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Operating Manual - Press
Operating Manual - Press
OPERATING MANUAL
Electronic Control DG production
line
WALTEC
Note: The operating instruction manual is valid for several machine types and
configurations. Sections that relate to modules and/or devices, which are
not contained in the extend of the delivery, become irrelevant.
Danger: It is not allowed to operate the machine/plant without the installed and
intact safety installations and protection devices!
The fundamental and special safety instructions in Operating Manuals of
machines or in the Technical Documentation must be observed strictly!
WALTEC
Maschinen GmbH
Kronacher Str. 2a
D-96352 Wilhelmsthal/Steinberg
WALTEC
Table of contents
1
1.1
1.2
1.3
Organisational measures
1.4
1.5
Safety instructions governing specific operational phases
12
1.5.1
Standard operation
12
1.5.2
Special work in conjunction with utilisation of the machine/plant and
maintenance and repairs during operation; disposal of parts and consumables
13
1.6
1.6.1
1.6.2
1.6.3
1.6.4
1.6.5
1.6.6
15
15
16
16
16
17
17
1.7
17
19
19
4.1
4.1.1
4.1.2
4.1.3
4.1.3.1
4.1.3.2
4.1.3.3
4.1.3.4
4.1.3.5
4.1.3.6
4.1.3.7
4.1.3.8
4.1.3.9
4.1.3.10
4.1.3.11
21
21
21
21
22
24
26
29
32
33
35
36
38
40
42
3
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4.1.3.12
4.1.3.13
4.1.3.14
4.1.3.15
4.1.3.16
4.1.3.17
4.1.3.18
4.1.3.19
4.1.3.20
4.1.3.21
4.1.3.22
4.1.3.23
4.1.3.24
4.1.3.25
4.1.3.26
4.1.3.27
4.1.3.28
4.1.3.29
4.1.3.30
4.1.3.31
4.1.3.32
4.1.3.33
4.1.3.34
4.1.3.35
4.1.3.36
4.1.3.37
4.1.3.38
4.1.3.39
4.1.3.40
4.1.3.41
4.1.3.42
4.1.3.43
4.1.3.44
4.1.3.45
4.1.3.46
4.1.3.47
4.1.3.48
4.1.3.49
4.1.3.50
4.1.3.51
4.1.3.52
4.1.3.53
4.1.3.54
43
44
45
47
48
49
50
52
53
54
57
59
60
61
63
64
65
67
68
69
71
75
77
78
80
84
85
87
89
91
92
93
94
96
97
98
98
100
101
102
103
104
105
106
108
6.1
Initial Position
108
6.2
108
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6.3
Monitor circuit
108
6.4
109
6.5
109
6.6
109
6.7
111
6.8
112
113
7.1
113
7.2
114
7.3
115
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Danger
(refers to orders and prohibitions designed prevent injury or
extensive damage)
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1.3.8
Observe all safety instructions and warnings attached to the machine/plant.
1.3.9
See to it that safety instructions and warnings attached to the machine are
always complete and perfectly legible.
1.3.10
In the event of safety-relevant modifications or changes in the behaviour of the
machine/plant during operation, stop the machine/plant immediately and report
the malfunction to the competent authority/ person.
1.3.11
Never make any modifications, additions or conversions which might affect safety
without the suppliers approval. This also applies to the installation and
adjustment of safety devices and valves as well as to welding work on loadbearing elements.
1.3.12
Spare parts must comply with the technical requirements specified by the
manufacturer. Spare parts from original equipment manufacturers can be relied
to do so.
1.3.13
Never modify the software of programmable control systems.
1.3.14
Replace hydraulic hoses within stipulated and appropriate intervals even if no
safety-relevant defects have been detected.
1.3.15
Adhere to prescribed intervals or those specified in the operating instructions for
routine checks and inspections.
1.3.16
For the execution of maintenance work, tools and workshop equipment adapted
to the task on hand are absolutely indispensable.
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1.3.17
The personnel must be familiar with the location and operation of fire
extinguishers.
1.3.18
Observe all fire-warning and fire-fighting procedures.
10
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11
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12
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1.5.2
Special work in conjunction with utilisation of the machine/plant and
maintenance and repairs during operation; disposal of parts and consumables
1.5.2.1
Observe the adjusting, maintenance and inspection activities and intervals set
out in the operating instructions, including information on the replacement of
parts and equipment. These activities may be executed by skilled personnel only.
1.5.2.2
Brief operating personnel before beginning special operations and maintenance
work, and appoint a person to supervise the activities.
1.5.2.3
In any work concerning the operation, conversion or adjustment of the machine
and its safety- oriented devices or any work related to maintenance, inspection
and repair, always observe the start-up and shut-down procedures set out in the
operating instructions and the information on maintenance work.
1.5.2.4
Ensure that the maintenance area is adequately secured.
1.5.2.5
If the machine/plant is completely shut down for maintenance and repair work, it
must be secured against inadvertent starting by:
locking the principal control elements and removing the ignition key and/or
attaching a warning sign to the main switch.
1.5.2.6
To avoid the risk of accidents, individual parts and large assemblies being moved
for replacement purposes should be carefully attached to lifting tackle and
secured. Use only suitable and technically perfect lifting gear and suspension
systems with adequate lifting capacity. Never work or stand under suspended
loads.
1.5.2.7
The fastening of loads and the instructing of crane operators should be entrusted
to experienced persons only. The marshaller giving the instructions must be
within sight or sound of the operator.
1.5.2.8
For carrying out overhead assembly work always use specially designed or
otherwise safety-oriented ladders and working platforms. Never use machine
parts as a climbing aid. Wear a safety harness when carrying out maintenance
work at greater heights.
Keep all handles, steps, handrails, platforms, landings and ladders free from dirt,
oil and other lubricants!
Operating Manual - Electronic Control Press line,z-en.doc
13
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1.5.2.9
Clean the machine, especially connections and threaded unions, of any traces of
oil, fuel or preservatives before carrying out maintenance/repair. Never use
aggressive detergents. Use lint-free cleaning rags.
1.5.2.10
Before cleaning the machine with water, steam jet (high-pressure cleaning) or
detergents, cover or tape up all openings which - for safety and functional
reasons - must be protected against water, steam or detergent penetration.
Special care must be taken with electric motors and switchgear cabinets.
1.5.2.11
After cleaning, remove all covers and tapes applied for that purpose.
