chart is
composed of the univocal identification number of the alarm (N°), of the displayed message and of
the code related to the explanation of the alarm (COD.) in the chart “Meaning of the alarm” in the
next paragraph.
N° MESSAGE COD.
1 Stop command by operator 1
2 Alarms acknowledgement needed 2
3 Filler: Air is lacking in pneumatic circuit 3
4 Oven phase needed 4
5 Problem - Oven 5
6 Oven phase recovery needed 6
7 Blowing wheel infeed grippers phase search needed 4
8 Problem - Blowing wheel infeed grippers 5
9 Blowing wheel infeed grippers phase recovery needed 6
10 Blowing wheel phase search needed 4
11 Problem - Blowing wheel 5
12 Blowing wheel phase recovery needed 6
13 Blowing wheel outlet grippers phase search needed 4
14 Problem - Blowing wheel outlet grippers 5
15 Blowing wheel outlet grippers phase recovery needed 6
16 Mold closure safety activated 7
17 Filler: Problem - CO2 3
18 Off-line power 8
19 Emergency button pushed 9
20 Main line power lack 10
21 Control panel conditioner failure 11
22 Directing device roller: Manuel control 12
23 Oven not in temperature 13
24 Startup procedure running 14
25 Preforms lack 15
90
N° MESSAGE COD.
26 Anomaly at machine inlet, stars area 16
27 Machine not at working speed 17
28 Oven outlet guide not in position 20
29 Blowing wheel: stopped shaft sensors anomaly 22
30 Mold lever out of template/ Not correct position template 19
31 Bolt closure safety activated 21
32 Blowing wheel: lubrication anomaly 23
33 Blowing wheel: lubricating cartridge empty 38
34 Problems blowing piston pos. stretch rod 24
35 Mold 1 OFF 25
36 Mold 2 OFF 25
37 Mold 3 OFF 25
38 Mold 4 OFF 25
39 Mold 5 OFF 25
40 Mold 6 OFF 25
41 Mold 7 OFF 25
42 Mold 8 OFF 25
43 Mold 9 OFF 25
44 Mold 10 OFF 25
45 Mold 11 OFF 25
46 Mold 12 OFF 25
47 Mold 13 OFF 25
48 Mold 14 OFF 25
49 Mold 15 OFF 25
50 Mold 16 OFF 25
51 Mold 17 OFF 25
52 Mold 18 OFF 25
53 Mold 19 OFF 25
54 Mold 20 OFF 25
91
N° MESSAGE COD.
55 Unfit mold 1 times change 26
75 Problem stretch rod 1 27
92
N° MESSAGE COD.
95 Problem section lamps 1 28
93
N° MESSAGE COD.
115 Safety door 1 open 29
124 High pressure air above maximum limit 30
125 High pressure air below minimum limit 31
126 Low pressure air above maximum limit 32
127 Low pressure air below minimum limit 33
128 Anomaly preform verticality control zone 34
129 Unfit blowing cycle basic times 35
130 OUTLET ACCUMULATION 36
131 Outlet obstruction 37
132 Oven in overtemperature 39
133 Next system off 40
134 Chiller not activated 41
135 Format change in progress 44
136 Oven water flow off 45
137 Problem with ring 1 46
138 Load preforms system emergency 47
139 Preforms loading system problem 48
140 Directing device rolls block 49
141 Lowered mold bottom 2 check active 50
94
N° MESSAGE COD.
142 Incorrect blowing piston position 51
143 Lowered mold bottom check active 18
144 Air belt fan thermal overload protection alarm 53
145 Lot end 54
146 Chiller forced operation enable 55
147 REMOTE ACCUMULATION 56
148 Remote obstruction 57
149 Programmed maintenance request 58
150 Block for maintenance intervention 59
151 Blowing activation zone anomaly 60
152 Not correct format change device position 61
153 Pause for high pressure value below normal 62
154 Pause for low pressure value below normal 63
155 Service air pressure above high limit 64
156 Pause for service air value below normal 65
157 LOW service air pressure 66
158 Service air pressure below low limit 67
159 Preform temperature tolerance above normal 68
160 Not homogeneous inlet product temperature 69
161 Wrong air recovery tank parameters 70
162 Tank filling problem-Air recovery 71
163 High air recovery tank pressure 72
164 Posyc automatic switching off 73
165 Belt problem - M101 74
95
N° MESSAGE COD.
181 Empty hopper 75
182 Too many bottles rejected at the wheel outlet 78
183 Oven modulation limit reached 82
184 Oven temperature low 83
185 Oven temperature high 84
186 Expulsion container lack - 1 85
187 Expulsion container lack - 2 85
188 Closure lever phase search cam safety 86
189 Wrong stop in phase parameters 87
190 Close the program and restart 88
191 Machine preheating active 89
192 Suction motor thermal overload protection alarm 53
193 Blowing wheel mechanic phase problem 90
194 Rejection container: Position not correct 43
195 Oven power activation problem 52
196 System unregistered - Please contact your supplier 93
197 Jog function enable - Filler wheel 94
198 Thermal overload protection alarm - Loading system preforms 53
199 Filler wheel mechanic phase problem 90
96
N° MESSAGE COD.
200 Machine emptying needed 95
201 Blowing wheel inlet forced expulsion 96
202 Blowing wheel outlet forced expulsion 96
203 Quick restart on accumulation mode 98
204 Blowing wheel water flow off 45
205 Unfit oven outlet preforms temperature 101
206 Not correct inlet gripper mechanic phase 90
207 Not correct outlet gripper mechanic phase 90
208 Discharge state system 102
209 Preforms unloading at the inlet 103
210 Oven mechanic phase problem 90
211 Blowing wheel wrong synchronization 104
212 Automatic lubrication activation failed 105
213 Low level in the oil unit 106
214 Waiting for bottle bottom cooling tank filling 107
215 Germicidal device alarm 108
216 Change-over keyboard active 109
217 Main line power anomaly 110
218 Mandril pick-up anomaly 76
219 Overload conveyor alarm 115
220 Bottles block conveyor emergency 116
221 OUTPUT FORCED OPERATION 120
222 Enable request - Elevator 42
223 Problem - Elevator 5
224 Elevator: Manual control 12
225 Phase needed - Filler wheel 4
226 Problem - Filler wheel 5
227 Phase recovery needed - Filler wheel 6
228 Enable request - Product pump 42
97
N° MESSAGE COD.
229 Problem - Product pump 5
230 Product pump: Manual control 12
231 Enable request - Caps system head 42
232 Problem - Caps system head 5
233 Caps system head: Manual control 12
234 Enable request - Caps transport 42
235 Problem - Caps transport 5
236 Caps transport: Manual control 12
237 Enable request - Caps elevator 42
238 Problem - Caps elevator 5
239 Caps elevator: Manual control 12
240 Enable request - Caps charger 42
241 Problem - Caps charger 5
242 Caps charger: Manual control 12
243 Problem: FILLBOX 121
244 Sanitation system anomaly 122
245 Dummy bottles anomaly 123
257 Filler wheel: Wrong synchronization 104
98
N° MESSAGE COD.
258 Product pressure below minimum limit 124
259 Product pressure above maximum limit 125
260 CRITICAL FILLER ALARM 126
261 Product tank: Reserve end 127
262 Filler clutch intervention 128
263 Sterile air thermal overload protection 53
264 Caps lack on caps closure system 129
265 Caps transport: Finishing 130
266 Caps transport: Reserve end 131
267 Caps loading system: Reserve end 132
268 Taps reset: Running procedure 133
269 Product pump: Motor fan thermal overload protection 53
270 Caps system head: Motor fan thermal overload protection 53
271 Bottles check system alarm 134
272 Caps loading system - Off-line power 135
273 Emergency button pushed - Filler 136
274 Caps transport: Thermal overload protection alarm 53
275 Caps loading system: Anomaly 137
276 Outlet belt: Limit switch 138
277 Outlet belt: Phase needed 139
278 Sanitation cycle in progress 140
279 Dummy bottles procedure in progress 141
280 Machine ready for sanitation cycle 142
281 Fan ozone such thermal overload protection 143
282 Jog function enable: Loading system preforms 142
283 Jog function enable: Caps loading system 143
284 Deactivated filling zone 142
285 CIP tank: Reserve end 143
286 Phase search running 142
99
N° MESSAGE COD.
287 Machine START request 143
288 Sanitation liquid not in temperature 142
289 Sanitation liquid in overtemperature 143
290 UV lamps alarm 142
291 Product/CIP system electrovalve anomaly 143
292 Thermal overload protection alarm - CIP pump 142
293 Product system valve in manual / sanitation mode 143
294 MODBUS bus anomaly 142
295 MODBUS bus alarm manual bypass 143
296 CO2 pressure anomaly 142
297 Jack pressure anomaly 143
298 Discard for stop downstream system 142
299 Warning from filler 143
300 Filler safety doors opening/Emergency button 142
301 Product request waiting by filler 143
302 Pause requested by filler machine 142
303 External ozone water device: Consent waiting 143
304 Sterile air thermal overload protection - Taps 142
305 Caps transport: Caps block anomaly 143
306 Nitrogen doser anomaly 142
307 External lines thermal overload protection alarm: Filler 143
308 Preform check camera anomaly 142
309 PREMIX - Product not available 165
310 PREMIX - Production end 166
311 Forcing CO2 vent activated 167
312 Product temperature low 168
313 Product temperature high 169
314 Forcing CO2 inlet activated 170
315 Forcing taps washing enabled 171
100
N° MESSAGE COD.
316 Caps batching belts door open 29
317 Phase needed - Transfer star 4
318 Problem - Transfer star 5
319 Phase recovery needed - Transfer star 6
320 Caps loading system - Batching belt block 172
321 Enable request - Caps directing device 42
322 Problem - Caps directing device 5
323 Caps directing device: Manual control 12
324 Caps loading system - Dividers position not correct 173
325 High temperature water cooling bottom 169
326 Water cooling bottom tank: Reserve end 174
327 Stop bottles sampling after sanitation 175
328 Filler Infeed Belt: Position not correct 176
329 Filler inlet bottles lack 177
330 Blowing zone deactivated 143
331 Blowing Zone: Off-line power 8
332 Phase needed - Slave axis 4
333 Problem - Slave axis 5
334 Homing request - Motorized stertch rods 4
335 Problem - Motorized stertch rods 5
336 Phase needed - Motorized stations 4
337 Problem - Motorized stations 5
338 Start Positioning - Motorized stertch rods 178
339 Motorized stertch rods: Profile parameters incorrect 179
340 Motorized stertch rods: Unsuitable format 180
341 Open bolt safety off 21
342 Preforms loading anomaly 181
343 Discharge mold pressure anomaly 182
344 Stretch rod ascend anomaly 183
101
N° MESSAGE COD.
345 Recirculation tank product anomaly 184
346 Sterile air: Filters cleaning anomaly 185
347 Problem - Panels cooling fans 186
348 Mold bottom water flow off 45
349 Oven cooling pump: Thermal overload protection alarm 53
350 Oven cooling pump: Manual control 12
351 Blowing group test in progress 77
352 Thermal overload protection alarm - Lamp panels 53
353 Lamp panels: Controller anomaly 192
354 Thermal overload protection alarm – Ventilation – Panels Suction 53
355 Modified parameter - Close the program and restart 88
356 Stop request by Supervisor 187
357 Supervisor communication fault 188
358 Cap/level check: Camera anomaly 189
359 Cap/level check: Discard system anomaly 190
360 Obstruction by external belts 191
361 Rejection container too full – Oven infeed 79
362 Blowing wheel: Off-line power 91
102
10.4 Meaning of the alarms