1.5.2.12
After cleaning, examine all fuel, lubricant and hydraulic fluid lines for leaks, loose
connections, chafe marks and damage. Any defects found must be rectified
without delay.
1.5.2.13
Always tighten any screwed connections that have been loosened during
maintenance and repair.
1.5.2.14
Any safety devices removed for set-up, maintenance or repair purposes must be
refitted and checked immediately upon completion of the maintenance and repair
work.
1.5.2.15
Ensure that all consumables and replaced parts are disposed of safely and with
minimum environmental impact.
1.5.2.16
For welding works at the machine/plant fasten ground cable of welding
apparatus directly to the part to be welded and shut off main switch of
machine/plant in each case. Otherwise electronic modules can be damaged. The
plant is earthed with big cross section cables and connected to all machine parts.
Connection to earth must be established for all welding works as long as the
machine part is connected to the control cabinet with any cable.
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Electric energy
1.6.1.1
Use only original fuses with the specified current rating. Switch off the
machine/plant immediately if trouble occurs in the electrical system.
1.6.1.2
Work on the electrical system or equipment may only be carried out by a skilled
electrician himself or by specially instructed personnel under the control and
supervision of such electrician and in accordance with the applicable electrical
engineering rules.
1.6.1.3
If provided for in the regulations, the power supply to parts of machines and
plants, on which inspection, maintenance and repair work is to be carried out
must be cut off. Before starting any work, check the de-energised parts for
presence of power and ground or short-circuit them in addition to insulating
adjacent live parts and elements.
1.6.1.4
The electrical equipment of machines/plants is to be inspected and checked at
regular intervals. Defects such as loose connections or scorched cables must be
rectified immediately.
1.6.1.5
Necessary work on live parts and elements must be carried out only in the
presence of a second person who can cut off the power supply in case of danger
by actuating the emergency shut-off or main power switch. Secure the working
area with a red-and-white safety chain and a warning sign. Use insulated tools
only.
1.6.1.6
Before starting work on high-voltage assemblies and after cutting out the power
supply, the feeder cable must be grounded and components, such as capacitors,
short-circuited with a grounding rod.
15
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1.6.2
1.6.2.1
Carry out welding, flame-cutting and grinding work on the machine/plant only if
this has been expressly authorised, as there may be a risk of explosion and fire.
1.6.2.2
Before carrying out welding, flame-cutting and grinding operations, clean the
machine/plant and its surroundings from dust and other inflammable substances
and make sure that the premises are adequately ventilated (risk of explosion).
1.6.2.3
Observe any existing national regulations if work is to be carried out in narrow
rooms.
1.6.3
1.6.3.1
Work on hydraulic equipment may be carried out only by persons having special
knowledge and experience in hydraulic systems.
1.6.3.2
Check all lines, hoses and screwed connections regularly for leaks and obvious
damage. Repair damage immediately.
1.6.3.3
Depressurize all system sections and pressure pipes (hydraulic system,
compressed-air system) to be removed in accordance with the specific
instructions for the unit concerned before carrying out any repair work.
1.6.3.4
Hydraulic and compressed-air lines must be laid and fitted properly. Ensure that
no connections are interchanged. The fittings, lengths and quality of the hoses
must comply with the technical requirements.
1.6.4
Noise
1.6.4.1
During operation, all sound baffles must be closed.
1.6.4.2
Always wear the prescribed ear protectors.
16
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1.6.5
1.6.5.1
When handling oil, grease and other chemical substances, observe the productrelated safety regulations.
1.6.5.2
Be careful when handling hot consumables (risk of burning or scalding).
1.6.6
High temperature
It is emphasised the machine/plant in operation contains many very hot parts.
Care must be taken when approaching the machine to make replacements or
adjustments. It is necessary to provide fencing and guarding around the
restricted area and provide personnel with protective clothing, gloves, spectacles,
helmets, etc.
17
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1.7.7
Before recommissioning the machine/plant these devices must be properly
removed.
1.7.8
Carefully refit and fasten all parts to be removed for transport purposes before
recommissioning the machine/plant.
1.7.9
Cut off the external power supply of the machine or plant even if only minor
changes of place are envisaged. Properly reconnect the machine to the supply
mains before recommissioning.
1.7.10
For recommissioning only proceed in accordance with the operating instructions.
18
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Control system
2
Danger: For any maintenance switch off the controller and lock main
switch, to avoid hazards!
Do never pull plugs, when they are current-carrying!
Do not disconnect any current-carrying cable!
19
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There are a lot of possibilities where lightning can strike, because of this a
perfect protection is not possible. But there are some more possibilities to
protect your line against lightning strikes, please contact WALTEC Company.
Fuses,
Switch contactors,
Relays for manual operation, because of safety in manual operation the
function may not be actuated through the electronic control.
Relays for release of automatic functions.
Programmable logic controller system with input, output modules and mains
unit.
Control panel for manual operation.
The control cabinet is to be installed so that it is protected from direct solar
radiation, direct radiation from the glass melting trough or other heat radiation.
Operating Elements
The labeling of the elements can be found in the circuit diagram located on the
backside of the front panel. The labeling contains the following information:
Example: 9S3 => Circuit Diagram Page 9 Switch Number 3
S
P
R
Switch or Pushbutton
Lamp or Indicator
Potentiometer
With this information, you can easily find the corresponding input in the controller.
It enables you to check the function of the element.
20
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4.1
Screen Description
See device manual
Siemens_BA_Simatic_IPC277_en.pdf &
of CD-ROM on Documents for Electrical assemblies
In the following the most important screens of the machine control are
explained.
21
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Permanent window
4.1.3.1
Message line
B
A
F07: Closer/Opener
F08: Take-out GPG
F09: Take-out Cam
F10: Fire polishing machine
F11: Additional functions
F12: Keyboard
S04: Exit
S05: Master axis
S06: Message display
S07: Data record processing
S08: Program information
S09: Mould select
22
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Fault messages
Meaning
Display of the currently processed program.
Display of the currently produced piece number per minute.
Display of the currently set operating mode of pressing machine,
e.g.: MANUAL. Further displays are: AUTOMATIC, REFERRING
(only if a positioning axis is available)..
Display of the currently set operating mode of fire polishing
machine, e.g.: MANUAL. Further displays are: AUTOMATIC,
REFERRING (only if a positioning axis is available).