The following chart indicates all the explanations of the alarm put in order according to code
(COD.). In the column “Message”, general terms have been used (in bold print and italics) to group
together the same kind of alarms but related to different functional groups. They are:
n, m = if the alarm has a whole number (e.g. “Safety door n open” for “Safety door 3 open” etc.)
electronic axis = if the alarm has the name of an electronic axis (e.g. “Locking driver electronic
axis” for “Locking driver divider bars” etc.)
machine zone = if the alarm has the name of a specific zone (e.g. “Machine zone thermal overload
protection alarm” for “Intermediate pads thermal overload protection alarm” etc.)
In the column “COD.”, a letter will indicate the type of alarm according to the following table:
Emergency messages. In this case, the machine stops immediately, without executing the
A
stop in phase.
B Emergency safety messages with the intervention of the safety brakes.
Problem messages implying the start push-button lock. The machine executes the stop in
C
phase procedure and does not start when you press the start push-button.
Problem messages implying a technical intervention request. The machine executes the stop
D in phase procedure; when you press the push-button start, the machine executes a cycle and
then stops again.
Pause messages. The machine executes the stop in phase and re-starts automatically when
E
the problem is solved.
Warning messages and request of check. The machine runs at the requested speed (mes-
F
sage only).
Messages implying the machine stop due to a problem; if the “unload” mode is selected, these
G
messages are not taken into consideration.
H Warning messages with verification request. The machine slows down until it stops.
CODE MESSAGE MEAN NOTE
1-H Stopped by operator The operator stopped the system.
The operator should acknowledge For any further information, please

2–HoD Alarms acknowledgement request
the alarms. refer to paragraph 10.1.
No service air was detected at the Check that the pneumatic circuit is
inlet of the filler's pneumatic circuit connected properly or check for
3-A Filler: Problem no air/CO2
or there are CO2 problems in the any anomalies in the digital pres-
case of the isobaric machine. sure switch.
103
The system needs a phase search

for the following reasons: 1) The
The system requests a "Phase turning on of the system; 2) The
Phase search req. for electronic
4-C search" of the electronic axis spec- changing of some axis parameters;
axis
ified in the alarm. 3) Axis irregular movement. For the
phase search procedure, refer to
chapter 5 in this manual.
Check that the axis is free to move.

Carry out a "Phase recovery" if re-
quired. Take note of the active
The driver of the brushless motor
alarms related to the stopped axis
5-A Problem electronic axis connected to the axis specified in
and consult the “DRIVERS
the alarm is stopped.
ALARMS” sheet. For any further in-
formation please refer to the driv-
ers manual, provided.
Usually this type of stop is due to

the incorrect passage of the prod-
uct among the machine's various
The system requests carrying out
Phase recovery req. for electronic parts. The system needs a “Phase
6-A the "Phase recovery" procedure of
axis recovery”. To carry out this opera-
the axis specified in the alarm.
tion, enter the “Phase recovery”
menu and then press the button as-
sociated with the stopped axis.
The reasons for such a request can

The system asks to carry out an
Bottoms closing automatic se- be: 1) An operator inadvertently left
7-D automatic bottoms closing se-
quence a mould open; 2) An emergency
quence.
occurred.
Check for the presence of mes-

sage “Emergency button pressed”
and, in that case, release any
pressed emergency buttons. At this
point and in order to reactivate the
power circuit you must press one
In general, an emergency button
8-A Power off of the machine's POWER buttons.
was pressed.
If the situation is not resolved,
check the messages relating to
door closing (e.g.: “Door 1 open”
etc.) and, if this is the case, the
presence of message “No mains
voltage”.
Check that all emergency buttons

An emergency button installed on
9-A Emergency button pressed are released and, if this is the case,
the machine was pressed.
check their working efficiency.
104
This problem occurs when there is

no source power supply (for exam-
ple, if a cut-off is caused by the
weather). In this type of situation
the backup battery installed in the
electrical panel is activated. The
There is a failure in the machine's
10 - F No mains voltage performance of the backup battery
power supply voltage.
has been calculated to last about
two hours. If you think that the
problem might persist for several
hours, manually empty the ma-
chine and turn off the system by
shutting down Windows.
Clean the ducts, fans and filters of

The thermostat of the electrical
the conditioner. Check the working
11 - F Panel conditioner failure panel warns there is an overheat-
efficiency of the fans and thermo-
ing.
stat adjustment, if necessary.
The indicated electronic axis was Check the setting made in the
12 – F o H Electronic axis Manual control set to a mode other than the auto- electronic axis' screen (STOPPED
matic one. or ALWAYS RUNNING)
Wait until the oven reaches work-

The temperature in the oven did ing temperature or make sure there
13 - E Oven temperature not reached not reach the threshold necessary aren't any problems with the read-
to properly heat the preform. ing of the PT100 temperature
probe.
105
Normally, this alarm is displayed

only for a few seconds while the
operator interface boots. If the
problem persists, this means that
the system can not communicate
with some devices. This situation
typically results in a general error
condition with subsequent reboot-
ing of the interface program. The
screen will display a message that
will help identify the faulty device
(or SERCOS loop). Carry out the
SERCOS system is initializing.
following checks, extending them
During this stage the system recog-
14 - A Initialization in progress to all devices connected to a given
nizes SERCOS devices present in
loop, in case the latter is faulty.
the machine.
Perform the following checks, re-
ferring to the wiring diagrams:1)
the address of the faulty device; 2)
the connections of the faulty de-
vice; 3) the voltage of the faulty de-
vice.4) the working efficiency of
Marts. If the interface program re-
mains ON without indicating any
errors this could mean that a loop
may not be closed. Check the dis-
tortion LEDs of every loop on Marts
and check their connections.
Solve the problem, if it exists, oth-

Since there are not enough prod-
erwise wait until there are enough
15 - E No preforms ucts on the inlet ramp, the produc-
products to allow the machine to
tion stops (system PAUSED).
restart (automatically).
A possible cause may be a mal-

function in the preforms stop pis-
ton. In fact, this failure may be due
to two main causes: 1) The piston
is stopped but the preforms keep
Anomaly at machine inlet in stars Indicates a fault in the preforms
16 - E entering (probable piston failure).
zone flow in the inlet stars zone.
2) The piston is open but no pre-
forms arrive (piston failure or pre-
forms stopped between the piston
zone and the preforms detection
zone at machine inlet).
In order to start the process, the Wait until the set production speed
The machine has not reached
17 - F machine must reach its production has been reached through the di-
working speed
speed. rect controls.
106
The sequence of operations per-

formed by the mould during carou-
sel rotation was not complied with.
As such, it seems that the carou-
Check active, to make sure bottom A safety device was triggered in
18 - A sel's configuration is not allowed
is down the carousel zone.
from a mechanical point of view. An
alarm was triggered to prevent
breakage caused by collisions be-
tween mechanical components.

Closing lever phase safety activat- A safety device was triggered in
19 - B sel's configuration is not allowed
ed the carousel zone.
It is necessary to proceed with the

phase search or phase recovery of
The preform guide at the oven out-
20 - B Oven outlet guide not in position the oven electronic axis and/or of
let is lowered
the blowing wheel infeed grippers,
in order to solve the problem

A safety device was triggered in
21 - A Bolt closing safety activated sel's configuration is not allowed
the carousel zone.
Check the correct operation of the

Blowing wheel: stopped shaft sen- The safety PLC signals an anomaly
22 - F sensor detecting the blowing-
sors anomaly of the blowing wheel rotation
wheel fifth wheel
Check the correct operation of the

There is an anomaly in the blowing- lubrication system; make sure
23 - A Blowing wheel: lubrication anomaly
wheel lubrication system there are no obstructions in the lu-
brication system
107
When the preforms are delivered to

the carousel by the carousel infeed
grippers, the blow-moulding piston
must be in rest position otherwise
The alarm tripped related to an in-
Incorrect position of blow-moulding an alarm trips. If the machine does
24 - B correct configuration of the blow-
piston not stop, the carousel infeed grip-
moulding piston.
pers would touch the piston and
cause the machine to stop as well
as probable damage to mechanical
parts which collided.
The mould is not used during the Mould n was disabled by the oper-
25 - F Mould n disabled
production. ator through the parameters.
The changes made to the times set One or more values entered in the
Change of mould n times unsuita- for the blow-moulding cycle of times change of mould n are ex-
26 - F
ble mould n do not respect the limits ceeding the machine's calculated
imposed by the machine. safety limits.
The stretch rods must be in rest po-

sition (fully raised) when not in pro-
27 - B Problem stretch rod n Unwanted state of stretch rod n
duction or alarm state. Otherwise
an alarm trips
Possible causes include a break-

down of the lamps or an alarm or
There is a problem with the power warning of the static relay (in this
28 - F Lamps problem in panel n
supplied to the panel's lamps case it may suffice to just cut-off
power to the machine and then re-
store it).
To clear the emergency state,

Machine access door n was check the condition of the speciic
29 - A Door n open
opened. door and, if necessary, the working
efficiency of the electric micro.
Pressure has exceeded the maxi-

High pressure air max limit exceed- The high pressure values are
30 - C mum high pressure specified by
ed wrong
the parameter. The machine stops.
Pressure is lower than a minimum

High pressure air min limit exceed- The pressure value in the high value for the high pressure speci-
31 - C
ed pressure circuit is wrong fied by the parameter. The ma-
chine stops.
Pressure has exceeded the maxi-

Low pressure air max limit exceed- The pressure value in the low pres-
32 - C mum low pressure specified by the
ed sure circuit is wrong
parameter. The machine stops.
Pressure is lower than a minimum

Low pressure air min limit exceed- The pressure value in the low pres- value for the low pressure specified
33 - C
ed sure circuit is wrong by the parameter. The machine
stops.
108
The rejection of non-perpendicular

There is a problem in the area preforms is detected for a certain
Problem in preforms perpendicu-
34 - C where preform perpendicularity is number of times. The machine
larity check zone
checked. stops at the end of the preforms
process.
One or more values entered in the

The basic timeframes set for the
Blow-moulding cycle standard basic timeframes have exceeded
35 - E blow-moulding cycle do not meet
times unsuitable the safety limits calculated for the
the limits set by the machine.
machine.

erwise check accumulation sensor
Bottles have accumulated on the working efficiency. Check parame-
36 - E Accumulation at outfeed belt at machine exit (system ter “Accumulation ON Time” in the
PAUSED). system parameters via menu
“Commands” - “Machine” - “Param-
eters” - “Accumulation”.

erwise check sensor working effi-
Product flow near machine exit is
37 - C Jam at outfeed ciency. The buzzer will keep
jammed.
ringing as long as the problem per-
sists.
Blowing wheel: lubricating car-

38 - F The lubricating cartridge is empty Replace the lubrication cartridge
tridge empty
Check if the fans, the cooling circuit

The temperature in the oven has
or the PT100 probe malfunction or
39 - D Oven overtemperature exceeded the maximum one set via
double-check the parameterization
the parameter
of the lamps' heating profile.
The system at blow moulder out- Activate the system that controls
40 - E Next system not activated
feed is deactivated. the blow moulder.
The machine's cooling system is Activate the cooling system or

41 - C Chiller not activated
deactivated. check if it's in emergency state.
The system needs an enabling for

the following reasons: 1) The turn-
ing on of the system; 2) The chang-
The system requests an "Enable"
ing of some axis parameters; 3)
42 - C Enabling request – electronic axis of the electronic axis specified in
Axis irregular movement. For the
the alarm.
enabling procedure, refer to the
phase search outlined in chapter 5
in this manual.
Put the rejection container in the

Rejection container: Position not The rejection container is not posi-
43- A correct position, so that the safety
correct tioned correctly
systems are activated accordingly
109
The operator is replacing the

moulds for a new format and raised
the piston that allows the mould
The moulds are being replaced for
44 - C Format change in progress bottom to remain in such a position
a new format
as to allow the immediate closing of
the mould when operations are fin-
ished.
There could be some malfunctions

The coolant required to maintain
concerning the operation of the
the structures in good condition is
45 - C No oven water flow flow switch or the water return
not flowing inside the oven's hy-
valve in the oven or a cooling sys-
draulic cooling circuit
tem (chiller) failure.
Refer to the diagnostic section in

- "I/O (01)" – "SYNOPTIC
A problem occurred in one or more OF RING N", check the type of
of the devices connected to SER- problem and, if necessary, reset
COS loop n. This problem occurs any devices in error state. Check
46 - A Problem in loop 1 when there is a fault in one of the I/ the configuration parameters in
O modules or in the presence of "MENU" - "MACHINE GENERAL
signal distortion (when it is man- (06)" - "PARAMETERS (10)" -
aged) "CONFIG. (*) The machine's type
of stop, when this alarm trips, de-
pends on what triggered it.
Release the emergency button of

the loading system or close the di-
Generally speaking, the emergen-
recting device inspection door. At
Preforms loading system emergency button was pressed on the load-
47 - F this point , in order to restart the
cy ing system or an inspection door of
power circuit, press the POWER
the directing device was opened.
button on the preforms loading sys-
tem.
The downstream push stop photo-

cell in the directing device does not Check the flow of the preforms on
detect any preforms after a set the lifter and in the directing device
48 - F Preforms loading system problem
movement time of the rollers and to check why the directing device is
the lifter, even though there are not filling
preforms in the hopper
The downstream push stop photo-

cell, or the one that detects the lack
of preforms on the inlet chute, does
Check and clear the jam inside the
49 - F Directing device rollers jammed not detect any preforms even
directing device.
though they are being detected by
the upstream calling photocell in
the directing device
The bottom of a mould is not in the Safety sensor no. 2 detected the in-
50 - A Check active for bottom 2 lowered best position for the optimal run- correct position of the bottom of a
ning of the machine mould.
110
Check what caused the stop or

The control lever connected to a
check the parameters of the blow-
51 - B Blow-moulding piston check 1 micro detected that the bottle stop
moulding cycle to reduce the total
piston did not go back up
duration of the cycle
Carry out the relevant electrical

The system can not supply electri- verifications: check the mains volt-
52 - A Oven power activation problem
cal power to the oven panels age and the safety systems of the
oven electrical circuit
To clear this problem, check if