Cycles
The date and clock time are set in the Mask Setting date and time
(S12 of Service).
In the message line of the permanent window is displayed the
operating messages of the control system and the unit as a whole.
When reason of operating messages is cancelled, message
disappears by itself.
Fault messages are also displayed in the message line of the
window immediately after occurring. They are marked by red back
colour. With the ACK key, you can quit the fault messages. If more
than one message is present, then further messages appears after
first one is quit. When messages are present the lamp inside key
F11 is flashing. By pressing this key you reach figure "Messages"
where you can branch to the operating messages or the fault
messages , they can be leafed through with the keys and .
If an error occurs, the screen shows an icon at S10 in each mask,
when pressed you will be forwarded to the mask Faults
SINAMICS.
23
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4.1.3.2
Figure 3: Manual mode settings for pressing cylinder and take out
Function
Actual value
Meaning
actual position, pressure, speed and motor and oil temperature of
pressing cylinder A and B and take out are displayed.
Pressure
Velocity
Offset
Position 1
Position 2
Actual values or output fields are mostly displayed in blue colour. Some
actual timing or position values are displayed in red colour. Setpoint values or
input fields are always in yellow colour with red background colour!
24
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Position, speed and pressure settings made on the manual pages are only
valid in manual mode of pressing machine (or fire polishing machine
respectively)!
25
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4.1.3.3
Screen Description: Indexing Table
F02 from Basic mask
26
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Example:
If the button for the pressing at no gob is set to off, all moulds which has
not been fed will not be pressed.
With F01 (home) you revert to the basic mask.
F02 from Indexing Table
27
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28
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4.1.3.4
2
4
C
D
E
F
G
J
K
L
Meaning
Indication of the step in program flow. It is important for fault
finding at the program. Kindly forward the stated number to
WALTEC at possible malfunction of program
Actual temperature of hydraulic oil, servo motor temperature,
hydraulic pressure and speed of pressing cylinder are displayed
When plunger has to be changed it will move to this position with
adjusted velocity.
Delay time and time (duration) for the plunger/ring lubrication can
be set and monitored in this mask. In the figure, the input fields are
shown in dark. The process (actual value) is shown in the fields to
the left.
see Screen Description: Cycle time.
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Function
Delay time (C2)
Rapid up (L4)
Meaning
Delay time cylinder down after start of peripheral equipment by the
signal "Indexing on". Peripheral equipment is all equipment and
devices, which are acting upon exactly one station of the indexing
table
Rapid speed down up to position (E1) Pressing speed down is
valid as long as pressure threshold is reached
with pressing pressure 1 (F3)
with pressing pressure 2 (G3). Pressing time 2 is started, when
pressing time 1 has been terminated
Slow speed up until position (J1)
From this position on the indexing table of machine is enabled for
turning. Already in this position mould parts must not collide to one
another. For security reason Enable table position is set 3mm
lower than topmost position (L1). Keep always in mind that zero
position of pressing cylinder is in top position
Rapid speed upward up to position (L1). When pressing cylinder
reached enable table position (K1) indexing table is allowed to turn
30
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In the following graphics the times, pressures and speeds are described in accordance
to the screen together with letters and numbers to indicate the sequence more clearly.
P ositio n
L1
L1
to p
L4
D4
E4
K1
J4
E1
J1
b e lo w
F2
G2
Tim e
Ra p id
spe e d
do wnwa rd
F3
G3
S ta rt
D elay
Press time 2
P re ssure
Press time 1
S ta rt by
S ig nal
IND E X on
C2
Ra p id
sp e e d
up wa rd
Tim e
31
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4.1.3.5
2
C
D
E
F
G
J
K
L
4
3
32
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4.1.3.6
E
A
33
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a)
b)
Position-actual value in mm
c)
The measuring units of the scaling are automatically shifted (mm/s, mm, bar).
Storing of a curve
One of the both active curves can be stored by means of key [F03] or [F04] and is
displayed visually as third curve. That means one is able storing a curve on the screen
for reference functions, and being able watching a possible variation concerning the
pressing curve, resulting by external influences. With [F5] the stored curve can be
deleted.
Activating / Deactivating of recorder
By means of the key [F07] the cyclic memorising of both measuring channels can be
started as well as stopped.
By pressing of [F07] "STOP" memorising gets inaccessible and it is appearing [F07]
"START". At the right screen "STATUS" there is appearing "STOP". If [F07] is once
more pressed, thus, there is appearing at [F07] "STOP" and at STATUS "ACTIVE". The
memorising of the measured values is once again released.
Automatic scaling of measured values
By the functions "scale at values 1" [F08] and "scale at values 2" [F09] the time raster
and with [F10] the scaling of the measured values is set by the control in such a way,
that the complete pressing cycle is getting visible on the screen.
For example, this function can be used at change-over of the production to another
article, seeing the complete cycle at first.
After that one is able scaling again a desired area manually
(time/position/pressure/speed) that details are getting visible.
34
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4.1.3.7
35
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4.1.3.8
Time
Meaning
Kick-outs are pneumatic lifting devices which will lift articles in
mould to enable take out of articles.
Delay after indexing the rotary table in seconds before the kick-out
1 or 2 is actuated, e.g. 0.10s. The elapsing time can be observed to
the left after it has been started, e.g. 0.00s.
Time for the working stroke and dwell time kick-out, e.g. 1.00 s. The
elapsing time can be observed to the left after it has been started,
Step
e.g. 0.00s.
Displays the step of the program process. It is Important to search
for errors in the program. In the case of possible program failures
Residual time
Blow out nozzle
Table rounds on
Blow out can be adjusted to clean the moulds only after the table
turned some rounds to avoid to cool down the moulds too much.
36
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Function
Active
Only by glass
Meaning
Lamp will flash when pneumatic valve is actuated.
Blow out can be adjusted to clean only the moulds when broken
Alarm
37
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4.1.3.9
Meaning
Kick-outs are pneumatic lifting devices which will lift articles in
mould to enable take out of articles.
Delay time
Delay after indexing the rotary table in seconds before the kick-out
1 or 2 is actuated, e.g. 0.10s. The elapsing time can be observed to
the left after it has been started, e.g. 0.00s.
Time for the working stroke and dwell time kick-out, e.g. 1.00 s. The
elapsing time can be observed to the left after it has been started,
e.g. 0.00s.