This indicates the tripping of the there is any mechanical friction and
magnetothermal circuit breaker in then rearm the magnetothermal cir-
53 - A Thermal alarm in machine zone
the machine area specified in the cuit breaker. Check motor input
alarm. and magnetothermal circuit break-
er calibration.
The system warns that the expect- Check the "Lots Production" mode
ed number of bottles has been by pressing in the main page on the
reached for the production lot. The BOTTLES COUNTER view, then
54 - F Lot terminated
machine will either stop or keep press "LOTS PRODUCTION (05)"
producing, depending on the relat- - "SETTINGS (04)" - "PARAME-
ing parameter. TERS (03)"
The chiller was forced via the direct

controls to purge the hydraulic cir-
Indicates that the chiller works
cuit. The machine can restart at
55 - F Chiller forcing activated through the operator's forced oper-
any time and the chiller will resume
ation
normally when the machine switch-
es to production state.
The customer provides an accumu-

This means that the customer sig- lation signal that identifies a partic-
56 - E Remote-controlled accumulation
nals an accumulation condition ular accumulation condition in the
next system.
The customer provides an obstruc-

This means that the customer sig-
tion signal that allows the machine
57 - C Remote-controlled obstruction nals an obstruction with automatic
to reject products without generat-
restart
ing product build-ups downstream.
After a specific set time, the techni-

cian in charge of maintenance is
A technical scheduled mainte-
58 - F Scheduled maintenance request notified to perform the required in-
nance intervention is requested.
tervention in a specific machine
zone.
111
The machine has performed a spe-

cific number of cycles, produced a
specific number of bottles or has
Stop due to maintenance interven- been running for a specific period
59 - C Request for machine maintenance.
tion of time. As such, the machine
needs maintenance or an overhaul.
The machine ends the preforms
process and stops.
The detected number of preforms

Check for the loss of any preforms
missing from the blow-moulding
on their route from the stars and
Anomaly in blow-moulding enable enabling zone is higher than the
60 - A through the oven to verify which
zone limit set via the parameter, al-
mechanical parts may have caused
though said preforms should have
the problem.
been present.
A format change is underway be-

cause the device that allows the re-
The incorrect position of a device leasing of the bottom is not in the
Incorrect position of format change
61 - A used for the format change was suitable position for the machine to
device
signaled. run. Complete the format change
or check that said device is proper-
ly positioned.
Pressure is lower than the value

Pause due to high pressure low Pressure in the high pressure cir- set as the limit. The machine ends
62 - E
value cuit is wrong the preforms process and switches
to paused condition.

Pause due to low pressure low val- Pressure in the low pressure circuit set as the limit. The machine ends
63 - E
ue is wrong the preforms process and switches
Pressure is higher than the value

Service air pressure max limit ex- Pressure in the service air circuit is
64 - C set as the limit. The machine ends
ceeded wrong
the preforms process and stops.

Pressure in the service air circuit is set as the limit. The machine ends
65 - E Pause due to service air low value
wrong the preforms process and switches

Pressure in the service air circuit is
66 - C Service air LOW pressure value set as the limit. The machine ends
wrong
the preforms process and stops.

Service air pressure min limit ex- Pressure in the service air circuit is
67 - A set as the limit. The machine stops
ceeded wrong
in emergency.
112
The temperature of the preforms

flow at machine inlet suddenly ex-
Preforms temperature tolerance The temperature of the preforms at ceeded a set tolerance as com-
68 - C
exceeded machine inlet is wrong pared to the working temperature.
The machine ends the preforms
process and stops.
A number of preforms with unsuita-

ble temperature, higher than the
Product temperature at inlet not The temperature of the preforms at
69 - C set limit, was rejected. The ma-
homogeneous machine inlet is wrong
chine ends the preforms process
and stops.
The user is informed that the pa-

Incorrect blowing air recovery tank The blowing air recovery tank parameters in question are not suita-
70 - F
parameters rameters were not set correctly. ble for the machine's working
efficiency.
The user is informed that air from

the tank cannot be used because
Tank filling-Blowing air recovery A problem was detected while fill-
71 - C the level inside the tank is lower
problem ing the tank
than the tolerance of the minimum
work value set via the parameter.
The user is informed that pressure

inside the blowing air recovery tank
High pressure in blowing air recov- Pressure inside the tank is too high
72 - C is too high. If blowing air recovery is
ery tank as compared to set limits.
enabled, the machine stops after
processing the preforms.
The backup batteries intervene

when mains voltage fails. The Po-
syc shutdown procedure is activat-
ed if the batteries discharge
because the power failure lasts too
long. This is done to ensure that
Indicates that Posyc automatic
73 - F Posyc automatic shutdown the current operating system will be
shutdown procedure is underway.
closed properly. This function is
available only if the devices mount-
ed on the loop (Digate) can support
this function. Even the main power
supply is disconnected when Po-
syc shuts down.
Check the problem via menu page

74 - G Problem with belt n External belt n has a problem. “CONTROLS” - “BELTS 04” - “Belt
n”
The preforms tipper is activated

The machine's preforms inlet hop-
75 - F Hopper empty and fills the hopper until the signal
per is empty
activation sensor trips
113
Stop the machine and carry out the

There is a problem with the preform
76 - C Mandril pick-up anomaly relevant mechanical verifications
pick-up by the oven mandrils
on the oven mandrils
At the end of the test, it is neces-

The test on the blowing group elec-
77 - C Blowing group test in progress sary to deactivate the change-over
trovalves is in progress
piston
During the production, the consec-

utive rejection of bottles or the re-
jection of a set number of bottles
within one minute (indicated via a
Too many bottles rejected at carou- Too many bottles were rejected parameter) causes the production
78 - C
sel outlet consecutively at carousel outlet. cycle to stop and preforms are re-
jected at carousel inlet (because a
high rate of rejections at carousel
outlet means that pressure is low at
machine inlet)
Rejection container too full – Oven It indicates that the rejection con-
79 - C Empty the rejection container
infeed tainer is too full
The phase check of the outfeed

Incorrect position - Outfeed gripper Check and correct the mechanical
80 - C grippers detected that gripper n is
n phase of the out-of-phase gripper
not in phase
The sensor that detects the me-

Check the working efficiency of the
Infeed/outfeed grippers mechani- chanical phase of the grippers at
81 - A optical fiber sensor or the sensor's
cal phase sensor problem carousel infeed/outfeed did not de-
detection of all the grippers.
tect anything
A modulated lamp reached the If necessary, change the power of

maximum power that may be ap- the modulating lamps to achieve a
82 - F Oven modulation limit reached
plied with the temperature check at greater range for checking temper-
oven outlet ature at oven outlet
Check consistency between set

Oven temperature is too low as
83 - C Low temperature in oven limits and oven temperature and
compared to set limits
change lamps limits or power
Check consistency between set

Oven temperature is too high as
84 - C High temperature in oven limits and oven temperature and
compared to set limits
change lamps limits or power
The preforms rejection container at Position the container correctly so

85 - A No rejection container - n carousel inlet or outlet is not in that the associated safety device
place can deactivate.
Reposition the cam, through the

Closing lever phase search cam The closing lever phase search
86 - B appropriate safety device, in home
safety cam is not in a safe position.
position.
114
Change the stop in phase value

and/or the emergency stop in
The stop in phase parameter and
phase value so that it is away from
the emergency stop in phase pa-
the absolute encoder value of
87 - F Incorrect stop in phase parameters rameter is not tolerated as com-
mould 1 because failures could oc-
pared to the positioning encoder
cur when synchronizing the posi-
value of mould 1 absolute sensor.
tions in the machine after the
phase search procedure.
Since the configurations of the car-

You must close the program and ousel's master and slave drivers
88 - F Close the program and restart
restart it. were exchanged, you must restart
the program.
The machine was stopped for a few

hours or was just turned on. When
the machine starts, the displayed
89 - F Machine pre-heating active The machine is pre-heating. message indicates the activation of
the machine's preheating phase.
The machine switches to produc-
tion state when pre-heating is over.

The sensor that detects the carou-
sensor, the sensor's detection of all
Carousel mechanical phase prob- sel's mechanical phase did not de-
90 - A the moulds or if there are any slid-
lem tect anything or detected an
ing problems of the fifth wheel or
incorrect value.
junctions.
Restore power supply by pressing

It indicates that the ICOS PS power the relevant push-button or check if
91 – A Blowing wheel: power off
supplier is deactivated there are any anomalies in the
ICOS PS power supplier
92 - F FREE Not used
Usually this warning appears when

the password is required to unlock
the console program but it was de-
cided to continue without entering
System not registered - Contact The system was not registered cor-
93 - D it. The machine can work properly
supplier rectly.
for a set length of time, after which
the program will be restarted. Con-
tact the supplier for the necessary
information.
The function, which allows the In order to restore start conditions

Jog function active – Carousel/Pre-
movement of the functional unit in- you must deactivate the Jog mode
94 – C/F forms loading system/Caps loading
dicated through the pushbutton through the specific key via the
system
panel, is active. pushbutton panel.
115
To be carried out if the program

The machine was just turned on
had been closed previously while
and an emptying cycle is request-
product was still inside the ma-
ed, which should be carried out if
95 - F Machine emptying request chine. You can avoid this cycle by
the program had been closed pre-
deactivating this function through
viously while product was still in-
the specific button if the program
side the machine.
started problem-free.
Rejection forcing at carousel in- Rejections forcing is active at car- The respective forcing button was
96 - F
feed/outfeed ousel infeed or outfeed. pressed in the main page.
97 - A FREE Not used
Since the downstream system is

The machine is restarting quickly releasing product, the blow mould-
98 - F Quick restart after accumulation even if accumulation is still active er can anticipate its restart even if
at outfeed. accumulation is still active, to opti-
mize production time.
99 - E FREE Not used
100 - E FREE Not used
The temperature of the preforms at Some panels may have turned off
Unsuitable preforms temperature
101 - F oven outfeed is lower than the limit incorrectly or there may be temper-
at oven outfeed
set in the check device ature probe problems.
The machine may have stopped in

emergency state during the pro-
The machine's unloading state is
102 - F Machine unloading duction. On restoring the anomaly,
active.
the activation of the unloading
phase is signaled.
Unloading of the preforms inside

The function is active via the appro-
103 - F Preforms emptying at infeed the hopper through rejection at
priate forcing command.
oven infeed.
During the carousel's first revolu-

tion, an incorrect mould is detected
in the position relating to the detec-
The carousel's positions in the ma- tion of mould 1 absolute sensor. It
104 - D Incorrect carousel synchronization chine are not synchronized correct- could either be the position set in
ly. the machine or the sensor which is
detecting two positions in the ma-
chine at the same time, and must
therefore be moved.
The lubrication check did not detect

any lubricant flow during lubrication You must check for any malfunc-
105 - F No automatic lubrication activation
for a number of activations that tions in the lubrication system.
may be set via a parameter.
116
You must either check for the pres-

The lubricant level in the tank is be-
106 - F Low oil level in control unit ence of lubricant in the tank or lev-
low the minimum level check limit.
el-check malfunctions.
The tank that cools the bottom of You must either wait until the tank
Wait to fill the tank that cools the
107 - E the bottle is not at the appropriate has filled or check for any malfunc-
bottom
level. tions in the filling system.
A failure is detected in the germi-

There may be faulty lamps on the
108 - F Germicide device alarm cide device located at machine in-
germicide device.
feed.
Format change pushbutton panel The pushbutton panel is active for The pushbutton panel was enabled
109 - C
active carousel manual rotation. in the format change page.
Indicates that surges have oc-

curred which are higher or lower
110 - C Mains voltage failure Warning from the energy meter.
than the thresholds set on the de-
vice.
111 - A FREE Not used
114 - C FREE Not used
Warnings from SMI supervisor sys- Check the fault in the systems
115 - E Alarm due to belts too full
tem. downstream of the blow moulder.
Warnings from SMI supervisor sys- Check the fault in the systems
116 - A Emergency at bottle stop belts
tem. downstream of the blow moulder.
119 - C FREE Not used
If not required, deactivate the pro-

cedure by pressing button "FORC-
The outputs forcing procedure was
120 - A OUTPUTS FORCING ING ON/OFF (24)" in page I/O
activated.
MANAGEMENT reached through
buttons - "I/O (01)”.
A fault was detected in the elec-

Check the fault by pressing buttons
tronic devices that manage bottle
121 - C Problem: FILLBOX - “Filling - “Fillbox (filling de-
filling (in the case of the Ecobloc
vices)”
machine).
The external sanitation system sig- Check the signals of the external
122 - E Sanitizer system fault
nals a fault in the Ecobloc machine sanitation system
117
Check the positioning of the false

bottles under the taps, the state of
A problem occurred linked to the the sensors that detect the false
123 - D False bottles unit fault
false bottles functional unit. bottles or the activation of the load-
ing and unloading of the false bot-
tles
Check the minimum set pressure

Product pressure min limit exceed- The pressure of the liquid at filler limit as compared to the set pres-
124 - C
ed inlet is lower than set parameters sure value for the product pump
check
Check the maximum set pressure

Product pressure max limit exceed- The pressure of the liquid at filler limit as compared to the set pres-
125 - C
ed inlet is higher than set parameters sure value for the product pump
check
An emergency occurred in the ex- Check and solve the emergency in

126 - A Filler critical alarm
ternal filler the external filler
The level of the tank containing the Check product flow at tank inlet or
127 - C Product tank: Reserve finished liquid for the filling operations is too any malfunctions in the sensor that
low for the production. checks the tank's low level
The bottle transfer stars inside the Solve any bottle jams, check the
filler underwent a mechanical phase between the transfer stars or
128 - A Filler clutches intervention
phase shift, probably due to a bot- any malfunctions of the star clutch
tle jam check micros
The lack of a cap is detected by the

check photocell at capper inlet; the Check that the photocell detects
129 – F/C No cap on capper machine stops if caps presence is correctly or if there are any prob-
not detected for consecutive pre- lems at capper caps inlet
forms.
Caps are missing at the beginning Check photocell reading or if there

130 - E Caps conveyor: Run out
of the conveyor are any jams upstream
Caps are missing at the end of the

Check photocell reading or if there
131 - E Caps conveyor: Reserve finished conveyor, near the area where
are any jams upstream
caps enter the machine
Caps loading system: Reserve fin- Caps are missing inside the load- Check photocell reading or fill the
132 - E
ished ing system loading system hopper with caps
The user is informed that the taps

133 - E Taps purge: Procedure in progress Wait until purging is over
purging procedure is in progress
The external bottle check system Check the fault to be able to solve
134 - F Bottles check system alarm
signals a fault the problem
118
Rearm the emergency button. In

The emergency button was
order to rearm the power circuit,
135 - F Caps loading system – Power off pressed on the caps loading sys-
press the POWER button on the
tem.
loading system.
The emergency button installed on Check that the emergency button is

136 - A Emergency button pressed - Filler
the filler was pressed. released
The detected fault is linked to the

Check for any faults, in the caps
caps loading system (jammed,
137 - F Caps loading system: Fault loading system diagnostics page to
thermal circuit breakers in alarm,
be able to check the problem
lifter obstruction)
While adjusting the height of the Adjust belt height using the phase
138 - F Outfeed belt: Limit switch bottle outfeed belt from filler, its lim- search button or through the manu-
it switch is detected up or down al controls
The phase search/adjustment of Carry out the height phase search

Outfeed belt: Phase search re-
139 - C the bottle outfeed belt from filler is via the appropriate adjustment
quest
requested page
The user is informed that the filler Wait until the sanitation procedure
140 - C Sanitation cycle in progress
sanitation procedure is in progress is finished
The user is informed that the load-

141 - C False bottles procedure in progress ing or unloading of the false bottles Wait until the procedure is finished.
is in progress
The user is informed that the ma-

chine is ready to carry out the san-
142 - C Machine ready for sanitation cycle
itation cycle in case the external
sanitation system is present
If you want to fill, you must enter

Indicates that the bottle filling zone page and disable button
143 - F Filling zone deactivated was deactivated in an Ecobloc ma- “FILLING ZONE DEACTIVATION
chine (17)” and enable button “PROC-
ESSED PRODUCT SYSTEM (23)”
You must remove the sanitizer

Indicates that the sanitizer level in
from the machine and repeat the
144 - C CIP tank: Reserve finished the CIP tank dropped to below min-
sanitation procedure starting by fill-
imum level
ing the CIP tank
An electronic axis is performing a After an axis phase search request,

phase search. When this proce- a device “Phase search” was done
145 - A Phase search in progress:
dure is over, it will stop in the cor- or the machine is undergoing a
rect work position. complete phase search procedure.
Indicates that the start button was