Time
Step
Residual time
Gob funnel
Table rounds on
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Function
Table rounds off
Meaning
Mould lubrication can be adjusted to stop lubricating of the moulds
for some counts of table rounds.
Active
Cooling
Article- and
mould cooling
outside
Mould cooling
inside
Flaps
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4.1.3.10
Main-closer
Opener
Delay time
Time
Meaning
Pre-closer is a pneumatic actuated closing mechanism located at
the feeding position which is used when hinged moulds are
mounted and to close the moulds to allow feeding.
Main-closer is a pneumatic actuated closing mechanism located at
the pressing position which is used when hinged moulds are
mounted and to keep hinged mould closed while pressing.
Opener is a pneumatic actuated opening mechanism located
before or at the take-out position which is used when hinged
moulds are mounted and to open hinged moulds to allow take out
of articles.
Delay after indexing the rotary table in seconds before the kick-out
1 or 2 is actuated, e.g. 0.10s. The elapsing time can be observed to
the left after it has been started, e.g. 0.00s.
Time for the working stroke and dwell time kick-out, e.g. 1.00 s. The
elapsing time can be observed to the left after it has been started,
e.g. 0.00s.
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Step
Residual time
Attention: The speed of travel is set on both throttle non-return valves. For
reasons of time, the return movement of the pneumatic cylinder should ensue
as quickly as possible. The return movement must always ensue so quickly
that the device has travelled back before the indexing table starts to move.
Back position of devices is monitored by proximity switch. If these switches
are not actuated table is not allowed to move and a warning message will be
displayed like Pre-closer A monitoring!
41
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4.1.3.11
Meaning
Rotating take-out device with two vertical axis (Arm1 and Arm2)
Pick up top
Pick up down
Slow up
used for taking out of articles. The arms can be moved separately.
Vertical axis positions can be shifted vertically by adding offset
value.
Initial position at the pick up position.
Pick up position of the glass article inside mould.
After picking up the article from the mould, the take out arm can be
Release ind.
table
Offset Arm 1 / 2
Base position
Turn
Set down top
Set down down
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Function (cont.)
Release glazer
Meaning
If arm at fire polishing machine is higher than this security position
following machine is allowed to turn or move!
Step
4.1.3.12
Meaning
Electronic cams are used to control the movement of the servo axis
and of pneumatic valves.
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Function (cont.)
Kick out up
Gripper closed
Meaning
Display of actual status (up / down) of kick out.
Cam defines when gripper (A1, A2, B1, B2) is closed.
Set-down arm
down
Take-out turn
down
Gripper open
All cams (starts and stops) can be shifted by this value at once.
Display of actual value of virtual master axis of press machine.
Virtual master axis will turn from 0 to 360 in one production cycle.
Act. Position
Master take-out
4.1.3.13
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4.1.3.14
F05: Burner II
F06: Conveyor / Stacker
F07: Manual mode polishing machine
Function
Meaning
Step
Actual values
v_max, a_max
Function of FPM
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Function (cont.)
Function of FPM
(continued)
Meaning
Gear: FPM will move with continuous speed. This mode should be
used when production speed is high.
Table: FBM will move according to adjustable cam. Start / stop or
fast / slow movement of spindles can be adjusted.
Number of spindles the pol. machine moves forward per cycle
(1, 2, or 3).
Initial position
Angle / position
acceleration
take-out device.
With this values the cam curve in this chart can be changed. The
maximum acceleration will be calculated automatically by the
control. The load of the machine can be decreased by setting a
lower value.
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4.1.3.15
Meaning
Count how many spindles are between take out position and
position of blow off nozzle. Set this values according to count.
Position cam when blow off valve will be actuated. Max. value is
spindle distance = 241,5 mm.
When blow off cam is reached valve will be actuated impulse time
seconds.
Setting according to indexing table mould numbering.
Selection which article will be blown off of spindle. Used to sort
Impulse time
A-B
Select blow off
1,2,..12
Select blow off
1-12
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4.1.3.16
Function
Actual values
Clutch position
Ramp
Stroke
Velocity / Accel.
position.
Meaning
Actual values for burner movement position, motor temperatures,
program step and so no are displayed. If an electrical axis is still not
referenced, then actual position value will blink yellow / blue.
Position of burner station (slide), where axis couples.
Defines, after how many millimeters the burner axis had to be
accelerated to the velocity of rim polishing machine.
Total stroke of burner slide movement.
Reversing velocity and acceleration of burner slide to the base
Base position
Spindle per step
Synch. each
Spindle
Burner shift
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4.1.3.17
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4.1.3.18
Function
Meaning
Actual values
Cross conveyor
Function
Velocitiy fast /
slow
Velocity
Position
Accel. / Decel.
Push bar stacker Pneumatic stacker with two cylinders for forward / backward and up
/ down movement. Used for stacking of articles into cooling lehr.
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Function (cont.)
Piece pushing
Meaning
Setting after how many production cycles (articles) stacker will be
actuated.
Staggered push.
If activated stacker will push articles each second time with 180
cam offset to allow higher packing of articles on cooling lehr.
Timer how long horizontal axis will move forward.
When articles are pushed in, stacker will move back as long this
Time forward
Time frontside
back
Time up
Time backward
Start pusher
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4.1.3.19
Meaning
actual position and motor temperature of all servo axis are
displayed.
Burner slide 1 and 2 maximum positions can be limited by setting
these positions (servo axis software limit).
Speeds can be set for all servo axis.
Actual values or output fields are mostly displayed in blue colour. Some
actual timing or position values are displayed in red colour. Setpoint values or
input fields are always in yellow colour with red background colour!
Position and speed settings made on the manual pages are only valid in
manual mode of polishing machine or press machine!
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4.1.3.20
Meaning
Totally 10 digital outputs can be used for additional functions
needed.
Text field for adding a label to each digital output.
Display if output is activated.
When actual count reaches setpoint count function will be activated.
Delay time
Time
Preselect
Start options
Automatic / Cont.
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4.1.3.21
Feeder impulse
Status
Int. clock
Linear shift
Meaning
Virtual master axis which gets synchronized to feeder by start
pulses from feeder.
There are two operating modes:
1) internal: virtual axis is freely running with speed set by
parameter int. clock
2) external pulse: virtual master axis gets synchronized by external
feeder impulse.