146 - F Machine START request
pressed:
119
Indicates that the sanitizer's tem- Wait until sanitizer temperature

perature probe detects a liquid reaches the required value or
147 - F Sanitizer temperature not reached
temperature that is not enough to check for any faults in the liquid's
carry out the sanitation heating system
Indicates that the sanitizer's tem- Wait until sanitizer temperature

perature probe detects a liquid reaches the required value or
148 - F Sanitizer overtemperature
temperature that is higher than the check for any faults in the liquid's
ideal sanitation temperature heating system
Indicates that there is a fault in the Check the working efficiency of the
149 - F UV lamps alarm UV lamps unit on the caps convey- UV lamps during the production cy-
or cle
Indicates that a hydraulic circuit

Product system/CIP solenoid valve, equipped with opening posi-
150 - F valves or if there are any faults in
valves fault tion check, opened instead of clos-
the valves' pneumatic connections
ing or vice versa
If you want to fill, you must enter

The manual mode was set for the page and disable button
Product system valves in manual
151 - F valves of the product/sanitation “FILLING ZONE DEACTIVATION
or sanitation mode
system in the filler zone (17)” and enable button “PROC-
ESSED PRODUCT SYSTEM (23)”
Check all the Ethernet connections

between the Ethernet switch in the
Detects a fault in the filler's Modbus
152 – C/F MODBUS fault electrical panel and the last device
network
that is on the filler's Modbus net-
work
If necessary, restore tripped alarms

through the MODBUS SYNOPTIC
PANEL page in the I/O MANAGE-
Any alarms from the filler's network
153 - F Modbus alarms manual disable MENT reached through buttons
are excluded, through forcing
- “I/O. Then press button
“MODBUS ALARMS DEACTIVA-
TION (02)”
Not used. For future implementa-

154 - F CO2 pressure fault
tions
Check for any faults in the pneu-

Jacks pressure is beyond work lim-
155 – C/F Jacks pressure fault matic circuit or the pressure detec-
its
tor
The user is informed that the prod-

Rejection due to downstream sys- uct is rejected at blow moulder inlet Check the fault conditions in the
156 - C
tem stopped and outlet because the belt is downstream system
stopped downstream of the filler
120
The user is informed that a problem

occurred on the external filler that Check the problem that should be
157 – C/F Warning from filler
may be preventing the filler from resolved on the external filler
ceiving the bottles
An emergency button was pressed

Filler doors/emergency buttons Check the conditions to be restored
158 - A or a door was opened on the exter-
problem on the external filler
nal filler
The blow moulder is running at pro-

duction speed and waiting for the
Wait for the go-ahead from the ex-
159 - E Wait for product request from filler filler to give the go-ahead to open
ternal filler
the gate and begin the production
cycle
The external filler requested the Check which problems occurred on

160 - E Pause requested from filler
blow moulder to stop in pause state the external filler
The Ecobloc machine is waiting for Wait for the go-ahead and check
External ozonator: Wait for go- the go-ahead from the external that the device does not have any
161 - E
ahead ozonator to continue the production problems that require operator in-
cycle tervention
A photocell on the caps conveyor is

not detecting any preforms while
Caps conveyor: Caps jamming Check and solve the jam to be able
162 - E the upstream and downstream
fault to resume the production cycle
photocells are detecting them
(means that caps are jammed)
Means that the external nitrogen Check the problem in the external
163 - F Nitrogen batching fault
batching is faulty device
Means that the camera that checks

Check the camera's electric con-
164 - F Preforms check camera fault for the preform's neck ring is off or
nections and if it signals any faults
signals a fault
The system that prepares the prod-

In order to restart the production
uct upstream of the filling machine
165 - C PREMIX - Product not available cycle, you must wait until product is
indicates that product is not availa-
available
ble
The warning from the product prep-

aration device entails the closing of
The system warns that product is
the gate and the end of the pre-
about to finish and therefore the
166 - E PREMIX - Producttion end forms processing in the machine
machine will end the production cy-
because the filling product is run-
cle.
ning out from the tanks supplied by
the customer
The forcing command was activat-

Indicates that the CO2 venting ed to carry out the operational test.
167 - C Forced CO2 venting activated
command is forced Deactivation is necessary to
resume the production cycle.
121
The customer should check the

temperature of the product at filling
Warns that the temperature of the
168 - D Liquid low temperature machine inlet since it is not suitable
reference liquid is low
for the correct running of the filling
cicle.
The customer should check the

temperature of the product at filling
Warns that the temperature of the
169 - D Liquid high temperature machine inlet since it is suitable for
reference liquid is hight
the correct runnning of the filling
cycle.

indicates that the CO2 inlet com- ed to carry out the operational test.
170 - C Forced CO2 inlet activated
mand is forced Deactivation is necessary to
resume the production cycle.

Indicates that the taps washing ed to carry out the operational test.
171 - F Forced taps washing activated
command is forced The machine can still continue the
production cycle.
Make sure thet too many caps

Indicates that there is a jam on the have not accumulated on the ob-
Cap loading system - Batching belt
172 - F batching belt of the cap loading struction-check photocell of the
jammed
system batching belt to avoid stopping the
production due to lack os caps.
Check for the actual and correct

Indicates that the diverters are not
Cap loading system - Incorrect di- shifting of the cap flow diverters or
173 - D in the corrrect position for the for-
verter position the working efficiency of the reed
mat being processed
sensors of the relating pistons.
Make sure that the cooling supply

Indicates that the cooling water is
Bottom cooling water tank: Re- to the tank was not shut off or
174 - D running out in the bottle's bottom
serve finished locked due to any type of unfore-
cooling tank
seen event.
You must reset the message by ac-

knowledging it and then run a new
End of bottle sampling after sanita- Indicates the end of the bottle sam-
175 - D sampling procedure or carry out all
tion pling procedure after sanitation
the steps to prepare the machine
for the production cycle.
Ensure that the belt at filling ma-

Indicates that the filling machine in-
chine inlet (and relating bottle-pas-
Filling machine inlet belt: Incorrect let belt (if present) is not in the cor-
176 - A sage sabre) has been positioned
position rect position for the production
correctly, with the correct detection
cycle.
of the positionning-check sensor.
Wait until a sufficient number of

Indicates that there are not enough
bottles has been conveyed, to al-
177 - E No bottles at filling machine inlet bottles to be processed on the belt
low the production cycle to be re-
at filling machine inlet
sumed
122
On pressing the start button, the

Indicates that the search is needed machine will run at reduced speed
Search for start position - motor-
178 - F for the start position of the motor- to allow the motorized rods to
ized stretch rods
ized stretch rods (if present). check the moulds, with respect to
the selected format
The motion profile parameters of Check the parametrization of the

Motorized stretch rods: profile pa-
179 - D the motorized stretch rods are in- blowing cycle relating to the motor-
rameters not correct
consistent ized rods' motion profile
Ensure that the correct format was

An unsuitable format was detected
Motorized stretch rods: Format un- selected or thet the correct moulds
180 - D with regard to the mould set in-
suitable were mounted, with respect to the
stalled in the machine
selected format
Check if there are any warnings on

The preform loading belt reports a the preforms loading system, either
181 - F Preform loading fault
fault upstream of the hopper or the di-
recting device.
The machine is stopped in emer-

A fault was detected with regard to
gency state because it was not
182 - B Mould pressure discharge fault the moulds' internal pressure after
possible to dischargepressure to
discharging
below a safety threshold
Check for any faults or times relat-

One or more rods did not go back
183 - B Motorized rod reascent fault ing to blowing cycle parameteriza-
up within the set time.
tion.
Where present, the product recir-

culation pump was unable to recir-
If present, product recirculation
184 - C Product recirculation tank fault culate the product quickly. Check
was not carried out correctly.
for any faults or blocking in the af-
fected valves.
The digital pressure switch reports

If present, this indicates a fault in a fault linked to the filters for obtain-
185 - F Sterile air: Filter cleaning fault the filters applied to the sterile air ing sterile air. Perform the neces-
pump sary checks for replacement,
where appropriate
One ore more fans of the tunnel's

If present, this indicates a fault in
186 - F Problem - Panel cooling fans panels may be stalled. Perform the
the fans of the tunnel's panels.
necessary checks.
The production line supervisor re-

187 – A – C – E quested a stop which may be of
Supervisor stop request The supervisor requested a stop
–F any kind (stop, pause, emergency
or only message).
The supervisor is either discon-

Failure to communicate with super- There is no communication with the
188 - F nected or is not communicating
visor client supervisor
with the machine.
123
The camera is not active. Check

A fault is reported in the camera
189 - D Cap/level check: Camera fault wheter the problem is electrical or
that checks cap/level
electronic.
Following a consecutive number of

missed rejection confirmations of
A fault is reported by the rejection
Cap/level check: Rejection system the system at filling machine exit, a
190 - E system used by the cap/level check
fault system fault is signaled. Check
performed via the camera
whether the problem is mechanical
or electrical.
Check whether the problem is me-

An obstruction is reported on the chanical or electrical or clear the
191 - E External belts obstruction
belts at filling machine exit obstruction to be able to restart the
production cycle.
124
Console manager (CONMGR) – Installation and use
11 CONSOLE MANAGER (CONMGR) – INSTALLATION

AND USE
11.1 Description
CONSOLE MANAGER (CONMGR) executes the operator panel selected among the available
ones on the POSYC; in this way, it is possible to use one spare POSYC for several MNS products.
After every start, the programme searches for the available operator panels and displays a menu
in order to select the operator panel to be used. If the operator panel has already been selected
and is still present, it will be executed automatically, unless the display of the selection menu is
requested within 10 seconds.
11.2 Operation
Two operation modes are available: automatic mode and manual mode. The first one is the default
mode; it executes the selected operator panel, unless the change to manual mode is requested,
within 10 seconds.
In any case, the programme will change to the manual mode, if one of these situations occurs:
- There was a change in the selected operator panel;
- No operator panel was selected for activation;
- Direct request from the user (by pressing the programme start window).
Automatic mode
After the start, the operator panel which will be operated is displayed. It will be possible to select
another panel (manual mode) within 10 seconds, by pressing anywhere on the window:
Otherwise, after 10 seconds, the displayed operator panel will be executed.
125
Manual mode
The list of the operator panels is displayed and it is possible to select the one to be executed, by
pressing the corresponding row and then the push-button ENABLE.
A List of the operator panels, with the active operator panel highlighted.
In order to activate another operator panel, press the corresponding row of the list in order
B to select it.
Respectively:
- It makes a new search of the operator panels available in the system;
C - It activates the new operator panel that has been selected;
- It executes the active operator panel and consequently shuts down the programme.
It leaves the programme and asks for the confirmation in order to execute the active
D operator panel.
When the activation of a new operator panel is confirmed, his working disk and the one of the
deactivated panel will be re-named. For the new operator panel, the following names will be used:
SK series: console
SR series: formconsole
MP series: mpconsole
DIVIPACK series: divicons
VLS conveyor lines: beltsman
VLSPRO conveyor lines: vlspro
For the deactivated panel, the working disk will be re-named according to the following elements:
“name of the panel working disk”_”serial number”_”version”_”n”, where “n” is a progressive number
which depends on the number of panels with the same elements.
126
The activation of a new operator panel may require the update of the MITEX programme of the
MARTS, as indicated by the confirmation message:
If you press “OK”, the active operator panel will be executed.
11.3 Minimum requirements
Processor Pentium 233 MHz
Memory 32 Mb
Graphics Vga 256 colors
Operational system WIN95/98, WIN NT 4.0 SP6, WIN XP
Environment MS-JAVA 2.0
11.4 Installation
Execute CMsetup.exe and start the POSYC again.
11.5 Disinstallation
It is possible to disinstall the programme, by eliminating the directory c:conmgr, the link to the
executable file in the system startup menu, called “ gos” and the link present on the desktop called
“ go”.
11.6 Preparation of a spare Posyc with CONMGR

If the CONMGR is used, the following requirements must be fulfilled:
A) The spare POSYCs destined to several product types or the interchangeable POSYCs must be
updated, if the software configuration of a Product is modified.
B) In case of installation of a new operator panel, please follow the below procedure:
1 • Before installing the new operator panel, re-name the directory of the panel that is active at that
moment, in order to avoid overwriting. If there is no space on the hard disk and you know that
the active operator panel will not be used any longer, you can cancel it;
2 • Install the new operator panel;
3 • Re-start the system, so as to execute the CONMGR programme; then, update the list of the
installed panels.
4 • Activate the required operator panel.
C) In case of updating or installation of Service Pack for operator panels already present, please
proceed as follows:
127
1 • Activate the operator panel to be updated with the CONMGR programme

2 • Execute the updating;
3 • Execute CONMGR again, in order to activate the required operator panel.
11.7 Troubleshooting
When you start the system, the programme does not start
Make sure that:
• The directory “c:conmgr” is present and contains the file “conmgr.exe”;
• The link to the programme is present in the automatic execution directory (there should be a link
called “ gos”).
No operator panel is found on the system

The programme CONMGR can recognize the presence of an operator panel if the following
conditions occur:
• The parameters database must be present and integral;
• The directory of the operator panel must include a sub-directory called “pages”, including a file
called “start.def”;
• The sub-directory “pages” must include a sub-directory called “main”, including a file called
“main.def”.
If no directory fulfils the above requirements, a message will be displayed after the initial search,
requiring to shutdown the programme.
The active operator panel is not executed

After the last start of CONMGR, if the active operator panel has been cancelled or no operator
panel is active, the following message will be displayed at the next start:
By pressing on the window, it will be possible to select the panel to be started.
The operator panel that has been started signals some problems during the data
transfer to the process controller
In this case, the process control programme must be updated.
In case of MNS machines, you must update the programme MITEX of the MARTS according to the
specific procedure
128
Machine commands
12 MACHINE COMMANDS
12.1 Glossary
Acronym WD
Meaning Working Disk
12.2 Functions
A Version of the Marts Remote Manager program.
B Press this button and the program will run the default command indicated on it.
Set of tabs containing the buttons for the actions that the operator can use to interact with
C Marts.
D Information on Marts status.
Countdown at the end of which the program, if not used by the operator, runs the main
E command (viewed by the button indicated by letter B).
F Status of the Real Time environment on Marts.
Press this button and the program will stop the countdown to wait for an action by the
G operator.
129
Machine commands
Below are outlined the meaning and use of each component shown to the operator (the numerical
indication is the one that you can find in the caption of the button to which the description refers):
• 0: the main button changes its action once the operator has pressed it in relation to the Marts'
status. As such, it may be inactive when it is unable to contact Marts' real time environment, it
may contain caption "Start mitex application" in case the real time environment was contacted
but the machine control application has not yet been launched or "Warm start mitex application",
when the environment was contacted and the application's status is running. Therefore, in the
second case the button allows you to start the operator interface without having to request Marts
initialization and, as such, without the need either to phase search the machine or empty it
("warm" start).
• 1.1: this button is active only when the check application is running and stops after the user
presses it.
• 1.2: press this button to launch the GUI without the need to communicate with Marts; in this
case, the actions performed by the operator on the machine will not be checked.
• 1.3: press this button to launch the GUI for diagnostics purposes. Normally, is will produce a
report file (WD: to be sent to SMI, useful for troubleshooting. Keep in mind, however, that this
file is re-initialized each time the interface is launched. As such, you must save a copy of it in
case you will have to send the report to SMI.
• 2.1: each time SMI provides a new control algorithm to be used on the machine, both for
diagnostics purposes and for the introduction of functionalities, or simply for version upgrades,
Marts needs to upgrade its resident program. Therefore, press this button to carry out this
action. For correct machine operation, it is important to press this button whenever SMI sends
the customer a new program. At the end of installation, the operator interface will start
automatically and, as such, the machine will start with the new program. The program sent to
Marts is usually identified by the PLC name while file extension can change according to the
type of machine (SERCOS II: *.isa, *.pci - SERCOS III: *.s3I).
• 2.2: when this button is pressed it performs the opposite action of button 2.1. In fact, the
automation program will be taken from Marts and copied to Posyc so that, if required, it can be
sent to SMI. Files downloaded from Marts are saved in the folder that has this name: plc_xxx.yyy
where xxx indicates the type of Marts used and can have the "isa", "pci" or "s3I" value whilst yyy
indicates the number of run Downloads. At the next download, the saved file will be called
plc_xxx.(yyy+1).
• 2.3: performs the same actions as button 2.1, but relates to the external belts management
program.
• 2.4: performs the same actions as button 2.2, but relates to the external belts management
program.
• 3.1: if pressed, Marts turns off.
• 3.2: if pressed, Marts restarts..
• 4.1: if pressed, a window is displayed to the operator so that he/she can view Marts' remote log,
online. This button, like all those in this section, is used only by SMI technicians or by operators
for diagnostics purposes on SMI request.
• 4.2: if pressed, Marts' log files are downloaded to Posyc.
• 4.3: if pressed, the directory is displayed to the operator (on Posyc) containing the log files
downloaded through button 4.2.
• 5.1: the buttons in section "5. RealTime env" allow the operator to perform actions in the real
time environment that allow running the automation program. Specifically, button 5.1 is activated
only in case the environment is not running. Once pressed, it communicates to Marts the
command for its own execution.
• 5.2: this button is active when the RT environment is running; the environment stops if pressed
by the operator.
• 5.3: this button is active when the RT environment is running; the environment restarts if
pressed by the operator.
130
Machine commands
• 5.4: this button is active when the RT environment is running; if pressed by the operator, a
window is displayed that contains information linked to tasks running on Marts.
• 5.5: if the operator presses it, a window is displayed that contains the modules downloaded in
the RT environment. An example is shown in the figure below:
• 6.1: if pressed by the operator, a type of interface containing some utilities is launched. This
command is used only during the first testing stage.
• 6.2: if pressed, a remote control shell is started from which to interact with the operating system
installed on Marts and, consequently, with the RT environment. This button may be used only
by SMI technicians.
• 6.3: if pressed, the user can see the versions of the SMI software present both on Posyc and
Marts.
• 6.4: press this button to download any Marts' coredumps to Posyc. They must then be sent to
SMI to be analyzed. This button should be used only on SMI technicians request.
• 6.5: pressing this button, usually inactive, will refresh Marts environment.
• 6.6: pressing this button, usually inactive, will refresh the service used for communication
between Posyc and Marts.
Each time the Marts Remote Manager program starts, program WD:/xxCONSOLE/
CLOSEALL.EXE must be run to ensure the release of the serial channels (for versions with
SMISHELL, Key 5 → "Close Serial link Communication").
The program features 20 seconds during which you can choose a function other than the one that
will be performed automatically. At the end of the indicated time, if no buttons were pressed, the
program will start in the mode indicated in button 0. Each time the Marts Remote Manager program
starts, any errors in Marts will be downloaded automatically as soon as Marts is connected.
The file is saved in Posyc in a file located in WD:/xxCONSOLE/MARTSERR.
The following states may be reported in the display (F) shown in the first screen:
131
Machine commands
MESSAGE EXPLANATION
OK Marts and Posyc are communicating properly.
REAL TIME ENVIRON-