Display of feeder impulse
If PLC detects feeder impulse regularly a green hook will be
displayed to show that everything is fine. If no feeder impulse is
detected an exclamation mark will be shown!
Enter here the amount of cuts that the machine should perform if
the source is set to internal, e.g. 20,0 /min
Phase shift of the entire plant (press & fire polishing
machine) to the master axis (e.g. feeder)
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Function (cont.)
Gobs per mould
Meaning
Depending on setting more gobs can be fed inside mould. Can be
used for example after job change to reheat the moulds quickly.
Actual speed
Actual position
Positional
tolerance
Interface
Feeding active
Press in STOP
Signal to feeder that press is in STOP condition and can not be fed
with glass.
Signal to feeder to increase gob weight.
Signal to feeder to decrease gob weight.
55
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4.1.3.22
Meaning
Actual messages or faults are always displayed below permanent
window. By tapping message text screen will open.
No.
Each message or error has a fixed number in the control. If you can
not solve problem by yourself, please always forward these
numbers to WALTEC and under what conditions problem occurred.
Display of time and date, when the incident has happened.
Each message or error will be indicated in their actual condition,
through:
G
Background
colors
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How to react if errors or faults are active and how to resolve them?
Most fault texts are self explaining but some are containing a reference
number, e.g. (14F1).
This number is a reference to an electrical device.
All devices and cables got a label and can be easily identified.
This number also is a reference to a page and column inside an electrical
draft.
First number tells you the page, the letter the kind of device (F = fuse) and
the last number tells you the column where you can find the faulty device
on the page.
Example:
Message text:
servo-hydraulic B: circulation pump bi-metal (14F1)
Error is related to servo-hydraulic system. Open page 14 column 1 of
electrical draft servo-hydraulic:
There you will find that motor protection switch 14F1 triggered.
Cause: Some over current problem for circulation pump B.
Remedies: Check cable, motor, setting of fuse 14F1 and fuse itself if its
switched on or off.
58
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4.1.3.23
59
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4.1.3.24
60
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4.1.3.25
61
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Data record name: Enter here the name of the data, which you wish to transfer, e.g.:
Feeder. You can also select a name from the contents.
F01: Back to the previous mask.
F02: Secures the actual data on the selected medium
F03: Data input from a medium into the memory of the machine controller
F06: Imports Excel table into data set.
F07: Exports the finally stored data as an Excel table in format CSV in a determined
destination directory of the optional server.
F08: Exports all stored data sets as an Excel table.
F10: Deletes selected data from the medium.
Attention: It is only allowed to put in data when the machine is running in manual
operation mode.
How to manage data sets on hard disc:
1. Storing a program
If you want to store data on the hard disc, enter a new name in the first line of the
screen (new data record).
You can enter letters and numbers for the program name.
After entering your desired name for the actual program data, push the ENTER
key to accept the name.
Now start transfer of data to the hard disc by pushing key F02
.
There will be a short message on the screen that confirms the action (success).
2. Loading a program
First you have to switch the machine to manual mode. It is not possible to load
another program during operation!
Move the cursor to the field data record name and push the ENTER key to get
a short list of all your programs.
Select the desired program by moving the cursor through the list.
To choose the highlighted program push the green ENTER key, the list will close
and the chosen program name keeps in the field.
.
Now push key F03
The program transfer to the PLC will start and a short message appears on the
screen.
Watch the message. If the transfer was successful, the actual program name will
be displayed in the first line of the permanent window of the screen. Go back to
the data screens (e.g. plunger curve) and look over the loaded data.
Now you can start production with the new loaded program!
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4.1.3.26
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4.1.3.27
Meaning
By setting this touch-button to all moulds (12), half of the moulds (6)
or no mould will be selected (0).
On / off touch-button for selecting / deselecting each individual
mould.
Display which mould is selected.
On / off touch-button for selecting which article processed in which
mould will be blown off on fire polishing machine.
Select
Active
Reject
Reject all
Mould by select.
If a mould has been switched off, the mould will remain active until it
reaches the mould select station. Station mould select can be set on the
Indexing Table screen (S09 from Basic mask).
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4.1.3.28
Function
Glass thickness
Meaning
Depending on setting glass thickness will be controlled differently.
1) Glass thickness measuring PC A to plunger A/B:
Measurement of pressing cylinder A only will control plunger A and
B of feeder.
2) Glass thickness measuring PC B to plunger A/B:
Measurement of pressing cylinder B only will control plunger A and
B of feeder.
3) Glass thickness measuring PC A/B separately:
Each plunger A or B will be controlled by assigned pressing cylinder
A or B.
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Function
Meaning
Set-point
Actual value
Threshold max.
Threshold min.
Maximal reset /
minimal reset
Scaling
Alarm
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4.1.3.29
Function
Meaning
Mould temp.
Delay evaluation
next page). There you can select a mould and the corresponding
graph for the temperature profile of the last hour will be shown
When indexing table stops this delay time is started. When time
elapsed temperatue is measured by pyroscope mounted above the
mould. Pyroscope must be adjusted by laser pointer to point
correctly inside mould.
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Function (cont.)
Actual mould
Actual value
Max
Min
4.1.3.30
Meaning
Actual mould measured is displayed.
Actual temperature of mould. On left side are moulds A. On right
side are moulds B.
Threshold value. If actual temperature is higher than threshold than
internal PLC-register for this mould will be set that according to
setting on indexing table page mould will not be fed / pressed
anymore.
Threshold value. If actual temperature is lower than this threshold
than another internal register will be set. Depending on this register
the mould can be processed differently.
Meaning
Display of average temperatures of all moulds.
68
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4.1.3.31
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Figure 388: Interrupted process for one cycle with negative residual time
Function
Cycle time
Indexing time
Dwell time
Meaning
time for one production cycle, e.g. 20 pieces/min -> 3.00 seconds.
time indexing table needs from start to stop of indexing, e.g. 1s
time indexing table is stationary, e.g. 3 s -1 s = 2 seconds.
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4.1.3.32
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F 31885
Warning number:
Warning text:
W 7454
LR: Position actual value preprocessing does not have a valid encoder
Now tap on icon F6 which will open PDF-documentation for Sinamics S120 drives.
Search in documents for Fault 31885 and Alarm W 7454 and you will find this error
description:
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As you can see in the last section there is always a list of remedies.