MENT MANUALLY Marts' Real Time environment was stopped; to restart, press button 5.4.
STOPPED
No communication to No communication between Marts and Posyc. Check their connection (Ether-
MARTS net or serial) and that Marts is turned on.
Connection established Marts and Posyc have established a connection.
COMMUNICATION
Marts does not respond; there may be communication problems. Check their
PROBLEMS: NO AN-
connection (Ethernet or serial) and that Marts is turned on.
SWER FROM MARTS
Application on MARTS re- The application is resetting on Marts. You must wait. This message is usually
setting in progress, waiting displayed after the operator has pressed "CLOSE AND RESTART" via the in-
reset end...." terface.
REAL TIME ENVIRON-

Marts' Real Time environment did not start; to start, press button 5.4.
MENT NOT RUNNING
12.3 Note
After an Update you must check, in the "Logo" or "About" page, that the Marts program has been
updated according to directions provided by SMI.
12.4 Troubleshooting
Below is a list of the most frequent messages that may be shown to the operator or technician when
using the Marts Remote Manager program, and instructions in case they appear:
• "Last detected connection media was Ethernet, but now MARTS does not respond over
network. - Press "Retry" to retry network connection - Press "Serial" to switch to serial
connection - Press "Offline" to start console offline.
Before it can run, the Marts Remote Manager program must know the type of communication to be
used to contact Marts. This task is carried out by a program (Marts Connection Detector) which
checks whether the Marts connection should take place through serial or Ethernet links. If the
system is configured with an Ethernet connection but the connection is not detected, then an error
message is generated requesting the user to try to perform the search for Marts through the serial
connection. If no maintenance was performed, this message means there is a communication fault.
As such, it is advisable to check the efficiency of the connection between Marts and Posyc. Also
check that Marts has been turned on in actual fact.
The Marts Remote Manager can also display warnings (simple messages to the operator) or other
types of error messages.
Concerning the error messages not listed in this manual, after checking communication between
Posyc and Marts (Ethernet or serial links) and that Marts has been started correctly, you must
contact SMI's technical support, providing the error message displayed by Marts Remote Manager.
132
Analytical table of contents
Blowing air recovery 18

Bottles per mould / grippers mechanical position 19
Chiller 20
Control mode 66
Description 125
Description 68
Disinstallation 127
Emergency state 27
Enable 48
Faults requiring the phase recovery procedure 46
Format selection / format change 16
Functions 129
General information and operation description 25
Glossary 129
Grippers mechanical position (carousel infeed) / without blow-moulding 18
How to create safety copies of the machine parameters 60
How to print the parameters 64
How to restore the machine parameters 62
Inserting the password 14
Installation 127
List of alarm messages 90
List of state messages 87
Lots production 23
Machine emptying 15
Machine speed 20
Machine start procedure 15
Machine switch-off 15
Main page (maximum configuration) 9
Managing alarms acknowledgement 83
Meaning of the alarms 103
Minimum requirements 127
Normal operation mode 26
Note 132
On phase waiting state 28
Operating modes 17
Operation 125
Operator panel description 7
Other forms of parameterization 65
Oven heating state 29
Parameters organization principles 51
Pause state 28
Phase recovery 44
133
Phase search 38
Possible faults and problems 35
Pre-heating state 30
Preliminary controls 33
Preliminary controls 37
Premise 37
Premise 43
Premise 47
Premise 67
Preparation of a spare Posyc with CONMGR 127
Procedure to start the machine and prepare it / production start 14
Production state 29
Saving of the recorded data on a flash memory 80
Selection of the functional group and access to the parameters 52
Stand-by state 29
Start-up procedure 33
States for detecting machine indexes 30
Stop state 29
Support functions for the parameters setting 57
Temperature control commands / preforms rejection and bottles rejection / lighting up of service
lamp 21
Troubleshooting 128
Troubleshooting 132
Unloading state 27
Utility functions for the parameterization 65
134
SMI S.p.A. Via Ceresa, 10 - 24015 SAN GIOVANNI BIANCO (BG) ITALY
Tel. +39 035 45 40 111 - Fax +39 035 45 40 209 - www.smigroup.it

نافخه

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

نافخه

Uploaded by

Copyright:

Available Formats

EBS Ergon

Operator Interface Manual

Manual code: DM220210

3 – MACHINE OPERATING MODES AND STATES 25

“Production stop – external causes” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4 – RESTART OF THE PRODUCTION AFTER AN ALARM 33

5 – SERVO MOTORS PHASE RECOVERY PROCEDURE 37

6 – SERVO MOTORS PHASE SEARCH PROCEDURE 43

7 – PROCEDURE TO ENABLE THE INVERTERS 47

9 – STATISTICS VIDEO PAGE 67

10 – ALARMS AND STATE MESSAGES 83

11 – CONSOLE MANAGER (CONMGR) – INSTALLATION AND USE 125

12 – MACHINE COMMANDS 129

ANALYTICAL TABLE OF CONTENTS 133

1.1 Operator panel description

5-colour column 3-colour column State Description

This goes off just before the machine starts

It turns on when there are some alarms which

It turns on when there is a problem or an

This is on when the machine is in the PAUSE

This is on when an action by the operator is

1.2 Main page (maximum configuration)

Warnings and signals

G Shows energy consumption, related charts and count reset.

H Indicates scheduled maintenance (if this option is enabled).

Button for machine phase search/phase recovery.

P Button to access the format change function.

- Bottle rejection OFF - Bottle rejection ON

- Preforms rejection OFF - Preforms rejection ON

- Separation opened - Separation closed

This button is inside the main page.

Z Control for turning on and off the machine's service lamps.

Button to access the oven unit. You may access the:

Button to access the carousel unit. You may access the:

B Enter password. Refer to paragraph 1.3"Inserting the password (page 14)".

C Back to the main page.

D To the next page or back to the preceding active pages.

E It activates the in-line manuals

It sets the percentage size of the active video page.

H REFRESHES the active video page.

I It closes the active video page.

1.3 Inserting the password

1 • Use the keyboard to key in the required password (default code is

2 • Confirms the entered Password.

1.4 Procedure to start the machine and prepare it / production

1.5 Machine start procedure

1.6 Machine emptying

1.7 Machine switch-off

1.8 Format selection / format change

Now carry out the following steps:

2.1 Operating modes

“WITHOUT PRODUCT” mode ”NORMAL” mode

2.2 Grippers mechanical position (carousel infeed) / without

2.3 Blowing air recovery

2.4 Bottles per mould / grippers mechanical position

2.5 Machine speed

A Allows you to activate/deactivate chiller forcing.

2.7 Temperature control commands / preforms rejection and

- Activated control - Deactivated control

- Check for preform temperature - Outlet oven temperature

-Non-forced rejection of preforms(not active) -Non-forced rejection of bottles(not active)

- Forced rejection of preforms (active). - Forced rejection of bottles (active).

- Service lamp on - Service lamp off.

2.8 Lots production