And because there is no communication between Control Unit and Encoder, document
suggests to:
- check the power supply voltage
- carry out POWER ON
- replace the component involved (cable, encoder, CU).
In our case encoder cable had been damaged or disconnected.
So after replacing or reconnecting problem should be solved. Maybe (depends on fault)
POWER ON will be necessary.
This warning (or alarm) has been also related to disconnected or damaged encoder
cable. Actual position of encoder cross conveyor could not be read.
With very high probability faults can be found outside electrical cabinet. First
at all try to locate damaged, burned (hot glass1) or disconnected cables.
Replace them if necessary. Only in case of main power faults (e.g. because
of lightning strikes) check also for faults inside cabinet.
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4.1.3.33
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F06: Limitation
S01: TRACE S7
S02: Machine Data burner LINDE
S03: Reset counter
S04: Login
S05: Logout
S06: Password list
S07: Message display
S08: Machine Data read in / read out
F12: Keyboard
S09: Lubrication
S11: Status / control
S12: Management date and time
S13: Status of digital inputs/outputs
S15: Lamp check
S16: Language selection
S17: Faults Sinamics
S18: Cooling indexing table
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4.1.3.34
In the left column the current status will be shown. In the second column a
short breakdown of the connection will be indicated. The time of
breakdown will be stored.
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4.1.3.35
Meaning
Parameters related to indexing table are listed and can be
modified. If an electrical axis is still not referenced (homed), then
actual position value will blink yellow / blue.
Depending on table mechanic different count of maximum moulds
can be set, e.g. 12 moulds or 6 moulds.
Full turning of table is 360 divided by 12 moulds are 30 step
width per mould..
Max. acceleration and deceleration of servo motor indexing table
can be reduced. Motor current is proportional to acceleration.
When motor is in position, torque is reduced automatically.
Before indexing table starts index cylinder will be actuated not to
block table turning.
Speed of indexing table in manual mode will be automatically.
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Function (cont.)
manual mode
Index
Periphery start
Motor current
Payload
Meaning
reduced to 10% of maximum speed.
Value after which the indexing cylinder engages depending on the
override setting of the indexing table drive in automatic mode.
Value after which the periphery is started depending on the
override setting of the indexing table drive in automatic mode.
Actual value of motor current is displayed. Actual motor torque is
always proportional to actual motor current and acceleration.
If because of high payload the positioning accuracy of indexing
table motor gets worse (position overshooting), just increase slider
value to reduce position overshooting.
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4.1.3.36
Function
Machine data
Start up
commissioning
Circulation pump
Encoder
System pressure
Maximum system
pressure
Minimum system
pressure
Meaning
Parameters related to pressing cylinder servo hydraulic A (B) are
listed and can be modified.
Page is used at initial commissioning (start up) of servo hydraulic
system. Tap on start up function inactive to activate / deactivate
commissioning.
Circulation (cooling) pump can be switched on / off. Status of pump
and minimal pressure switch is displayed
For position measurement of hydraulic cylinder a linear absolute
value encoder with SSI-interface is used. When cylinder is in top
most position actual position of encoder must be set to zero by
tapping zero.
Actual value of system pressure (input pressure of hydraulic
pump).
System pressure should not exceed upper limiting value of 10 bar.
System pressure should not exceed lower limiting value of 2.5 bar.
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Function (cont.)
Filling pump on
Filling pump off
Monitoring time
Maximum stroke
Maximum
pressure
Maximum velocity
Relief after
pressing
Actual values
Setpoint values
Meaning
If actual system pressure falls below 3 bar filling pump is switched
on automatically.
If actual system pressure is higher than 3 bar + 0.3 bar filling pump
is switch off automatically.
When filling pump is activated timer is started. When timer elapsed
and setpoint pressure is not reached an alarm is generated.
Maximum possible stroke of pressing cylinder, e.g. 500 mm.
Maximum allowed hydraulic pressure of pressing cylinder, e.g. 300
bar.
Maximum speed of pressing cylinder according to production data,
e.g. 830 mm/s.
When timer is elapsed pressure is relieved.
Actual position, pressure, speed, oil and servo motor temperature
are displayed. Actual values are displayed in blue colour.
Setpoint for speed and pressure of pressing cylinder are set.
Setpoint values or input fields are always in yellow colour with red
background colour.
For first commissioning and filling or refilling of system with oil or
pump replacement see documentation servo hydraulic
Voith_Servohydraulik_Befllanleitung_EN.pdf.
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83
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4.1.3.37
Meaning
Used to adapt input voltage or current of analogue input module to
PLC internal parameter.
Analogue input signal, like mould temperature or temperature of
indexing table rotor, must be scaled using a minimum and
maximum parameter.
Actual temperatures (if correctly scaled) of moulds and rotor of
indexing table are displayed
Mould temperatures below 100C can not be measured with
pyroscope.
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4.1.3.38
Function
Limitations
Maximum speed
Acceleration
Actual value
Gearing factor
Select drive
direction
Meaning
The maximum speed and the maximum acceleration can be
entered on this mask, which dependents on the physical condition
of the drive. This is performed by the WALTEC company at startup. These values refer to the actual resulting speed and
acceleration of the axis depending on the current cycles. This
means that the current cycles are included into the calculation and
is compared with the limits when the plunger curve is changed. An
error message appears on the mask and the last loaded curve is
activated should the set limits be exceeded.
Definition of the maximum allowed traveling speed of the servo
axis.
Definition of the maximum allowed acceleration of the servo axis.
Actual speeds and accelerations.
Parameter to adjust speed of spindle turning. When setpoint speed
of spindle turning fire polishing machine is set to zero this
parameter has to be adjusted until spindle stops turning.
In case of blockage of fire polishing main drive (for example chain
is blocked because of glass pieces). By selecting Select VM Jog
reward in manual mode chain of main drive can be moved back to
be able to remove blockage.
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Max. sinus
position
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4.1.3.39
Function
Machine data
Reference point
coordinate
Reference point
shift
Jog velocity
New ref. point
Zero encoder
Meaning
Parameters for incremental (relative) encoders and servo axis.
After power off or motor replacement all servo motors containing
relative encoders will loose its actual position and needs to find
(home) reference point again! If an electrical axis is still not
referenced (homed), then actual position value will blink yellow /
blue.
In ref.-mode (homing) axis is looking for reference point signal then
stops and sets current position to this parameter.
In ref.-mode (homing) axis is looking for reference point signal then
stops moves this distance and then sets actual position value
When axis is not referenced this parameter defines how fast axis
will move.
If new ref. point is tapped, axis can be referenced again.
For position measurement of hydraulic cylinder a linear absolute
value encoder with SSI-interface is used. When cylinder is in top
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4.1.3.40
OUT
FWD
BWD
ARFD
FAULT
WARN
Meaning
On this page actual values, basic control and status bits of all
Sinamics drives can be monitored. Used for diagnosis of servo
drive.
Tap on selection box to select Sinamics drive.
Actual values for position, speed, motor temperature, motor
current, output voltage and DC link voltage are displayed.
Actual control bits are displayed, like:
Jog forward
Jog backward
(for more information, check Sinamics documentation).
Actual status bits are displayed, like:
Axis is moving forward
Axis is moving backward
Axis is referenced (homed)
Axis is in fault state
Axis is in warning state
(for more information, consult Sinamics documentation).
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4.1.3.41
Function
Status infeed
Control word
Status word
Actual values
Meaning
On this page actual values, basic control and status words of all
infeed modules be monitored. Used for diagnosis of infeed
modules.
Control bits send from PLC to infeed module.
Status bits send from infeed module to PLC.
Actual value for frequency, input voltage, current, active power and
module temperature is displayed.
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4.1.3.42
Utilization
Meaning
Status of digital inputs and outputs of Control Unit 320 can be
monitored. Not all signals are connected to PLC-I/O-modules.
Some signals related to motion control (reference point switches,
hardware limit switches), emergency stop, start impulses, cams
and so on are connected directly to I/O of the control unit CU320
CPU utilization in [%]. If too close to 100% no additional code or
drive can be added which can be controlled.
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4.1.3.43
Function
Status TM31
Meaning
Status of digital I O and analog inputs of Terminal Module 31 is
displayed. Not all signals are connected to PLC-I/O-modules.
I/O-Signals related to servo hydraulic system are connected to
terminal modules TM31 inside cabinet of servo hydraulic.
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4.1.3.44
Meaning
Can be used to sample and visualize graphically PLC data of all
kind. Channels, sampling time, interval and trigger must be
selected.
Visualize 4 channels at the same time.
Defines trigger parameter.
Defines data channels being sampled
Scale min and max value of y axis channel 1 automatically
Scale min and max value of y axis channel 2 automatically.
Example:
Actual position of indexing table drive is stored in database DB81.DBD36. When motor
is running flag M103.0 is active. This flag can be used for triggering starting of sampling
of motor position indexing table.
In picture above channel 1 (blue curve) has been used for sampling of motor position.
Scaling of y-axis maximum value is set to 60000 which means 60.000.
Sampling interval is set to 6000 which means 6000ms = 6.000seconds.
You can see that table turned two times 30.
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Meaning
Maximum 4 channels can be used for data
sampling. Here we use channel 1.
Selector if Database (DB), Input (I), Output
(O) or a Memory-flag (F) will be sampled.
Selector if DWORD, WORD, BYTE, BIT will
be sampled.
Defines data base number being sampled.
Depending on selection above Byte and or
Bit-number must be chosen.
To activate sampling.
To activate average value sampling.
Meaning
Signal used for starting of sampling.
Selector if Database (DB), Input (I), Output
(O) or a Memory-flag (F) will be used for
triggering.
Selector if DWORD, WORD, BYTE, BIT will
be used as trigger parameter.
Defines data base number
Depending on selection above Byte and or
Bit-number must be chosen.
Actual trigger value can be monitored.
Interval how long data will be sampled.
Maximum 64 seconds are possible
If activated sampling is cyclic.
Conditions can be set which must be fulfilled
to start sampling.
Threshold value which must be exceeded to
start sampling.
Conclusion:
Sampling is started when trigger value is smaller than 1, in other
words when motor stopped.
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4.1.3.45
Meaning
Can be used to change settings for machine parameter for LINDE
burners. Totally adjustments for four burners can be made.
Three different settings are available:
1) Enable signal continuous: Burners will be always switched on.
2) Enable signal when station is on: Burners will be only switched
on if station or device is enabled.
3) Enable delayed burner switch off, when section is off: If burner
section is disabled then burners will be switched off after delay
time.
Option 2 and 3 can be used to save gas and / or oxygen.
Option 3 can be used to make fine adjustment regarding delayed
switch off of burners.
Delay time can be adjusted by setting input field delay burner
off.
Will flash in green colour when burner is active
96
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97
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Meaning
Oil quantity for press and polishing machine can be adjusted. Too
less oil will increase friction and wear of machine parts.
Amount of cuts after lubrication will be started, e.g. 500 pieces.
The amount of the already processed cuts can be read in the front
of the field, e.g. 198.
Lubrication duration in seconds, e.g. 2.00s. Status of valve and
pressure switch are displayed. Lubrication valves can be actuated
manually by pressing softkey valve on.
Note: Set the impulse duration at least so long that the lubrication
pump can totally complete its cycle, otherwise a sufficient lubrication
cannot be guaranteed! On manometer oil pressure must be higher
than approximately 60 bar.
98
WALTEC
Meaning
Used for synchronizing of PLC time with panel time.
Internal date and time of programmable logic controller (PLC).
Internal date and time of operator panel
Input fields for entering actual date and time
S18Touch-button for synchronizing PLC and panel time.
99
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4.1.3.49
Meaning
Status of digital inputs of programmable logic controller. Page can
be used to monitor digital inputs of PLC. Only 4 X 8 bits can be
displayed at the same time.
100
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4.1.3.50
Meaning
Status of digital outputs of programmable logic controller. Page
can be used to monitor digital inputs of PLC. Only 4 X 8 bits can
be displayed at the same time.
101
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4.1.3.51
Meaning
Page can be used to monitor the state of analogue inputs of PLC.
If there is an over range condition colour of bar will change from
blue to red (see picture above).
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4.1.3.52
Meaning
Machine parameter for cooling of indexing table torque motor can
be set and actual temperatures monitored. Depending on
temperatures warning and alarms are generated.
Cooling pump on
Setpoint value for the motor temperature, at which the cooling
pump will be switched on.
Hysteresis
This value is deducted from the value Cooling pump on, to
ensure stable running of the pump. Example: 55 3 = 52C at
52C the pump is switched off.
Cooling pump off if Actual temperature of the rotor (the magnets) IR must not be
more than the set value higher than the actual temperature of the
stator (the coils) KTY.
Example: Set value 20C. Rotor temperature must not be more
than 20C higher than the stator temperature.
If this setpoint value is reached, the cooling is switched off, to
avoid rotor touches stator.
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4.1.3.53
Meaning
Temperature recording of actual temperature of stator coils (KTYsensor) and rotor (Infrared-sensor). Also influx and reflux
temperature of cooling liquid are recorded. Finally status of pump
(on/off) will be recorded too.
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4.1.3.54
Meaning
Submenu with the selection of the PLC
Submenu with the selection of DB, I, O, F, T, C
Input of the desired data block
Start address of I, O, F and data DBW, DBD, DBB
Bit of start address I, O, F and data DBW, DBD, DBB
Selection of the desired types of the dates: BIN, HEX, DEC
Selection of the: CHAR; WORD; INT; DWORD; DINT; REAL
Actual value
Note: There is the possibility of the observation of the status values
up to the individual bits. Even control of each individual bit would be
possible.
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Attention: In the case that machine or axis data must be read into the
machine, the machine must be restarted in order for the data to be
loaded into the machine controller.
Attention: Program data may only be read into the machine while the
machine is in a standstill condition. Axis and machine data are only
stored again, if the program was changed by the supplier!
The following switches and keys are to be operated for switching on:
1.
2.
3.
Push "Emergency off Reset" key. All Emergency off keys have to be
unlocked!
4.
Attention: The axes must be moved one after another to the markers
so, that no collision with any machine parts can occur. No safety locks
are provided!
Turn switch MAN-AUTO-REF to REF =reference point.
Press reference point push-button
When the reference point is reached the lamp in the reference point
push-button does not longer flash and the corresponding message
disappears from the screen.
5.
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6.1
Initial Position
The machine is to be operated in the initial position with the manual function
push-buttons. The operating messages show which component groups are not in
initial position, as soon as you switch over to automatic operation. It is only
shown for components which are switched in.
All cylinders and adjustment parts of the machine must be set according to the
needs of production.
6.2
6.3
Monitor circuit
The machine is monitored automatically so that collision movements of important
functions cannot occur in automatic mode.
When monitor responses (displayed by a message at the screen) and the
machine stops, check which function has failed. The concerning limit switch was
not reached, or is defective, wrongly assembled or the cable to the limit switch is
defective.
To eliminate malfunction switch machine over to manual mode. After elimination
automatic mode can be reengage.
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6.4
6.5
6.6
Danger: If you want to work on the facility you switched off with "STOP"
or you work in the danger area of the facility you must shut off also with
pre selection switch "0-I".
If malfunctions occur in automatic mode, these are indicated in the fault field of
the VDU and can be corrected. The indicated error messages has to be deleted
with the yellow ACK key in manual mode, after the malfunctions are eliminated.
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Emergency-off
Through actuation of the red emergency off button, the machine is immediately
stopped, all motors are switched off and the control system is isolated from the
machine. To restart the machine in automatic mode, the machine must be
restarted as described under point Switching Machine on for Manual Operation
.
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6.7
If individual functions are not controlled in automatic mode, the machine remains
in automatic mode. On the basis of the circuit diagram, the number or the
relevant output is sought and the output modules checked as to whether the
green LED indicates that the output is controlled. If automatic operation is not
possible, it can be checked via manual operation whether the function is
executed or whether the output is controlled. If the output is controlled, the cable
to the assembly and the appropriate part are to be functionally checked.
During manual action, the functions are switched via relays. On the basis of the
circuit diagram, it is to be checked whether the appropriate relay switches
through or sticks.
In automatic operation the functions are released also by relays, check also
these.
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6.8
112
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113
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1 revolution of
resolver
Cam
Signal of limit
switch
Travelling
speed of axis
Machine
zero point
Ref. point
shift
114
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115
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Index
1st machine cycle ............................. 108
automatic mode ........................ 108, 109
control cabinet .................................... 19
control cabinet .................................... 20
cooling unit ......................................... 19
Data record processing ................ 61, 97
electric axis ....................................... 109
emergency off ................................... 110
emergency off key ............................ 106
initial position .................................... 108
malfunctions ..................................... 109
malfunctions S7-300 ......................... 111
monitor.............................................. 108
mushroom button.............................. 109
Figures
Figure 1: SIMATIC IPC277 ............................................................................................ 21
Figure 2: Basic Mask ..................................................................................................... 22
Figure 3: Manual mode settings for pressing cylinder and take out ............................... 24
Figure 4: Indexing Table 1 ............................................................................................. 26
Figure 5: Indexing Table 2 ............................................................................................. 27
Figure 6: Info about indexing table registers .................................................................. 28
Figure 7: Pressing cylinder A ......................................................................................... 29
Figure 8: Pressing cylinder B ......................................................................................... 32
Figure 9: Pressing Cylinder Curve ................................................................................. 33
Figure 10: All pressing cylinders .................................................................................... 35
Figure 11: Kick-out 1 and 2 and blow out nozzle ........................................................... 36
Figure 12: Mould lubrication, Gob funnel and Cooling ................................................... 38
Figure 13: Closer and Opener ....................................................................................... 40
Figure 14: Take-out device on press machine ............................................................... 42
Figure 15: Cam control 1 for Take-out device................................................................ 43
Figure 16: Cam control 2 for Take-out device................................................................ 44
Figure 17: Fire polishing machine.................................................................................. 45
Figure 18: Fire polishing Blow Off & Blow out................................................................ 47
Figure 19: Burner movement I ....................................................................................... 48
Figure 20: Burner movement II ...................................................................................... 49
Figure 21: Cross conveyor / Push bar stacker ............................................................... 50
Figure 22: Manual Polishing machine............................................................................ 52
Figure 23: Additional functions ...................................................................................... 53
Figure 24: Master Axis ................................................................................................... 54
Figure 25: Master Axis Trace......................................................................................... 56
Figure 26: Message display ........................................................................................... 57
Figure 27: Message archive with printer function. ......................................................... 59
Figure 28: CPU diagnosis cache ................................................................................... 60
Figure 29: Data record processing on SD card.............................................................. 61
Figure 30: Program information ..................................................................................... 63
Figure 31: Mould selection............................................................................................. 64
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